AU2016204854B2 - Improved panel and post systems - Google Patents

Abstract

P5162AU00 ABSTRACT The present invention provides panels (100,200,300,400) for a fence or barrier, as well as fence post components (1500,1600) and constructions (1500+1500, 1500+1600). The panels can include sound absorption characteristics, and advantageous methods of construction of such panels. 29 1/13 100 102 104 106 L,10 10 6 "--10 14 4FI 2~

Description

1/13

100

102104 106

L,10

10 6

"--10

14

4FI 2~

P5162AU00

Improved panel and post systems

Field of the invention

[001] The present invention relates to panels used to construct fencing and barriers.

Background of the invention

[002] Sound barriers or sound attenuating fences are needed along roadsides, especially busy highways, to reduce noise pollution from the road. These barriers or fences are often constructed from panels erected between posts. The panels therefore need to have the sound attenuating properties, aside from structural integrity and strength that allows these panels to be used in roadside applications. Sound attenuating and/or endurable panels also have applications in residential or industrial fencing, e.g. around the playground of a childcare centre to contain the noises from the children playing within, or to reduce noises from the machinery in a factory.

[003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[004] The present invention provides a panel for a fence or barrier, comprising: a pair of outer layers; at least one inner layer, the at least one inner layer being located adjacent and inboard of one respective outer layer; the at least one inner layer being a sheet having a plurality of perforations; and a centre core between the inner layers.

[005] The at least one inner layer can have a thickness in the range of about 0.25 to 2 millimetres.

[006] A layer of adhesive or bonding material located between the centre core and outer layer can form a bonding matrix through the intervening at least one inner layer.

[007] A layer of bonding material applied to or located on one face of the at least one inner layer will pass through the perforations and reach an opposite face of said at least one inner layer.

[008] Perforations on said at least one layer result in a combined open area of about 25% to 45% of a total area of the said at least one layer.

P5162AU00

[009] Perforations on the at least one inner layer can be about 3 millimetres in diameter.

[010] Adjacent perforations on the at least one inner layer can be distanced so that their centres are about 5 millimetres apart.

[011] The outer layers can be about 4 to 5 millimetres in thickness.

[012] The panel can have an overall thickness in the range of about 75 to 300 millimetres.

[013] The panel can have a height in the range of about 0.5 to 2 metres.

[014] The perforations on the inner layer can be produced by drilling, punching, or milling, any appropriate forming process such as the inner layer being cast.

[015] The perforated at least one inner layer can be formed from one of a range of materials including steel, aluminium, or carbon fibre.

[016] The outer layers can be made from fibre cement.

[017] The central core can be made from a noise attenuating material.

[018] The central core can be expanded polystyrene.

[019] The panel can include a second inner layer which is also a sheet having a plurality of perforations.

[020] The present invention also provides a method of constructing a panel for a fence or barrier mentioned in the paragraphs above, including the steps of providing a centre core having two opposite lateral faces; laminating first an inner perforated sheet and then an outer layer to each lateral face, whereby a bonding material located between the centre core and the outer layers is pressed through perforations of the inner perforated sheets and then cured to bond the outer layers and the inner perforated sheets to the centre core.

[021] The bonding material can expand during lamination.

[022] The present invention also provides a panel for a fence or barrier, comprising a first outer layer on a first side of the panel, and a second outer layer on a second side of the panel opposite the first side, the second outer layer being spaced from the first outer layer, and a sound absorbing layer and a core layer located between the first and second outer layers.

P5162AU00

[023] There can be an intervening panel member located between the first and second outer layers.

[024] The sound absorbing layer and the core layer can be located one on each side of the intervening panel member.

[025] The first outer layer can be perforated.

[026] The intervening panel member can be located closer to the second outer layer than the first outer layer.

[027] The core layer can be of a different material than the sound absorbing layer.

[028] The core layer can be another sound absorbing material.

[029] The core layer can be expanded polystyrene.

[030] A position of the intervening panel member can be chosen depending on sound absorption requirements on the panel.

[031] The intervening panel member can be made from wood or another material with dense fibres.

[032] The sound absorbing layer can be made from rock wool, glass wool, or a fibrous or shredded polyethylene terephthalate material.

[033] The outer layers can be made from aluminium.

[034] The present invention also provides a panel component for a fence or barrier, the panel component having an inner face which in use faces an interior of the fence or barrier, and an outer face which in use faces an exterior of the fence or barrier, the panel component having a body portion, a first edge that extends along a longitudinal length of the body portion, and a second edge that opposite the first edge across the body portion, the first edge and second edge both being profiled so that the panel component is adapted to be assembled to a like panel component whereby the first edge of the component is adjacent to the second edge of the like component, and the respective profiles of the first edge and the second edge together providing one or more joining locations inboard of the exterior of the fence or barrier, the profile of the first edge being at least partially in conformance with the profile of the second edge.

[035] The first edge can include a bevelled attachment end adjacent the body portion, the attachment part extending at an angle away from the body portion.

P5162AU00

[036] The bevelled attachment end of the first edge can extend into a channel portion.

[037] The sidewalls of the channel portion can be generally parallel to the body portion.

[038] A base of the channel portion can be generally perpendicular to the body portion.

[039] The intermediate arm can be generally perpendicular to the body portion.

[040] The profile of the second edge can be the same as the profile of the second edge.

[041] The profile of the second edge partially can conform to the profile of the second edge.

[042] The second edge can have a bevelled portion extending from the body portion, and the bevelled portion of the second edge mirrors the bevelled attachment part of the first edge.

[043] The bevelled portion of the second edge can be connected to an end section.

[044] The end section can have an overhang or hook.

[045] The body portion can include a series of grooves where a profile of the grooves complements those of the bevelled portion(s).

[046] Two like panel components can be assembled in an end-to-end fashion whereby the second edge of one panel component is adapted to be located adjacent to, and at least partially conforms to the profile of, the first edge of the other panel component.

[047] The present invention also provides a panel for a barrier or fence, comprising: two panel components as mentioned in the paragraphs above, the two panel components being in alignment and positioned so that the inner faces of the panel components face each other; a generally U or C shaped cap section having two free arms separated by a middle arm, the cap section being located between the free ends of the second edges of the two panel components, whereby each free end of the respective second edge is positioned against a

P5162AU00

respective one of the two free arms of the cap section, the corresponding free end of the second end portion and free arm of the cap section being secured together.

[048] The first edges of the two panel components can be secured together at their respective free ends.

[049] The panel can have another generally U or C-shaped cap section having two free arms separated by a middle arm, the other cap section being located between the free ends of the first edges of the panel components, wherein the free end of each first edge is secured to corresponding respective free arm of the other cap section.

[050] The securing can be done by clinching, bolting, welding or screwing.

[051] The present invention also provides an extrusion for a barrier or fence post, including a first projection which ends in a first end formation, and a second projection which ends in a second end formation, the first and second formations being parallel to each other, the first and second end formation being adapted to engage respectively with second and first end formations of a like extrusion, one of the first and second formations being of an arcuate keyway shape, and the other one of the first and second formations being of a curved shape adapted to complement and engage with the arcuate keyway shape.

[052] The post component can include an inner face and an outer face, two side edges each extending between the inner and outer faces, wherein the first and second projections extends generally perpendicularly from the inner face.

[053] The inner face can be symmetrical about a midline of the extrusion.

[054] A width between the inner and outer faces can increase from the midline to each side edge.

[055] The post component can further have hooks extending from the inner face, the hooks being located adjacent the side edges.

[056] The present invention also provides a post comprising a pair of post components mentioned above which are inter-engaging.

[057] The present invention further provides a corner post comprising a post component mentioned in the paragraph above, and a comer component which engages the post component.

P5162AU00

[058] The corner component can include a first portion which has a first projection arm, the first projection arm having a first end formation which engages the first end formation of the post component, the corner component further having a panel receiving channel adjacent the first portion, a base of the channel having a second end formation located outside of the channel, the second end formation engaging the second end formation of the post component, wherein the channel is oriented so that its base is generally perpendicular to the first projection arm.

[059] According to one aspect, the present invention provides a panel for a fence or barrier, comprising: a pair of outer layers; at least one inner layer, the at least one inner layer being located adjacent and inboard of one respective outer layer; the at least one inner layer being a sheet having a plurality of perforations; a centre core between the inner layers; and a layer of adhesive or bonding material located between the centre core and one of the pair of outer layers configured to pass through the perforations and reach an opposite face of the at least one inner layer and form a bonding matrix through the intervening at least one inner layer; wherein the adhesive or bonding material is configured to expand during lamination.

Brief description of the drawings

[060] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[061] Figure 1 is a perspective view of a first panel, where a portion of the outer layer and an inner layer is partially cut away to show the layers beneath;

[062] Figure 2 is a cross section view of the panel shown in Figure 1; and

[063] Figure 3 is a side view of a second panel;

[064] Figure 4 is an exploded perspective view of the outer and inner layers of the panel shown in Figure 3;

[065] Figure 5 is a cross section of a panel similar to and a mirror image offigures 3 and 4;

[066] Figure 6 is a cross section of another panel similar to that shown in figure 5;

[067] Figure 7 is a partial perspective view of the outer layers of the panel of figures 3 and 4, joined by an assembly flange;

P5162AU00

[068] Figure 8 is a partial perspective view of two panels of Figures 3 and 4 joined together;

[069] Figure 9 is a cross section of the outer layers of the panel being joined by joining flanges to achieve a wider width;

[070] Figure 10 is a schematic cross section of the outer layers of the panel being joined by only one joining flange to achieve a narrower width;

[071] Figure 11 is a schematic cross section of a join between two panels in a first embodiment, where the panels have differently profiled longitudinal edges;

[072] Figure 12 is a schematic cross section of the join between two panels in a second embodiment, where the panels have longitudinal edges of the same profile, each panel including a joining flange to connect its outer layers;

[073] Figure 13 is a schematic cross section of the join between two panels in a third embodiment, where the panels have longitudinal edges of the same profile, where the outer layers of each panel are directly joined to each other;

[074] Figure 14 is a schematic cross section of the join between two panels in a fourth embodiment, where the panels have longitudinal edges of the same profile, where the outer layers of each panel are joined to each other by a joining channel;

[075] Figure 15 is a schematic cross section of two post extrusion to be joined to form a post for two panels arranged in a straight line;

[076] Figure 16 is a schematic cross section of a comer panel extrusion for forming a corner post;

[077] Figure 17 is a schematic cross section of a comer post formed by the assembly of the corner extrusion shown in Figure 16 and the linear extrusion shown in Figure 15;

[078] Figure 18 is a perspective view of the post shown in Figure 15;

[079] Figure 19 is a perspective view of the corner extrusion shown in Figure 16;

[080] Figure 20 is a perspective view of the corner post shown in Figure 17. .

Detailed description of the embodiment or embodiments

[081] Figure 1 depicts an acoustic fencing or barrier panel 100. It is suitable for constructing fences or barriers which have sound absorbing or attenuating qualities, either

P5162AU00

along or around a property or along the road side. The embodiment of the acoustic panel 100 for roadside use, e.g. along a highway, further needs to withstand potential impacts from stones, rocks or the like, or any other particles which may fly off from trucks or cars at speed. The acoustic panel 100 is a composite panel made from a laminate structure.

[082] As shown in Figures 1 and 2, the laminate structure includes a pair of outer layers 102, which provide the exterior surfaces of the panel 100. Adjacent and inboard of each outer layer 102 is a respective inner layer 106. One or both of the inner layer 106 being a perforated sheet having a plurality or array of perforations, holes, or apertures 108 throughout the inner layer 106. The pair of inner layers 106 are located on either side of a centre core 104, and is of a suitable material to provide rigidity and strength to the laminate structure 100. The centre core 104 provides mechanical properties and sound attenuating properties of the panel 100, and is thus made from a sound attenuating or absorbing material, such as expanded polystyrene or another suitable material.

[083] Figure 2 depicts both inner layers 106 as being perforated sheets, but in some embodiments, only one of the inner layers 106 need be present or if a second inner layer is present it need not be perforated.

[084] The outer layers 102 are fibre cement sheets of about 4 to 5 millimetres in thickness. The pair of inner layers 106 are each about 0.25 to 2 millimetres in thickness. The inner layers 106 are steel sheets, but can be made from other material that provides a sufficient strength per weight ratio of the panel 100. Possible alternative materials include, but are not restricted to, aluminium and carbon fibre. The perforations on the inner sheets 106 are produced by drilling, punching, or milling, laser cutting, electron beam cutting, water jet. If needs be, the inner sheets can be cast.

[085] The perforations 108 of each inner sheet 106 result in a combined "open area" of about 25% to 45%, and most preferably 30%, of the total area of the perforated layer 106. In one example, the perforations are about 3 millimetres in diameter, with a 5 millimetre distance between the centres of adjacent perforations.

[086] The thickness of the centre core 104 makes up a large portion of the overall thickness of the panel 100, and is chosen in accordance with the required mechanical and acoustic properties. The panel 100 generally has a thickness in the range of about 75 to 150 millimetres. A thicker panel 100 has a thicker core 104 to provide more bulk and or

P5162AU00

sound attenuation or absorption. The panel 100 can have a height as required or needed but generally in the range of 0.5 to 2 metres meets most needs.

[087] A layer or layers 105 of adhesive or bonding material is applied between the centre core 104 and each outer layer 102. The adhesive or bonding layer 105 forms a bonding matrix through the apertures or holes of the intervening inner sheet 106, by the application of the laminating process which presses the layers together. In a preferred embodiment, the adhesive or bonding glue chosen will expand slightly during lamination, to ensure the adhesive, bonding material, or glue will pass through the perforations to form the bonding matrix.

[088] Therefore, the layer or layers of bonding material 105 which is or are applied to or located on one or both faces of each perforated sheet 106 will pass through the perforations 108 and reach, or progress through to an opposite face of the perforated layer 106, on the overlying of the corresponding outer layer 102 and by it being pressed to the centre core 104, or vice versa.

[089] The bonding matrix which results from the bonding material and layers 105 expanding through the perforations 108 of the inner sheets 106 further helps the cohesion of the layers. The perforations 108 and the resulting bonding matrix help prevent or reduce risks of delamination caused by the thermal expansion differential between the different materials of the layers in the laminate structure.

[090] A method of constructing the panel involves providing a centre core 104 having two opposite faces. First a layer of bonding material or adhesive 105 is laid or applied, next an inner perforated layer 106 and another layer of bonding material or adhesive 105 is applied, and then an outer layer 102 applied. The layers of bonding material 105 will be pressed or otherwise flow through and occupy the perforations 108 of the inner perforated layer 106. This then cures to bond the outer layers 102, the inner layer 106, and the centre core 104 together. The bonding material 105 expands during lamination which assists entering the perforations 108. Then the process is repeated for the other side. If there is no perforated inner sheet on the other side, the outer layer 102 can be directly bonded to the core 104, or a non-perforated layer bonded to the core 104 and another outer layer applied.

[091] Figures 3 to 4 depict another fence or barrier panel 200 for the construction of a fence or barrier. This panel 200 has a series of V-shaped grooves 214 which extend

P5162AU00

along the outer length of the panel 200. To enhance the sound transmission into the panel 200 to be absorbed by the materials in the panel, one or both of the outer layers 202, 204 of the panel 200 is perforated, but if required, the outer layers 202, 204 can have no perforations if sound absorption is not needed.

[092] Referring to Figure 4, the panel 200 has two outer panel components, being a first outer layer 202 on a first side of the panel 200, and a second outer layer 204 on a second side of the panel 200 opposite the first side. The second outer layer 204 is spaced from the first outer layer 202, to provide a space or gap in which materials contributing to the mechanical properties including the sound attenuating or absorbing qualities of the panel 200 are located.

[093] The first outer layer 202 can be perforated to help the transmission of soundwaves through the layer 202 to the core. The first outer layer 202 can be made from steel, e.g. from a perforated steel sheet. However other materials, such as aluminium or carbon fibre, providing suitable strength are alternative options. One of the outer layer 202, 204 in use, if sound absorption is required, will preferably have perforations and will be generally oriented toward a source of sound or noise. The perforations help reduce the reflection of the sound or noise by the outer layer. The second outer layer 204 can also be perforated, to create a panel that is suitable for locations where noise emanates from either sides of the fence or barrier or for aesthetic reasons. While the outer layers 202, 204 are perforated in the preferred embodiment, in other embodiments this does not need to be the case.

[094] To provide the panel 200 with "tuneable" acoustic qualities so as to improve sound absorption effectiveness, an optional intervening panel member, plank, or board 206 is provided between the first and second outer layers 202, 204. The intervening or interior plank 206 is made from a dense fibrous material, such as wood or any other appropriate method. As will be discussed, the space between the interior plank 206 and the first outer layer 202 will be occupied by a sound attenuating layer 210 (see figures 5 and 6). Between the interior plank 206 and the second outer layer 204 there is a core layer 208 made from expanded polystyrene. The two outer layers 202, 204 are closed at the top by an assembly or joining flange 234. A side cap 290 closes the panel 200 at each side by covering the space between the first and second outer layers 202, 204. As shown in Figure 4, the side cap 290 also has a series of grooves 292 to match the grooves 214 on the outer layers 202, 204.

P5162AU00

[095] Figures 5 and 6 are cross sections taken through a panel of the type shown in Figure 4 except that figures 5 and 6 are a mirror image construction of the panel of Figure 4. The interior plank 206 is shown in Figures 5 and 6 to be located closer to the second outer layer 204 than the first outer layer 202, however it can instead be located midway between the outer layers 202, 204 as in Fig 4, or closer to the first outer layer 202 as may be required according to the sound attenuation desired. Generally speaking, if one of the outer layers 202, 204 has perforations and the other one 204, 202 does not, the interior plank 206 will be located closer to the outer layer without the perforations.

[096] As can be seen in Figures 5 and 6, a sound absorbing layer 210 is located between the second outer layer 202 and the intervening panel member 206. The sound absorbing layer or "wadding" layer 210 is made from, for example, rock wool, glass wool, or a fibrous or shredded polyethylene terephthalate (PET) material. On the other side of the intervening panel member 206, there is a core layer 208, which is preferably expanded polystyrene (EPS). In embodiments where the intervening panel member 206 is not provided, the sound absorbing layer 210 is located next to the core layer 208.

[097] The acoustic qualities of the panel 200 are determined by a range of factors. These include the thickness and characteristics of the wadding layer 210 and of the core layer 208; the characteristics of the interior plank 206 if one is provided; the thickness and characteristics of the outer layers 202, 204, and the thickness of the intervening or tuning panel 206. Other factors being the same, the acoustic qualities of the panel 200 are in particular tuneable, by varying the thickness of the wadding layer 210, or in other words the position of the intervening panel 206 in relation to the second outer layer 204. An increased distance between the intervening panel 206 and the second outer layer 204 (adjacent the sound source) will mean an increased thickness of the wadding layer 210 there between. This allows more sound attenuation or absorption to be achieved. Therefore, panels with the same thickness can be tuned to have different sound absorption properties, i.e. allow different sound transmission.

[098] The sound waves which pass through the perforated second outer layer 204 will be attenuated or absorbed by the sound absorbing layer 210. The sound waves will be further reduced by the intervening plank or tuning panel 206.

[099] The difference between the panels shown in Figures 5 and 6 is that the panel 200 shown in Figure 5 has a smaller thickness compared to the panel 200 shown in

P5162AU00

Figure 6. The panels are constructed slightly differently to achieve the different thicknesses. The panel construction will be discussed below.

[0100] In Figures 5 and 6, each outer layer 202 and mirror image layer 204 have profiled longitudinal upper and lower edges 218, 216, and a main body 211 which extends between the profiled edges 216, 218. The edges 216, 218 are profiled to enable the outer layers 202, 204 of like panels to be assembled together directly or indirectly, by clinching, welding, screwing, or by another means, to form a section or a partial section of a barrier or fence.

[0101] In Figure 5, the outer layers 202, 204 are not directly joined to each other. Whereas lower and upper joining channels 232, 234 are needed to join the outer layers 202, 204. Whereas in Figure 6, the outer layers 202, 204 are spaced apart by a smaller distance to create a thinner panel with a less wide channel 234, and no channel 232. The lower horizontal edges 216 of the outer panels 202, 204 of Fig 6 meet and are secured against each other, eliminating the lowerjoining flange 232. The upperjoining flange 234 is still needed to join the upper longitudinal edges 218, but a smaller joining flange 232 is required for the panel of Figure 6 compared to that required for the panel of Figure 5. The widths of the joining channels 232, 234 will be selected according to the final width desired of the panel 200.

[0102] The assembly of like panels 200 will increase the width or height of the assembled section thus formed, depending on whether the panels 200 are oriented horizontally or vertically.

[0103] As can be seen in Figures 4 to 7, the outer layers 202, 204 have profiled faces and edges in the form of V-shaped grooves that are mirror images of one another, but the main body 211 between the profiled edges need not have V-shaped grooves. The edges of the outer layers 202, 204 have clinchings 212 (see Figure 7) which secure the outer layers 202, 204 to the side cap 290 (shown in Figure 4).

[0104] A panel 200 is formed with two opposing panel outer layers 202, 204 and any attachment feature which enables the assembly of the two opposing outer layers 202, 204, and any filling or acoustic components provided between the two opposing outer layers 202, 204. Features of the profiled edges discussed in relation to an outer layer 202, 204 will mirror in their profiled edges of the opposite outer layer 204, 202. The same

P5162AU00

reference numerals will thus be used to refer to the same mirrored features of the profiled edges on the outer layers 202, 204.

[0105] In the following discussion, for simplicity the panel member will be assumed to be horizontally oriented in use. That is, the panel member's longitudinal axis will be horizontally oriented. The first longitudinal side will be the top side of the panel member, and the second longitudinal side will be the bottom side of the panel member. However, the skilled addressee will appreciate that the panel member can be oriented in any direction in use, to be assembled so that they lie horizontally, vertically, or obliquely.

[0106] As best shown in Figures 7 and 8, in the depicted embodiment the outer layers 202, 204 have a lengthwise profiled or corrugated pattern, there being a generally 'V'-shaped pattern 214 in its profile at regular intervals. Each panel outer layers 202, 204 has a profiled first longitudinal edge 216 and a profiled second longitudinal edge 218, running along the longitudinal length of the panel outer layers 202, 204. In the embodiment shown the first profiled edge 216 is the lower edge and the second profiled edge 218 is the upper edge. The outer layers 202, 204 of the neighbour panels will be assembled so that the lower edges 216 of the outer layers 202, 204 of one panel will be joined to the upper edges 218 of the outer layers 202, 204 of the next panel.

[0107] It is preferred that the first and second edges 216, 218 are profiled to include a bevel 220, 222 (shown in Figures 5 and 6). When the upper edge 218 and the lower edge 216 from neighbouring panels 200 are joined together, the bevels 222, 220 will be placed adjacent each other and complement or replicate the V grooves 214 of the body portion 211 of the outer layers 202, 204. This is done by providing bevelled portions 220, 222 in the profiled edges 216, 218 with gradients that match those of the V grooves 214.

[0108] In embodiments where the panel outer layers 202, 204 do not in itself include a pattern (e.g. see Figures 9 and 10), the profiles of the lower and upper edges 216, 218 will enable an overall pattern to be formed by the joining of the edges of adjacent outer layers. Like panels will be assembled so that their respective first and second longitudinal sides will be joined together.

[0109] The discussion below in relation to one of the outer layers will also apply to the opposite outer layer, which has the same or a mirror image profiled edge.

[0110] As shown in Figures 5 to 11 but as can be best seen in Figures 9 to 11, the first profiled edge 216 of the outer or external layer 202, 204 includes a bevelled

P5162AU00

attachment end 220 which is directly adjacent the main body 211 of the external layer 202, 204. As discussed above, the attachment part 216 is bevelled to the body portion 211, for example at an angle that forms or matches an intended V-shaped groove.

[0111] The bevelled attachment end 220 extends away from the body portion 211, and toward an interior direction. Therefore in use the attachment end 222 will extend toward a matching end 220 on the opposite panel outer layer 204, 202. The attachment end 220 is connected to a channel made up of a first sidewall 224 which is connected to the bevelled attachment end 220, a channel base 226, and then a second sidewall 228 which is a free end or flange of the profiled edge 216. The channel's base 226 is generally perpendicular to the main body 211, and the channel's sidewalls 224, 228 are generally parallel to the main body 211.

[0112] In the embodiments of Figures 4 to 11, the profile of the second edge 218 is different from that of the first edge 216, but will generally or at least partially complement or matingly engage the profile of the first edge 216. The second edge 218 also has a bevelled attachment end 222, to match with the bevelled attachment end 220 in the first edge 216. The bevelled part 222 of the second edge 218 is angled away from the main body 211 portion and inwards so that in use, it obliquely extends toward its mirrored attachment end 222 on the opposite outer layer. The bevelled part 222 of the second edge 218 extends into an end projection or flange 230 which has an overhang 231. The end projection 230 is the depicted embodiment is generally parallel to the main body 211 of the outer layers 202, 204, except for its overhang 231 which is at an angle of approximately 90 degrees to the main body 211.

[0113] The spacing between the two outer layers 202, 204 is determined by the desired thickness of the panel 200. In Figure 9, the two outer layers 202, 204 are spaced apart far enough that the first edges 216 of the respective outer layers 202, 204 do not meet. To close the panel, a generally U or C shaped assembly, attachment, or joining flange or channel 232 will be placed between the free ends 228 of the profiled edges 216 of the opposite outer layers 202, 204. The free legs or flanges 232.1, 232.2 of the joining channel 232 will preferably be placed flush against the respective free ends or flanges 228 of the profiled edges 216 of the opposite outer layers 202, 204. The free legs 232.1, 232.2 of the joining channel are secured to the respective free ends 228 by welding, clinching, screws, pop rivets or bolts as indicated by lines 240. The most preferred method of securement is by clinching.

P5162AU00

[0114] A second attachment or assembly flange or channel 234 of a generally U or C shape is provided between the end flanges 230 of the opposing second edges 218. The free legs 234.1, 234.2 of the second attachment flange 234 will preferably be provided flush against, and secured to the respective end sections 230. The free legs 234.1, 234.2 of the second attachment flange 234 are secured to the respective end projections 230 on the opposite profiled edges 218 by welding, clinching, screws, pop rivets or bolts as indicated by lines 260.

[0115] In the embodiment shown in Figure 10, the outer layers 202, 204 are placed closer together to form a thinner panel 200. The mirrored first profiled edges 216 are located directly adjacent each other. Their respective free ends 228 can be directly secured together by welding, clinching, screwing, or bolting as indicated by line 270, without any joiningflange. The mirrored second profiled edges 218 are joined by a joining flange 234 similar to those of the panel 200 shown in Figure 9.

[0116] By making the outer layers 202 and 204 with their respective joining flanges 228 and 230 mirror images of each other, only a single inventory for layers 202 and 204 need be had to make panels of any desired thickness by simply adding appropriately sized channels 232 and correspondingly sized channels 234.

[0117] The end projection 230 of the second profiled edge 218 extends further outboard or away from the main body 211 than the channel 224, 226, 228 of the first profiled edge 216. Specifically, the end projection 230 of the second profiled edge 218 will extend further from the main body 211 than the first sidewall 224 of the channel. Figure 11 shows that when two panels 200, 200' are assembled, the edges 216', 218 from neighbouring panels are adapted to be fitted together, that is, one within the other, and assembled. The effect of this configuration is that the second profiled edges 218 of one panel 200 will be inserted into the space between the first profiled edges 216' in the adjacent panel 200'. Therefore, the first profiled edge 216 is also considered a receiving edge, and the second edge 218 is also considered an insertion edge. The receiving edges 216' on the opposing outer layers of a panel 200' therefore also form (together with the attachment flange 232 if one is used) a receiving end of the panel 200'. Similarly, the insertion edges 218 on the opposing outer layers of the panel 200 form (together with the attachment flange 234) an insertion end of the panel 200. The insertion end of panel 200 is fitted into the receiving end of panel 200'. The two panels 200, 200' are assembled with either a clearance fit or a friction fit.

P5162AU00

[0118] Therefore, as can be seen from Figures 3 to 11 above, two adjacent panels, each being formed by a pair of opposing panel components, are adapted to be assembled in an end-to-end fashion. The insertion edge of the one panel is adapted to be received by the receiving edge of the adjacent panel. Thus the insertion edge preferably at least partially conforms to the profile of the receiving edge, and vice versa. Within each panel, one or more joining locations whereby the opposite panel components are secured together or secured to an attachment flange, will be located inboard of the exterior of the panel.

[0119] In the embodiments shown in Figures 3 to 11, the first and second edges 216, 218 are different to each other. However, in alternative embodiments, the first and second profiled edges 216, 218 can be the same as will be described below with reference to figures 12 to 14.

[0120] Figure 12 depicts an alternative panel construction and embodiment of the attachment between adjacent like panel components 300, 300'. Both longitudinal edges 316, 318 (316', 318') of the panels 300 (300') are the same as the "receiving edge" 216 shown in Figures 3 to 11. To assemble two panels 300, 300' together, assembly bars or blocks 390 are be placed into the spaces created between and defined by the adjacent edges 316, 318'. Specifically each space is generally defined by the channel portions 224, 226, 228 in the profiled edges. The bars or blocks 390 can be RHS or SHS or may be extruded joining pieces.

[0121] Figure 13 depicts a similar embodiment as that shown in Figure 12, except that channels 432, 432' are also included between the outer layers 402, 404 for each panel 400, 400'. An assembly block 490 is provided in the space bound by the two assembly flanges 432, 432'. Other assembly blocks 491 (drawn in dashed lines) placed in the spaces defined between the adjacent edges 416, 418' can replace the assembly block 490 provided between the assembly flanges 432, 432'. Alternatively they can be provided in addition to the assembly block 490 between the assembly flanges 432, 432'.

[0122] Figure 14 depicts another alternative embodiment, where both longitudinal edges 516, 518 (516', 518') of the adjacent panels 500, 500' are the same as the insertion edges 218 shown in Figures 3 to 11. As the two panels 500, 500' are placed against each other, a space 505 will be formed between the attachment flanges 324, 324' for the respective panels 500, 500'. An assembly bar or block 590 is placed inside this space 505 to help prevent the assembled panels 500, 500' from moving from side to side.

P5162AU00

[0123] In the above embodiments depicted in Figures 12 to 14, the assembly bar or blocks 390, 490, 590 can extend through substantially the full length of the panel, or substantially the full length of a section or all of the barrier. Alternatively, the assembly bar or blocks 390, 490, 590 can be provided at discrete locations, e.g. at regular intervals along the length of the panels.

[0124] Figures 15 to 20 depict a post system or post assembly, to accept panels in a fencing or barrier system. The post system generally includes post components which are profiled extrusions, whereby two extrusions can be interlocked together, to create spaces which are adapted to accept the panels. Generally there are two types of post extrusion components, including a linear extrusion and a corner extrusion. Two linear components are placed in opposition to each other and interlocked, to create spaces for adjacent panels which are arranged in a linear or straight line. A linear component and a corner component are interlocked together to create spaces for adjacent panels that are arranged in a corner.

[0125] Figure 15 shows two linear extrusions 1500 to be interlocked together to form one post between two adjacent panels (not shown) arranged in a straight line. Each linear extrusion 1500 is generally shaped similar to one half of an "H". The extrusion 1500 includes an exterior face 1505 and an interior face 1510 which will respectively face the sides of the barrier or fence. The linear component 1500 is generally symmetrical about a midline 1515 which extends between the exterior face 1505 and the interior face 1510, and located about half way between the two side edges 1520, 1525. The exterior face 1505 is depicted as having a straight profile between its two side edges 1520, 1525, but an alternative profile can be provided. The interior face 1510 preferably has a sloping profile, so that the linear component 1500 is narrowest at or closer to the midline 1515, and widest toward the edges 1520, 1525.

[0126] A first and a second assembly projection 1530 and 1535, respectively being a female assembly projection 1530 and a male assembly projection 1535, extend from the interior face 1510. The assembly projections 1530, 1535 are provided generally at a right angle in relation to the exterior face 1505. The assembly projections 1530, 1535 are one provided on either side of the midline 1515, being equidistant from the midline 1515. Therefore, when two linear components 1500, 1500' are arranged to face each other, the female projection 1530 of one linear component 1500 will align with the male projection 1535' of the opposite linear component 1500', and vice versa.

P5162AU00

[0127] The female assembly projection 1530 has an end receiving formation 1532, which is or includes a keyway of preferably an arcuate shape. Optionally, an attachment extension 1533 extends from the female projection 1530 so that in use the extension 1533 will overlap with the male projection 1535' of the opposite linear post 1500'; to provide an assembly location, where one or more screws, rivets, clinches or bolts as indicated by the dashed lines 1560 can be used to permanently secure the linear extrusions 1500 together.

[0128] The male assembly projection 1535 has a second end insertion formation 1537. The first end receiving formation 1532 is shaped and sized to receive and retain an end insertion formation 1537. Therefore, when the two linear components 1500, 1500' are assembled, the end receiving formation 1532 of one linear component 1500 will retain the insertion formation 1537' of the opposite linear component 1500', and the insertion formation 1537 of the first linear component 1500 will be retained by the receiving formation 1532' of the opposite linear component 1500'. It will be understood that the positions of the female and male projections 1530, 1535 can be swapped, where the first projection is male and the second projection is female.

[0129] The assembly projections 1530, 1535 can further optionally have side formations 1534, 1539 which extend a short distance toward the nearest side edge 1525, 1520 of the linear component 1500. These optional formations 1534, 1539 help define assembly positions between adjacent extrusions 1500, 1500'. For instance, the attachment extension 1533 of extrusion 1500 will reach the formation 1539' provided on the male projection 1535' of its cooperating extrusion 1500'.

[0130] The interior face 1510 of the linear component 1500 further has hooks 1540, one located near each side edge 1520, 1525. The ends of the hooks 1540 are oriented toward the middle of the component 1500. As will be described later, these hooks 1540 enable the assembly between a linear component 1500 and a comer component 1600 (see Figure 16).

[0131] When two linear extrusions 1500 placed in opposing orientations are slidingly assembled, they generally form an H-shaped post. Opposed spaces 1550, are created between the two linear components 1500. Because of the sloping profiles of the interior faces 1510 of the linear components 1500, the spaces 1550 will be bound by sloping sidewalls, such that the space is narrowest at the opening into which the panels are to be inserted, and widens toward the interior of the post. The panels will preferably have a slight taper in their side

P5162AU00

edges, so that they can be forced into the sloping spaces 1550, but prevented from easily reversing out of the spaces 1550 by the narrower openings.

[0132] Interior hooks 1551 are provided around the interior corners of the linear extrusion 1500, for example, at the inside comers between the exterior panel 1505 and the side edges 1520, 1525. These allow an end cap (not shown) with aligned cooperating assembly stubs to be assembled on the assembled post or on each linear extrusion, to help close off and protect the extrusion 1500 against e.g. moisture or dirt. Potentially linear extrusions can also stacked on top of each other, and assembled by poles or rods received by the hooks 1551.

[0133] When assembling the post, a reinforcing square hollow section or RHS 1593 can be located internally. The RHS 1593 can be a fence post concreted or otherwise set into the ground and the post of extrusions 1500 and 1500' slid over the RHS 1593. The projection 1534 and 1539 keep the post assembly 1500 and 1500' centrally located relative to the RHS 1593.

[0134] Figure 16 depicts a corner component 1600 which can be interlocked with a linear component 500 described above, to provide insertion spaces for corner panels in a fencing or barrier system. Figure 17 depicts the comer component 1600 in an interlocking or engaging relationship with the linear component 1500.

[0135] The corner extrusion 1600 has two end arms 1605, 1610 which are substantially parallel to each other. Both end arms 1605, 1610 are generally or substantially perpendicular to a middle extent 1607 of the extrusion 1600. The 1st portion 1601 of the extrusion 1600 is formed by the first arm 1605, the middle extent 1607, and the parts there between. The first portion 1601 has generally a very similar geometry as one half of the linear component 1500, because the first portion 1601 in use will form a first panel receiving space with a linear component 1500. To enable interlocking between the first portion 1601 and the cooperating linear component 1500, the first arm 1605 will have first end formation 1608 which complements the first end formation on the cooperating linear component.

[0136] A second portion, being a panel receiving channel 1616 is provided adjacent the first portion 1601. Specifically adjacent the middle extent 1607 which is part of the first portion1601, receive another comer panel (not shown). Preferably, the channel 1616 has sloping sidewalls 1625, 1630, so that it is narrowest at its mouth 1616 and widest at its base 1619, the base 1619 being parallel to the middle extent 1607 of the first portion 1601. The

P5162AU00

gradient of the sloping sidewalls will be the same as those bounding the receiving spaces 1550 bound between opposing interlocked linear components 1500. To enable the second portion 1615 to interlock with or attached to the cooperating linear component 1500, the channel base 1619 has a second end formation 1621 which is located on the side of the base 1619 external to the channel 1615, which will complement the second end formation 1537 on the linear component. Therefore, the distance between the first and second end formations 1608, 1621 is the same as that between the male and female end formations 1532, 1537 in the linear component 1500. Further both end formations 1608, 1621 of the corner component 1600 will be spaced from the middle extent 1607 by the same distance.

[0137] As depicted in figs 16 and 17, the first and second end formations 1608, 1621 are respectively a male end formation and a female end formation to complement the female and male end formations on the linear component 1500 shown in Figure 15. It will be understood that the reverse embodiment, where the first and second end formations 1608, 1621 are respectively female and male, will be used, if the cooperating linear component 1500 also has the locations of its female and male end formations swapped.

[0138] The first end formation 1608 of the first arm 1605 is a male formation to cooperate with a female end formation 1532 on the cooperating linear component. However, the first end formation 1608 will be a female formation, if the formation on the cooperating linear component 1600 is male.

[0139] The corner component 1600 has a third portion 1603 located adjacent the channel 1616, comprising a corner edge extent 1604 and the second projection 1610. The comer edge extent 1604 is collinear or aligned with the middle extent 1607 and generally perpendicular to the second projection 1610. So that the third portion 1603 can interlock or engage with the cooperating linear component 1500, the second projection 1610 includes a hooked projection which ends in a hook 1612, adapted to receive a hook 1440 of the linear component 1500.

[0140] Other hooks 1620 similar to those provided on the interior face 1510 of the linear component 1500 are provided at various locations in the comer extrusion 1600. For instance they are located near the mouth of the channel 1615, and also in the first portion 1601 at a location which will align with a hook 1540 of the same configuration in the linear component 1500. Hooks 1540 on extrusion 1500, and 1620 on extrusion 1600 also provide a single line of contact between the walls of the fence or barrier panels inserted in spaces 1550

P5162AU00

and 1715/1716 making it easier to insert fence or barrier panels, by comparison to having multiple lines or areas of contact.

[0141] Interior hooks 1651 are provided around the interior comers of the comer extrusion 1600. These allow the extrusions 1500, 1600 to be closed by end caps having cooperating studs or projections. Potentially adjacent extrusions can be stacked on top of each other, and assembled by poles or rods received by the hooks 1651.

[0142] As seen from Figure 17, when assembled, the first and second end formations of the linear component 1500 respectively interlock or engage with the first and second end formations of the comer component 1600. The hook 1612 on the second projection 1610 will engage an aligned hook 1540 on the cooperating linear component 1500. In this way 3 locations of engagement between extrusions 1500 and 1600 are present. A panel receiving space 1716 is bound between the linear component 1500 and the first portion 1601 of the comer extrusion 1600, and the channel 1715 in the corner extrusion 1600 provides the second panel receiving space. It can be seen that the first and second panel receiving spaces 1716, 1715 are at a 90 degree angle to each other, to correspond with the angle between the corner panels.

[0143] The above extrusions or post components are preferably made from 1.5mm thick aluminium. . The thickness can be according to design or utilization requirements. The following dimensions are also provided as examples only. The linear component 1500 is approx. 250mm wide. It is about 78.2mm in width as measured from the external face 1505 to the tips of the assembly projections 1530, 1535, and 39.6mm in width across its side edges 1520, 1525. The distance between each assembly projection 1530 (1535) and the nearest side edge 1525 (1520) is about 67.5mm. In use, each pair of opposing linear components 1500 are spaced part so that the aligned hooks 1540 provided on the interior faces 1510 of the pair of components 1500 are spaced apart by about 76.2mm.

[0144] Figure 18 shows in three-dimension, a linear H-post constructed from two linear extrusions 1500 discussed above. Figure 19 shows in three-dimension, the comer extrusion 1600 discussed above. Figure 20 shows in three dimensions a corner post, constructed from one half-H extrusion and a corner extrusion as discussed above.

[0145] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the

P5162AU00

sense of "consisting only of'. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[0146] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0147] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (13)

P5162AU00 Claims

1. A panel for a fence or barrier, comprising: a pair of outer layers; at least one inner layer, the at least one inner layer being located adjacent and inboard of one respective outer layer; the at least one inner layer being a sheet having a plurality of perforations; a centre core between the inner layers; and

a layer of adhesive or bonding material located between the centre core and one of the pair of outer layers configured to pass through the perforations and reach an opposite face of the at least one inner layer and form a bonding matrix through the intervening at least one inner layer;

wherein the adhesive or bonding material is configured to expand during lamination.

2. A panel as claimed in claim 1, wherein said at least one inner layer has a thickness in the range of about 0.25 to about 2 millimetres.

3. A panel as claimed in claim 1 or claim 2, wherein the perforations of said at least one inner layer result in a combined open area of about 25% to 45% of a total area of said at least inner one layer.

4. A panel as claimed in any one of claims 1 to 3, wherein the perforations of said at least one inner layer are each about 3 millimetres in diameter.

5. A panel as claimed in any one of claims I to 4, wherein adjacent perforations on said at least one inner layer are distanced so that their centres are about 5 millimetres apart.

6. A panel as claimed in any one of claims I to 5, wherein the outer layers each have a thickness in the range of about 4 to about 5 millimetres.

7. A panel as claimed in any one of claims 1 to 6, having an overall thickness in the range of about 75 to about 300 millimetres.

8. A panel as claimed in any one of claims I to 7, having a height in the range of about 0.5 to about 2 metres.

9. A panel as claimed in any one of claims 1 to 8, wherein said at least one inner layer is formed from one of steel, aluminium, or carbon fibre.

P5162AU00

10. A panel as claimed in any one of claims I to 9, wherein said outer layers are made from fibre cement.

11. A panel as claimed in any one of claims 1 to 10, wherein the central core is expanded polystyrene.

12. A panel as claimed in any one of claims I to 11, wherein said panel has a second inner layer which is also a sheet having a plurality of perforations.

13. A method of constructing a panel for a fence or barrier as claimed in any one of claims 1 to 12, including: providing a centre core having two opposite lateral faces; laminating first an inner perforated sheet and then an outer layer to one lateral face, whereby a bonding material located between said centre core and the outer layers expands during lamination and is pressed through perforations of the perforated inner layer and then cured to bond the outer layer and the perforated inner layer to the centre core.