NZ542571A - A modular structure including rails made from PVC tube - Google Patents

Abstract

A modular structure, such as a fence or barrier, is disclosed. The structure has at least one horizontal rail (16), with each rail made from a single PVC tube. Apertures are formed by removing surface portions of rail, and vertical posts (18) are received in the apertures to locate each rail to the posts.

Description

£-(.15-71 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION After Provisional 2004905524 filed in Australia on 24 September, 2004 Davies Collison Cave Reference: 12662910 APPLICANT(S) Sam Scott, an Australian citizen of 155 Rolfe Road, Hall, Australian Capital Territory 2618 Australia My/Our contact address is: My/Our address for service is: DAVIES COLLISON CAVE DAVIES COLLISON CAVE 1 Nicholson Street c/- James & Wells G.P.O. Box 4387QQ Level 9, James & Wells Tower Melbourne 3000 56 Cawley Street Victoria, AUSTRALIA Private Bag 11907 Telephone: 61 3 9254 2777 DX CP 34005 Facsimile 61 3 9254 2770 Ellerslie Auckland Email: chodkinson@davies.com.au NEW ZEALAND INVENTION TITLE: A modular structure We/I, Sam Scott hereby declare the invention for which we pray that a patent be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: iponz 27 SEP 2005 P:\REC\NZ\Docs\126629IO 266.doc - 23/9/05 P:\OPER\MRF\Specifications\l2662910 spcci 246.doc.22/10/2007 - 1A- A modular structure Field of the invention This present invention relates to a modular structure, and more particularly a preferred form of the present invention relates to a temporary or semi-permanent 5 modular structure able to be readily assembled and disassembled. Preferred forms of the present invention may relate to a modular fencing structure, a modular enclosing structure or a modular frame structure, for example.

Background of the invention Numerous applications exist for temporary or semi-permanent modular structures, including as fences to form animal yards, barriers or partitions. While many previously proposed temporary fences like electric fences and those formed using star pickets or droppers that are directed towards such applications exist, they are generally difficult to expeditiously assemble and disassemble, lack sufficient 15 flexibility of construction and are often quite expensive.

Summary of the invention Preferred forms of the present invention seek to provide an improved modular structure suited for use as a temporary or semi-permanent fence that is able to be 20 readily assembled and disassembled, or at least seek to provide a useful alternative to structures previously proposed.

According to one aspect of the present invention, there is provided a modular structure including at least one substantially horizontal hollow tubular rail, the or 25 each rail being a single polyvinylchloride (PVC) tube, and a plurality of substantially vertical posts, wherein the at least one rail has a plurality of apertures formed therein by removing surface portions of rail and each post is inserted into an aperture so as to locate the at least one rail to the posts.

Preferably, each post is provided with at least one spacer adapted to fit around the exterior of the post and support the at least one rail so as to vertically locate the at intellectual property office of n.2. 2 5 OCT 2007 received P:\OPER\MRF\Specifications\l26629IO speci 246.doc-22/l0/2007 least one rail to the posts without fastening. More preferably, at least one end of each spacer is adapted to conform to the exterior of the at least one rail.

Preferably, the at least one rail includes an upper rail and at least one lower rail, 5 the posts being inserted respectively into the apertures of the rails so as to locate the upper rail on upper ends of the posts and the at least one lower rail on upper ends of the spacers. More preferably, each upper end of each post includes a threaded projection which passes through the upper rail and cooperates with a washer and a nut so as to releasably secure the upper rail to the posts.

Preferably, each spacer is a PVC tube. Each rail may be cylindrical and each spacer may be a cylindrical PVC tube, for example.

Preferably, an end cap is secured to each free end of each rail.

Preferably, the at least one rail includes a plurality of rails and adjacent ends of the rails are connected by a connector adapted to fit around the exterior of the adjacent ends.

A modular structure according to the present invention would normally include a plurality of posts, rails and spacers, such that a form of the present invention may provide a recyclable temporary or semi-permanent modular fencing structure, a modular enclosing structure or a modular frame structure. Practical applications of the present invention may include fences, temporary holding yards for livestock, 25 people barriers and temporary guards to protect young trees from livestock, for example.

According to a further aspect of the present invention, there is provided a method for assembling a modular structure including the steps of: (a) assembling a 30 plurality of substantially vertical posts; (b) forming a plurality of apertures in at least one substantially horizontal hollow tubular rail by removing surface portions of the intellectual property office of n.z. 2 5 OCT 2007 received P:\OPER\MRF\Specifications\l2662910 speci 246.doc-22/10/2007 at least one rail, the or each rail being a single PVC tube; and (c) inserting each post into an aperture so as to locate the at least one rail to the posts.

Brief description of the drawings The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a fence; Figure 2 is a perspective view of a post of the fence of Figure 1; Figure 3 is a perspective view of an upper rail of the fence of Figure 1; Figure 4 is a perspective view of a lower rail of the fence of Figure 1; Figure 5 is a perspective view of a spacer of the fence of Figure 1; Figure 6 is perspective view of the spacer of Figure 5 fit over the post of Figure 2; Figure 7 is a section view taken along the line A-A in Figure 1 showing the spacer of Figure 2 in use to vertically space apart two rails; Figure 8 is a perspective view of an alternative fence having a single (upper) rail; Figure 9 is a plan view of a connector in the form of a sleeve for connecting end-to-end two axially aligned rails; Figure 10 is a side view of the sleeve of Figure 9 taken along the line B-B; Figure 11 is a plan view of the sleeve of Figure 9 connecting end-to-end two axially aligned rails; Figure 12 is a plan view of half of an alternative connector in the form of an elbow half-pipe for connecting end-to-end two perpendicularly aligned rails; Figure 13 is a view of the elbow half-pipe of Figure 12 taken along the line C-C; Figure 14 is a plan view of two of the elbow half-pipes of Figure 13 connecting end-to-end two perpendicularly aligned rails; Figure 15 is a view of the elbow half-pipes of Figure 14 taken along line D- D; Figure 16 is a plan view of half of an alternative connector in the form of intellectual property office of n.z. 2 5 OCT 2007 P:\OPER\SAS\Jul-Dec 05\12662910_cap_NZ.doc-23/09/05 .4. substantially T-shaped half-pipe for connecting end-to-end three rails; Figure 17 is a view of the T-shaped half-pipe of Figure 16 taken along the line E-E; and Figures 18 to 22 are schematic views showing examples of how forms of the present invention may be applied in practice.

Detailed description In the description below, the same reference numerals will be used throughout the description and accompanying drawings to refer to the same parts.

Figure 1 shows a modular structure in the form of a fence 10. The fence includes a plurality of spaced apart substantially vertical posts 12 (shown in broken line in Figure 1), a plurality of substantially horizontally arranged rails including an upper rail 14 and two lower rails 16, and a plurality of spacers 18.

A post 12 of the fence 10 is shown in Figure 2. The post 12 is a cylindrical length of steel, although it will be understood that the post 12 may be formed from other suitable materials. Further, the shape of the cross-section of the post 12 may not be circular, and may be rectangular or triangular, or the post 12 may be a star 20 picket, for example. A threaded protrusion or portion 20 extends from an upper end 22 of the post 12 for receiving a nut or similar threaded fastener, such as a wing nut 24 (shown in Figure 1).

The upper rail 14 and a lower rail 16 of the fence 10 are shown in Figures 3 and 4, 25 respectively. Advantageously, the rails 14, 16 are formed from polyvinylchloride ("PVC") cylindrical pipes or tubes, such as the type commonly used many plumbing applications. PVC pipes are normally readily available, relatively cheap, able to be conveniently recycled from other applications and are relatively light facilitating both the transport and ready assembly and disassembly of the fence. 30 Advantageously, PVC pipes are also relatively sturdy making them suitable for a range of different applications, are relatively resistant to corrosion and offer P:\OPER\MRF\Specifications\l2662910 speci 246.doc-22/10/2007 significant flexibility as they are normally available in a range of different thicknesses, sizes and lengths that are able to be straightforwardly cut to form rails 14,16 of dimension and shape to suit various requirements.

It will be understood that the shapes of the cross-sections of the rails 14, 16 may not be circular, and may be other shapes. Further still, while the rails 14, 16 shown in Figures 3 and 4 are formed from straight elongate lengths, it will be understood that they may have other shapes, and they may be formed from curvilinear lengths (see Figure 19), for example.

Each rail 14, 16 also includes a plurality of spaced apart apertures 26 for receiving the posts 12, as will be described below, in the form of holes 28 (upper rail 14) and through-holes 30 (lower rails 16) for engaging the posts 12. The apertures 26 may be formed by removing respective surface portions of the rails 14, 16, such as by 15 cutting or drilling, for example. The holes 28 that do not fully pass through the upper rail 14 are able to be formed by removing respective surface portions that may be subsequently used to form washers 32 (shown in Figure 1), while the through-holes 30 that pass fully through the lower rails 16 are able to be formed by removing respective pairs of diametrically opposed surface portions form the rail 20 16. The cross-sections of the apertures 26 of the rails 14, 16 are preferably circular in shape, although it will be understood that they may be other shapes such as rectangular or triangular, for example. In one practical form of the present invention, for example only, the rails 14, 16 are cylindrical and have a diameter of about 100 millimetres with spaced apart apertures 26 formed every 2 to 3 metres 25 or so along their length for receiving posts 12 spaced apart the same distance, with the apertures 26 being complementarily shaped to engage the posts 12 and to limit movement of the rails 14, 16 relative to the posts 12. The posts 12 may have an outer diameter of about 50 millimetres (around 2 inches), for example.

The upper rail also includes a plurality of spaced apart holes 34 for receiving therethrough a threaded protrusion 20 extending from the upper end 22 a post 12.

NTELLECTUA^ROPERTV | office of n.z. 2 5 OCT 2007 RFCEIVED P:\OPER\MRF\Specifications\12662910 speci 246.doc-22/10/2007 The spacing of the holes 34 corresponds to the spacing of the larger holes 28.

A spacer 18 of the fence 10 is shown in the Figure 5. The spacer 18 is advantageously formed from a length of cylindrical PVC pipe or tube that is 5 dimensioned to fit over a post 12 of the fence to coaxially surround an exterior portion of the post 12, such that the spacer 18 is able to be moved along the length of the post 12, as indicated by the arrow 36 in Figure 6. It will be understood that the shape of the cross-section of the spacer 18 does not need to be cylindrical and could be other shapes, and that the spacer 18 may be made 10 from other suitable materials. Further, it will be understood that the spacer 18 may not fully coaxially surround the post 12 and may only partially fit around the exterior of the post 12, for example. Preferably, the largest dimension of the cross-section of the spacer 18 is larger than the largest dimension of the cross-sections of the apertures 26 of the rails 14, 16 such that the spacers 20 are able to 15 support the rails 14, 16 so that the do not move relative to the lengths of the posts 12 once located by the spacers 18, as will be described below.

To assemble the fence 10, the posts 12 may be vertically mounted spaced apart, such as in concrete or other ground for example, which is generally indicated by 20 the reference numeral 38. Spacers 18 are able to be placed over each of the posts 12 and a first lower rail 16 (as indicated by the arrow 40) having complementarily spaced apart through-holes 30 formed along its length that are dimensioned to receive therethrough the spaced apart posts 12 is placed over the posts 12 such that each post 12 is inserted through a respective through-hole of 25 the rail 16. The rail 16 is lowered down to rest substantially horizontally on the spacers 18, which function to vertically space apart the rail 16 from, and locate it relative to, the ground 38.

Further spacers 18 are then able to be placed over each post 12 and lowered 30 down on the first lower rail 16, and a second lower rail 16 (as generally indicated by the reference numeral 42) is able to be lowered down the posts 12 onto the further spacers 18. The further spacers 18 act to vertically space apart the intellectual property office of n.2. 2 5 OCT 2007 received P:\OPER\MRF\Specifications\126629IO speci 246.doc-22/l0/2007 horizontally arranged lower rails 16, as shown in Figure 7, and thereby vertically locate the second lower rail 16, as shown in Figure 1.

A respective third spacer 18 is then able to be placed over each of the posts 12 and lowered down on the second lower rail, and the upper rail 14 having complementarily spaced apart holes 28 formed along its length that are dimensioned to engage the spaced apart posts 12 is able to be placed over the posts 12 such that each hole 28 of the substantially horizontally arranged rail 14 receives the upper end 22 of a respective post 12.

It will be understood that spacers 18 locate the rails 16, 14 without the need for fasteners, however in certain applications it has been found to be practical to secure the upper rail 14 to the tops of the posts 12 to avoid any possibility of dislodgment of the upper rail 14 from the posts 12. The upper rail 14 may be secured to the tops of the posts 12 by way of the threaded protrusions 20 extending from the upper ends 22 the post 12, for example, that are received though the holes 34 in the rail 14. Wing nuts 24 are able to be tightened onto the threaded protrusions 22 over washers 32 to releasably secure the upper rail 14 to the posts 12, and thereby to provide a relatively rigid and secure fence 10.

Advantageously, the washers 32 are formed from the surface portions removed when forming the holes 28 in the rail 14, with the washers able to be formed by drilling holes in the removed surface portions for receiving therethrough the threaded portions 20.

While the use of threaded fasteners in the form of the wing nuts 24 engaging the threaded protrusion 20 to secure the upper rail 14 to the posts 12 have been described, it will be understood that other suitable fasteners may be used. i intellectual property office of n.z. 2 5 OCT 2007 received P \OPER\MRF\Spccifications\! 2662910 speci 246 doc-10/09/2007 The lengths of the spacers 18 can be used to determine the vertical spacings and hence locations of the rails 14, 16. Advantageously, the upper and lower ends 44, 46 of the spacers 18 of the fence disposed between the rails 14, 16 conform to the outer surfaces of the rails 14, 16 to facilitate the receipt of the rails 14, 16 in the 5 ends 44, 46 of the spacers 18, as shown in Figures 1 and 8. Similarly, the lower ends 46 of the spacers 18 disposed between the ground and the first rail 16 preferably provide a generally flat surface that substantially conforms to a preferably generally flat supporting surface surrounding the posts 12 that is provided by the ground 38.

End caps 48 may be used to close the openings 50 at the free ends 52 of the rails 14, 16 of the fence 10, as shown in Figure 1. Advantageously, the caps 48 may be PVC caps that are able to be press fit over the ends 52 of the rails 14, 16, for example, although it will be understood the caps 48 may be formed from any suitable material. Further, a fastener, such as self-tapping screw, or an adhesive, for example, may be used to securely fix the caps 48 to the end portions of the rails 14, 16. Alternatively, the caps 48 may substantially be plugs that are able to be inserted into to the interior of the openings 50 at the ends 52 of the rails 14, 16.

While the fence 10 includes one upper rail 14 and two lower rails 16 vertically spaced apart from one another by spacers 18, it will be understood that the number and vertical spacing of the rails 14, 16 is able to be adapted to suit requirements. For example, an alternative modular structure in the form of a fence 54 having one upper rail 14 and no lower rails 16 is shown in Figure 8. The fence 25 54 has three spaced apart posts 12, again preferably vertically mounted in cement or other ground 38. The holes 28 of the rail 14 may snugly receive the ends 22 of the post 12 to retain the rail 14 on the top of the posts 12 such that the posts 12 do not require the threaded protrusions 20 and correspondingly the rail 14 does not require the holes 34 to be formed in it. It will also be understood that as the rail 14 30 of the fence 54 sits on the top of the posts 12, there is no requirement in the P:\OPER\SAS\Jul-Dec 05\12662910_cap_NZ.doc-23/09/05 instance of the fence 54 for spacers 18 to vertically space the rail 14 from the ground 38.

In an alternative form (not shown), the fence may include one or more lower rails 5 16 and no upper rail 14, with the lower rails 16 vertically spaced apart from the ground 38 or one another by spacers 18 that fit over the posts 12.

It will also be understood that, while the fences 10 and 54 both have three posts 12, the number and sizes of the posts 12 may be varied to suit requirements.

To join adjacent rails 14, 16 end-to-end at corners or to provide fences longer than the lengths of the rails 14, 16, the fencelO may also include connectors such as the sleeve or ring 56 for connecting axially aligned rails 14 (or 16) that is shown in Figures 10 to 12. With reference initially to Figures 9 and 10, the sleeve 56 has 15 openings 58, 60 at either end for receiving the ends 52 of the rails 14. The sleeve 56 is shaped to correspond to the shapes of the cross-sections of the rails 14, and may be formed from a section of cylindrical PVC pipe, for example, although it will be understood that the cross-section of the sleeve 56 may be other shapes and that it may be formed from other suitable materials. Advantageously, the sleeve is 20 provided with chamfered edges (as indicated by reference numeral 62) to provide a gradual transition from an outer surface of each of the rails 14, 16 to an outer surface of the sleeve 56 in use.

The sleeve 56 is shown connecting adjacent ends 52 of two axially aligned rails 14 25 to one another in Figure 11. The end 52 of a first of the rails 14 is shown inserted into a first end 58 of the sleeve 56, and is secured to the sleeve 56 using a fastener, such as a self-tapping screw 64 for example, passing through both the sleeve 56 and the rail 14. Alternatively, the rail 14 may be secured to the sleeve 56 by way of an adhesive or a securing collar, for example. The end 52 of a 30 second of the rails 14 is shown ready to be inserted into the second opening 60 (as indicated by reference numeral 66) and subsequently secured to the sleeve 56 P:\OPER\SAS\Jul-Dec 05\12662910_cap_NZ.doc-23/09/05 to connect the rails 14 to one another.

A first half of an alternative connector for connecting two perpendicularly aligned rails to one another in the form of an elbow half-pipe 68 is shown in Figures 12 5 and 13. The elbow half-pipe 68 defines first and second perpendicularly aligned half-pipes 70, 72 for receiving ends 52 of two perpendicularly aligned rails 14 (or 16).

Two of the elbow half-pipes 68 are shown connecting two perpendicularly aligned 10 rails 14 to one another in Figures 14 and 15. The two elbow half-pipes 68 are arranged adjacent one another to substantially define a tubular elbow 74 having generally circular openings 76 and 78 into which the rails 14 to be connected to one another may be located. The end 52 of a first of the rails 14 is shown located in the first opening 76, and the end 52 of a second of the rails 14 is shown ready to 15 be inserted into the second opening 78 (as indicated by reference numeral 80). Again, a fastener such as a self-tapping screw 64 for example, may be used to secure the rails 14 to the elbow half-pipes 68 to connect the perpendicularly aligned rails 14 to one another.

A first half of a further alternative connector for connecting three rails end-to-end in the form of a T-shaped half-pipe 82 is shown in Figures 16 and 17. The T-shaped half-pipe is similar to the elbow-half pipe 68, with the T-shape half-pipe 82 defining half-pipes 84, 86, 88 for receiving the ends 52 of three respective rails 14 (or 16). Two of the T-shaped half-pipes 82 may be arranged adjacent one another to 25 define a tubular T-shaped part for connecting three rails 14 (in a similar manner to the elbow 68.

Advantageously, the elbow half-pipes 68 and the T-shape half-pipes 82 are formed by cutting conventional tubular PVC connectors in half, although it will be understood that the connectors may be formed from other materials.

P:\OPER\SAS\Jul-Dec 05\12662910_cap_NZ.doc-23/09/05 Further, it will be appreciated that other conventional connectors may be used to connect the rails 14, 16 end-to-end at various angles to one another. For example, three rails 14, 16 may be connected end-to-end by a substantially Y-shaped connector (not shown).

Further, while the connectors described above all substantially function at least partially fit around exterior surfaces of the rails 14, 16, it will be understood that other forms of connectors may be used. For example, the connectors may be in the form of brackets or inserts that are able to be inserted into the interiors of the 10 openings 52 of the rails 14, 16.

Figures 18 to 22 illustrate the adaptability of forms of the present invention to form modular structures such as barriers, yards, enclosures and the like that may be different shapes and sizes, and that may be optionally temporary, semi-permanent 15 or permanent. Advantageously, parts of the structures are able to be assembled and disassembled for later re-use and/or reassembly in a number of different arrangements. Forms of the present invention may be used to construct a stockyard or holding yard 90 for use to hold livestock 92 (Figure 18); or a round horse training and exercise yard 94 for holding and working horses 96 (Figure 19), 20 or a fence or guard 98 for protecting trees 100 from livestock 92 (Figure 20), or a pedestrian barrier 102 for controlling crowd 104 movement (Figure 21), for example. It will also be understood that forms of the present invention may also be used to form structures such as stables 106 having yards 108 (Figure 22), for example.

The modular structure has been described by way of example only and modifications and variations may be made without departing from the spirit and scope of the invention. Further, while the suitability of forms of the present invention to meet requirements for temporary or semi-permanent modular 30 structures will be understood, it will be also be understood that forms of the present invention are also applicable to permanent modular structures. Further, it P:\OPER\SAS\Jul-Dec 05\12662910_cap_NZ.doc-23/09/05 will also be understood that while the present invention is particularly applicable to forming fences, barriers and guards, forms of the invention may also encompass enclosing or frame structures, such as building frames and tent style arrangements, for example.

Throughout the specification, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated step or integer or group of steps or integers but not the exclusion of any other step or integer or group of steps or integers.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in New Zealand.

Claims (13)

P:\OPER\MRF\Specifications\126629IO speci 246.doc - 13- THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A modular structure including at least one substantially horizontal hollow tubular rail, the or each rail being a single polyvinylchloride (PVC) tube, and a plurality of substantially vertical posts, wherein the at least one rail has a plurality of apertures formed therein by removing surface portions of rail and each post is inserted into an aperture so as to locate the at least one rail to the posts.

2. A modular structure according to claim 1, wherein each post is provided with at least one spacer adapted to fit around the exterior of the post and support the at least one rail so as to vertically locate the at least one rail to the posts without fastening.

3. A modular structure according to claim 2, wherein at least one end of each spacer is adapted to conform to the exterior of the at least one rail.

4. A modular structure according to claim 2 or 3, wherein the at least one rail includes an upper rail and at least one lower rail, the posts being inserted respectively into the apertures of the rails so as to locate the upper rail on upper ends of the posts and the at least one lower rail on upper ends of the spacers.

5. A modular structure according to claim 4, wherein each upper end of each post includes a threaded projection which passes through the upper rail and cooperates with a washer and a nut so as to releasably secure the upper rail to the posts.

6. A modular structure according to any one of claims 2 to 5, wherein each spacer is a PVC tube.

7. A modular structure according to claim 6, wherein each rail is a cylindrical PVC tube and each spacer is a cylindrical PVC tube. FiNTBlECTUALPROPEBTV 1 office of n.z, I 2 5 OCT 2007 received P:\OPER\MRF\Specifications\l2662910 speci 246.doc - 14-

8. A modular structure according to any preceding claim, wherein an end cap is secured to each free end of each rail.

9. A modular structure according to any preceding claim, wherein the at least one rail includes a plurality of rails and adjacent ends of the rails are connected by a connector adapted to fit around the exterior of the adjacent ends.

10. A modular structure according to any preceding claim, wherein the modular structure is at least one of a fence, a barrier, a yard and an

11. A method for assembling a modular structure including the steps of: (a) assembling a plurality of substantially vertical posts; (b) forming a plurality of apertures in at least one substantially horizontal hollow tubular rail by removing surface portions of the at least one rail, the or each rail being a single PVC tube; and (c) inserting each post into an aperture so as to locate the at least one rail to the posts.

12. A modular structure substantially as hereinbefore described with reference to Figures 1 to 17 of the accompanying drawings.

13. A method for assembling a modular structure substantially as hereinbefore described with reference to Figures 1 to 17 of the accompanying drawings. end of claims [intellectual property i office of n.z. l 2 5 OCT 2007 IRECEIVED