WO2006085185A1

WO2006085185A1 - Rolled metal section; posts and frame members made from same; and assembly fittings

Info

Publication number: WO2006085185A1
Application number: PCT/IB2006/000217
Authority: WO
Inventors: Robert James Waller Hamlin
Original assignee: Robert James Waller Hamlin
Priority date: 2005-02-09
Filing date: 2006-02-06
Publication date: 2006-08-17

Abstract

A rolled or otherwise formed metal section (1) has a generally channel shape in cross-section with a pair of opposite flanges interconnected by a web of the channel. The web of the channel and each flange is interconnected by an arcuate corner section (3) that extends over from about 25 percent to about 45 percent of the width of the channel (being the distance between opposite flat sections of the two spaced flanges). The arcuate corner sections are generally of part circular shape in cross-section with a radius of curvature of from about 15 to about 25 percent of the width of the channel and an angle of arc in excess of 90 degrees, typically from 130 to 160 degrees. The free edge of each flange is formed into an arcuate inwardly directed lip (5). Different sizes of sections are provided for use as posts and frame members and various connector fittings for assembling frames are provided.

Description

ROLLED METAL SECTION; POSTS AND FRAME MEMBERS MADE FROM SAME; AND ASSEMBLY FITTINGS

FIELD OF THE INVENTION

This invention relates, in the first place, to a rolled metal section and to a post or other frame member including a stay, brace and other structural frame member made from that section.

In one particular application, the invention relates to a post made from a rolled metal section, the post being particularly suitable for use as a fence supporting post or a post for supporting trellis wires such as grape vine trellis wires.

In another application, the invention relates to frames constructed using sections of this invention as frame members, typically in association with posts of this invention, and the invention also relates to assembly fittings particularly adapted for use in association with the posts and other frame members forming frames serving various functions.

It is to be understood that the term "frame" as used in this specification is intended to mean any assembly of two or more elongate frame members that, in this instance, assume the form of rolled metal sections, and the term therefore includes an assembly of a post and associated stay supporting same; posts interconnected by braces or beams; beams supported by one or more posts and posts held in position by one or more stays. In particular, but not exclusively, the term is intended to mean any assembly of two or more elongate frame members wherein the frame is part of a fence or trellis construction BACKGROUND TO THE INVENTION

Wooden posts and other structural frame members are becoming increasingly expensive, prone to rotting and are sometimes in short supply. As a result, other materials of construction for use as fence and, in particular, trellis supporting posts are gaining in popularity and cost effectiveness. Metal posts and frame members that may be tubular in construction, but more typically assume the form of a rolled section, are of particular significance in this regard.

Accompanying the use of such metal posts and frame members is the consideration of achieving value for money having regard to the weight of metal used in a post or frame member and the cost of forming same. Also, a metal post or frame member can be rather flexible without detracting from its load supporting characteristics.

However, in certain applications, excess flexibility has disadvantages. In particular, applicant considers it undesirable for a metal post to be flexible beyond a certain rather low limit in application to supporting trellis wires for vines, in particular grape vines. This is due to the fact that movement occasioned by the action of wind on the vines can cause the posts to flex and, in consequence, have deleterious effects on the grape quality or production capacity of the vines.

OBJECT OF THE INVENTION

It is, accordingly, one object of this invention to provide a rolled metal section and a post or other frame member made from such a section wherein the metal section exhibits desirable characteristics particularly for use as a vine or fence supporting post or frame member that may also be used for other numerous purposes.

P0403PCT 2006/02/06 It is another object of the invention to provide one or more fittings for enabling frames to be constructed utilising posts and frame members according to the invention.

SUMMARY OF THE INVENTION

In accordance with one aspect of this invention there is provided a rolled or otherwise formed metal section that has a generally channel shape in cross- section with a pair of opposite flanges interconnected by a web of the channel and wherein the web of the channel and each flange is interconnected by an arcuate corner section and the free edge of each flange is formed into an arcuate inwardly directed lip, and wherein further, each of the flanges has a flat section between its associated arcuate section connecting it to the web and its associated arcuate inwardly directed lip, the section being characterised in that the arcuate corner sections connecting the web with each flange extend over from about 25 percent to about 45 percent of the width of the channel (being the distance between the two flat sections of the two spaced flanges).

Further features of this aspect of the invention provide for the arcuate corner sections to be of generally part circular shape in cross-section with a radius of curvature of from about 15 to about 25 percent of the width of the channel and preferably about 17 to 20 percent with the angle of arc preferably being in excess of 90 degrees, more preferably between 120 and 180 degrees, still more preferably between 130 and 160 degrees and most preferably about 150 degrees; for the arcuate sections to be interconnected by a central flat section of the web that is preferably recessed with respect to the arcuate corner sections; for the arcuate inwardly directed lip of each flange to have a width of from about 15 percent to about 25 percent of the width of the channel preferably about 18 percent; for the arcuate inwardly directed lip of each flange to be of generally part circular shape in cross-section with a radius of curvature of from about 7.5 to about 12.5 percent of the width of the

P0403PCT 2006/02/O₆ channel and preferably about 8 to 10 percent with the angle of arc preferably being between 120 and 180 degrees and most preferably about 165 degrees; and for the flat section of each flange to be provided with a series of spaced, typically elongate, apertures therethrough;.

The invention also provides a post or other frame member formed from a cut length of a section as defined above. In this instance, a series of spaced apertures through the flanges, and optionally through the web, and in particular, a central flat section of the web, where same exists, are configured for cooperation with clips or other fasteners that may be employed to attach items such as fence or trellis wires to a post or frame member in order to become supported thereby or that may be employed for connecting frame members to each other.

Preferably the section is formed by the continuous rolling of coiled metal strip and the metal strip is punched in the early stages of production and prior to significant shape in consequent on rolling in order to form a series of apertures or other perforations extending along the length of the final section.

It will be understood that any suitable metal can be used for forming the section but that corrosion resistant steel, typically stainless steel, will generally be preferred. Alternatively, a mild steel suitably treated to render it corrosion resistant may be employed in which case, after cutting the section into predetermined lengths, such as lengths suitable for use as posts, the lengths are subjected to a suitable treatment to render them corrosion resistant.

In accordance with a second aspect of the invention there is provided a spacer pad provided with a generally flat face and an oppositely directed contoured face having, in cross-section, a centrally extending ridge formation generally complementarily shaped to a recess in a rolled metal section, the spacer pad having one or more perforations therethrough and being

P0403PCT 2006/Q2/06 configured such that its flat face may operatively engage a cooperating flat face associated with a cooperating frame member to enable the cooperating frame member to be secured to the metal section using a fastener passing through aligned perforations in cooperating frame member, metal section and cooperating spacer pad.

Further features of the invention provide for the spacer pad to be of generally disc shape with said ridge extending generally diametrically across one face thereof and in which case a perforation is at least provided through the central region of the spacer pad; for the spacer pad to be made of injection moulded plastics material that provides electrically insulating properties as well as sufficient rigidity to enable frame members to be secured together sufficiently rigidly; and for the frame members to include generally channel shaped frame members having a recess in the web thereof with which the ridge of the spacer pad is to cooperate.

In accordance with a third aspect of the invention there is provided a connector fitting having a generally flat face and an oppositely directed contoured face having, in cross-section, a pair of grooves complementarily shaped to a pair of arcuate inwardly directed lips of the flanges of a rolled metal section as defined above the connector fitting having one or more perforations therethrough configured such that its flat face may operatively engage a cooperating flat face associated with a cooperating frame member to enable the cooperating frame member to be secured using a fastener passing through aligned perforations in cooperating frame member, metal section and cooperating connector fitting.

In accordance with a fourth aspect of the invention there is provided an end fitting having a functional formation at one end thereof and a spigot formation configured to be received in an end of a section as defined above.

P0403PCT 2006/Q2/06 A further feature of this aspect of the invention provides for the functional formation to be selected from a domed end cap, and a connector, in particular but not exclusively, an angle connector for connecting two frame members in end to end relationship; and for the connector spigot formation to be configured as a double spigot for interchangeable cooperation with two different sizes of sections as defined above.

It is a particular feature of the invention that the rolled metal section defined above be employed as posts and frame members in two different cross- sectional sizes thereof, and that braces be provided that correspond in cross- sectional shape to the web portion of the rolled metal section with a major portion of the side flanges removed.

In order that the above and other features of the invention may be more fully understood embodiments thereof will now be described with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:-

Figure 1 is an isometric view of a length of one embodiment of section according to the invention that is suitable for use in forming posts and frame members;

Figure 2 is a cross-section thereof;

Figure 3 is an exploded perspective view illustrating a joint between a supporting post and an inclined beam;

Figure 4 is an isometric view of a section having a smaller cross- sectional size for use particularly as stays and beams;

PQ403PCT 2006/02/06 Figure 5 is an isometric view of a brace having the cross-sectional shape of the composite web portion of the rolled metal section illustrated in Figures 1 and 2;

Figure 6 is an isometric view of a brace having a cross-sectional shape of the composite web portion of the rolled metal section illustrated in Figure 4;

Figure 7 is a rear perspective view of a spacer pad configured to be used in association with the rolled metal section illustrated in

Figures 1 and 2;

Figure 8 is a similar rear perspective view of a spacer pad configured to be used in association with the smaller cross-sectioned frame member illustrated in Figure 4;

Figure 9 illustrates, in elevation, a connection between a transverse beam and upright post using spacer pads according to the invention;

Figure 10 is a cross-section taken through a joint between a larger cross-sectioned and a smaller cross-sectioned frame member with the frame members being illustrated as extending in the same direction purely for illustrative purposes;

Figure 11 is a view similar to Figure 10 but showing a joint between a larger cross-sectioned frame member and a brace member;

Figure 12 is a perspective illustration of a washer configured to be received in the keyhole shaped perforation through the web of the smaller cross-sectioned frame member; CT 2006/02/O₆ Figure 13 is a view similar to Figure 10 but showing a joint between a larger cross-sectioned frame member and a brace member using a connector fitting engaging the arcuate inwardly directed lips of the section of the frame member;

Figure 14 is a schematic elevation of an end fitting in the form of an angle connector for connecting frame members in end to end relationship;

Figure 15 is a cross-section through the spigot taken along line XV to

XV in Figure 14;

Figure 16 is an end view of a post section and brace section clamped together all a closed box section;

Figure 17 illustrates an end fitting in the form of a domed end cap for attachment to a free end of a post or frame member and,

Figures 18, 19 and 20 illustrate schematically examples of frameworks to which the present invention can be applied.

DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

In the embodiment of the invention illustrated in Figures 1 and 2 a section, generally indicated by numeral (1), is produced that is suitable for use in forming fence or trellis supporting posts as well as other frame members as will become more apparent from the following. The section is formed from coiled metal plate by a continuous rolling process wherein successive stages are employed to form a channel section from a suitable gauge of metal plate in strip form, in a manner that is generally well-known to those skilled in the art.

P04Q3 PCT 2006/02/06 The resultant channel section has a web composed of a central flat section (2) adjoined on each side by arcuate corner sections (3) that form part of, and connect each side of the central flat web section with, a flat section (4) of each flange of the channel. The two flat sections (4) of the flanges are in planes that are parallel to each other. The free edge of each flange is formed into an arcuate inwardly directed lip (5). It will be appreciated by those skilled in the art that the central flat web section may be formed in the early stages of the rolling process and can, thereafter, be employed for the purpose of accurately guiding the partly formed section through subsequent rolling stages of the production process.

In has been found that the relationship of the various proportions of the section are important for reasons of strength and rigidity, particularly from the point of view of metal content. Consequently, as a general rule, the arcuate corner sections that connect the central flat section of the web with the flat section of each flange occupy about 25 percent to about 45 percent, and preferably about 30 to 40 percent, of the width of the channel (being the distance between the two flat sections of the flanges). The arcuate sections are of generally part-circular shape in cross-section with the angle of arc being in excess of 90 degrees, and in this instance about 150 degrees.

Simply by way of example, in the instance of a channel section having an overall width of about 56 millimetres and a depth of about 35 millimetres, a radius of curvature of 10 millimetres passing through an angle of arc of about 150 degrees is advantageously employed for the arcuate corner sections. This gives an arcuate corner section having a width of about 22 millimetres that represents about 34 percent of the width of the channel, and a central flat section of the web having a width of about 20 millimetres. Indications are that this proportion is approaching optimal for use as a fence or trellis post.

The arcuate inwardly directed lip of each flange generally has a width of from 15 percent to 30 percent, preferably about 18 percent, of the width of the

P04Q3PCT 200δ/02/Q6 channel and these lips are generally of part circular shape in cross-section. In the instance of the specific example given above, the radius of curvature of the lips is about 5 millimetres passing through an arc of about 165 degrees. The innermost free edge (6) of each returning lip terminates in a plane that is at a slight incline, typically about 15 degrees, to the plane of the associated flat section of the flange.

In the specific example of the invention described above the material used was a 1 ,1 millimetre strip of grade 430 stainless steel.

In the early stages of the continuous rolling process of a section suitable for use as posts, and conveniently at the outset of the process, the metal strip is provided with a series of spaced longitudinally elongate apertures (7) for cooperation with clips for holding transverse wires relative to the post and other perforations (8) through the flat web section for receiving other fittings or fasteners. The shape and nature of the apertures will depend entirely on the service to be performed by the completed section. Clearly the spacing of the elongate apertures and circular perforations is selected for the particular application such as that appropriate to use as trellis posts for supporting grape vine trellis wires or, alternatively, for use as fence posts.

For use in the construction of frames, a smaller cross-sectioned frame member section (10) that is aimed at use as a stay or beam and that is illustrated in Figure 4, may be made proportionally smaller and, in this instance, to an overall width of 35 millimetres and depth of 22 millimetres. The spacing of the elongate apertures (11) is the same as those (7) of the larger section whilst the configuration of the apertures (12) may be somewhat different and could be keyhole shaped as further described below.

Further sections that are produced for use in frameworks assembled using the sections described above, are a larger cross-sectioned brace member (14) (illustrated in Figure 5) and a smaller cross-sectioned brace member

P0403PCT 2006/02/06 (15) (illustrated in Figure 6) each of which corresponds in cross-sectional shape to the cross-sectional shape of the composite web of the larger and smaller sections respectively with the flat sections of the flanges and inwardly directed lips removed. It is to be noted that a substantial cost saving is achieved in instances in which the brace member can be employed in place of a full section has been brace member utilise is about one half of the steel.

Turning now to Figures 7, 10 and 11 of the drawings, there is illustrated a larger spacer pad (16) of circular shape and having a flat face (17) and an oppositely directed contoured face (18). The contoured face has a diametrically extending broad ridge (19) that is configured to be accommodated neatly within the groove defined by the flat central section (2) of the web and arcuate corner sections (3) adjoining same. The cooperation between the groove and contoured face of the spacer pad is most clearly shown in Figures 10 and 11. These larger spacer pads will thus also cooperate with the larger brace member sections as will be quite apparent from a reference to Figure 11.

A similar spacer pad (21) (Figure 8) is configured with a flat face (22) and ridge (23) for use in cooperation with the smaller frame member section (10) or, in the alternative, the corresponding smaller brace member (15) as illustrated in Figures 10 and 11 respectively.

It will be understood that the pads described above enable either two larger or two smaller cross-sectioned frame members to be secured to each other in back-to-back relationship with the flat faces of the pads engaging each other and a fastener passing through the central apertures (20) provided in the pads. As illustrated in Figures 3, 10 and 11 , the fastener could take the form of a pop rivet (27) or any other suitable fastener such as a nut and bolt. Clearly, the two frame members can extend at any angle relative to each other and relative to the axis of the fastener, as indicated in Figure 9.

P0403PCT 200δ/02/₀₆ In this regard it is to be mentioned that indexing protrusions and recesses could be provided in the flat surfaces in order to enable particular angles to be achieved at which frame members extend relative to each other. Typically, such angles would be spaced apart by 15 degrees, or could be a selected set of angles such as 30 degrees, 45 degrees, 60 degrees and 90 degrees.

Figure 12 illustrates a washer (24) that has a central perforation (25) and a keyhole shaped protrusion (26) corresponding to the keyhole shape of aperture (12) provided in the smaller channel shaped frame member section (10). The purpose to be served by these washers is to receive a fastener such as a nail, bolt or the like passing therethrough in order to fix the relevant frame member or brace to an existing wooden support. The use of such a water enables electrolytic corrosion to be avoided.

In the event that circumstances require the front of a channel shaped frame member to be attached to another, the connector fitting (28) illustrated in Figure 13 may be employed. Such a connector fitting is injection moulded from plastics material and has an operatively outer flat face (29) and an inner face provided with a pair of laterally spaced grooves (30) that a complementary to the outer surface of the inwardly directed lips (5). In this instance, a fastener (31) may pass through to the web (2) of the channel shaped frame member. Using these connector fitting is posts and frame members can be connected front to front and by using one connector fitting and one spacer pad, back to front.

In order to further extend the versatility of the frame members there may be provided injection moulded end fittings for application to the ends of particular frame members. Typical of such end fittings is an angle connector (32) (see Figure 14) that has a spigot (33) shaped to fit neatly within the relevant cross- section of a post or frame member cut from a section of this invention.

P0403PCT 2006/02/06 As shown in Figure 15, the spigot may have an outer surface (34) configured to fit neatly into the larger section and an inner surface (35) configured to fit onto the outer surface of the smaller of the two sections described above. Additional spigot webs (36) could be provided to fit on the inside of the smaller of the two sections. Of course, the spigots can be secured in the operative position in any suitable way, as may be required.

Reverting to the angle connector of Figure 14, the spigot has at its operatively outer end, a connector formation (37) that in this instance has an abutment face extending at 45 degrees to the axis of the spigot. The abutment face has a suitable perforation (38) for receiving a fastener passing therethrough. Such an angle connector can be used to connect two frame members at right angles to each other, as indicated by dotted lines (32a) or alternatively by reversing the one angle connector, two frame members can be connected in collinear relationship.

It is to be noted that in practice, and as illustrated in Figure 16, it is possible to secure a brace member (14) across the arcuate inwardly directed lips of a channel section (1) thereby creating a box section of substantially greater strength. Such a facility may be provided for any partway along the length of a post, for example, typically in the region in which it enters the ground.

Figure 17 illustrates another end fitting in the form of an end cap (39) carried at the end of a spigot (40) as described above. Such an end Is particularly useful in the event that a fabric or mesh cover is to be supported by the upper end of a post, for example. The centre of the dome may be provided with an aperture to enable clips or fasteners to be utilised to attach a cover or mesh to the end cap.

Accordingly, any required framework that may be typical of a fence or trellis construction, can be constructed using the components described above and simply for the purpose of illustration, Figure 17 illustrates a pair of posts (41)

P0403PCT 2006/02/Q₆ joined by a transverse beam (42) at their upper ends; Figure 14 illustrates a frame in which a pair of gabled beams (43) are supported at the upper ends of a pair of posts (44) and interconnected by means of a transverse brace (45); and Figure 15 illustrates an inclined beam (46) supported at the upper ends of a pair of posts (47) with a pair of stays (48) reinforcing the posts and a transverse brace (49) connecting the longer post to the transverse beam. In each instance the joint between one frame member and another is made as described above.

It will be understood that numerous variations may be made to the various components described above and that the frames can assume numerous different forms.

The invention therefore provides an extremely useful rolled metal section, posts and other frame members including stays, braces and, other structural frame members made from that section as well as a variety of fittings enabling the easy assembly of frames utilising these components.

P0403PCT 2006/Q2/06

Claims

CLAIMS:

1. A rolled or otherwise formed metal section (1) that has a generally channel shape in cross-section with a pair of opposite flanges interconnected by a web of the channel and wherein the web of the channel and each flange is interconnected by an arcuate corner section (3) and the free edge of each flange is formed into an arcuate inwardly directed lip (5), and wherein further, each of the flanges has a flat section (4) between its associated arcuate section connecting it to the web and its associated arcuate inwardly directed lip, the section being characterised in that the arcuate corner sections connecting the web with each flange extend over from about 25 percent to about 45 percent of the width of the channel (being the distance between the two flat sections of the two spaced flanges).

2. A rolled or otherwise formed metal section as claimed in claim 1 in which the arcuate corner sections are of generally part circular shape in cross-section with a radius of curvature of from about 15 to about 25 percent of the width of the channel with the angle of arc being in excess of 90 degrees.

3. A rolled or otherwise formed metal section as claimed in claim 2 in which the radius of curvature of the arcuate corner sections is from about 17 to about 20 percent of the width of the channel with the angle of arc being between 120 and 180 degrees.

4. A rolled or otherwise formed metal section as claimed in claim 3 in which, angle of arc is between 130 and 160 degrees.

5. A rolled or otherwise formed metal section as claimed in any one of the preceding claims in which the arcuate sections are interconnected

P0403PCT 2006/02/06 by a central flat section (2) of the web that is recessed with respect to the arcuate corner sections.

6. A rolled or otherwise formed metal section as claimed in any one of the preceding claims in which the arcuate inwardly directed lip of each flange has a width of from about 15 percent to about 25 percent of the width of the channel.

7. A rolled or otherwise formed metal section as claimed in claim 6 in which the arcuate inwardly directed lip of each flange is of generally part circular shape in cross-section with a radius of curvature of from about 7.5 to about 12.5 percent of the width of the channel and an angle of arc between 120 and 180 degrees.

8. A rolled or otherwise formed metal section as claimed in any one of the preceding claims in which the flat section of each flange is provided with a series of spaced apertures (7, 8, 12) therethrough.

9. A post or other frame member formed from a cut length of a section as claimed in any one of claims 1 to 8.

10. A post or other frame member as claimed in claim 9 in which a series of spaced apertures is provided through the flanges, and optionally through the web the apertures being configured for cooperation with clips or other fasteners employed to attach items to a post or frame member.

11. A frame comprising a plurality of posts or other frame members as claimed in either one of claims 9 and 10 in which a spacer pad (16, 21) is provided with a generally flat face and an oppositely directed contoured face having, in cross-section, a centrally extending ridge (19, 23) formation generally complementarily shaped to a recess in a

P0403PCT 20Q6/02/06 post or frame member, the spacer pad having one or more perforations (20) therethrough and being configured such that its flat face may operatively engage a cooperating flat face associated with a cooperating frame member to enable the cooperating frame member to be secured to the metal section using a fastener (27) passing through aligned perforations in cooperating frame member, metal section and cooperating spacer pad.

12. A frame as claimed in claim 11 in which the spacer pad is of generally disc shape with said ridge extending generally diametrically across one face thereof and a perforation is provided through the central region of the spacer pad.

13. A frame as claimed in either one of claims 11 or 12 in which there is provided a connector fitting (28) having a generally flat face (29) and an oppositely directed contoured face having, in cross-section, a pair of grooves (30) complementarily shaped to a pair of arcuate inwardly directed lips of the flanges of a rolled metal section, the connector fitting having one or more perforations therethrough configured such that its flat face may operatively engage a cooperating flat face associated with a cooperating frame member to enable the cooperating frame member to be secured using a fastener passing through aligned perforations in a cooperating frame member, metal section and cooperating connector fitting.

14. A frame as claimed in any one of claims 11 to 13 in which an end fitting is included having a functional formation (37, 39) at one end thereof and a spigot formation (33, 40) configured to be received in an end of a post or frame member section.

P0403PCT 2006/Q2/06

15. A frame as claimed in claim 14 in which the spigot formation is configured as a double spigot for selective cooperation with either one of two different sizes of post or frame member section.

16. Spacer pads, connector fittings and end fittings especially configured for the purpose of utilisation in a frame as claimed in any one of claims 11 to 15.

P0403PCT 2006/02/06