CROSS REFERENCE TO RELATED APPLICATIONS

This application is the U.S. national phase of international application PCT/AU2016/000038 filed Feb. 13, 2016 which designated the U.S., and claims the priority of Australian patent application No. 2015900469 filed Feb. 13, 2015, the entire contents of both of which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention is directed extruded aluminum members which are comprised of parts that snap fit together without requiring any screws or rivets. Such members can be used in the construction of assemblies such as post and rail fences, fence panels and balustrades and the like to improve ease of manufacture and installation.

BACKGROUND OF THE INVENTION

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

Aluminum panels comprising spaced apart post members and an array of spaced apart parallel slat members which are snap fitted together without separate fasteners are quite common and find popularity due to their aesthetic appeal, clean lines, and resistance to weathering and corrosion. Popular uses for such panels include fence panels and screens.

Australian patent application 2006230672 illustrates a known type of snap together aluminum panel. This panel comprises unitary post members into which slots are cut and edges of slat members pass into the slots. The slats are held in the posts by clamping legs/fins. The post and clamping legs are formed as a single piece typically by extrusion.

This type of panel assembly suffers from a number of disadvantages. One disadvantage is in the increase cost of manufacture of the post containing the cutouts. The cutouts are formed using a computer controlled cutting machine such as a CNC router. This is a complex and relatively expensive manner in which to provide cutouts.

Another disadvantage is that the clamping legs/fins can lose their memory over time. The reason for this is that the “hinge” part of the legs comprises the area where the legs extend from an inner wall of the post, and this area (the hinge area) is relatively small and therefore more likely susceptible to fatigue over time. Should this occur, the slats can move or slip or begin to rattle and it may be necessary to replace the entire post.

Another disadvantage with this type of panel is that it is quite difficult to fit the panel into a desired position. For example, panels may be required to be located between brick or block uprights. In that case the panels need to be fastened to the uprights using masonry anchors or something similar. The design of the panel is such that an internal masonry anchor cannot be used as there is no access to the internal back wall of the panel post. Thus, external brackets may need to be used which can be unsightly. Alternatively, a masonry anchor can be drilled entirely through the post which leaves a visible anchor point which is also unsightly.

Another disadvantage is that if there is any damage to a particular slat, it becomes necessary to remove the entire post from the brick or block uprights (for example). Refitting of a new post can be time-consuming and may require drilling of new openings in the uprights.

There is a need for improved snap-fit members which are composed of at least two parts that can be fastened together readily for use in the construction of assemblies such as fences, fence panels, balustrades and the like and which can overcome at least some of the above-mentioned disadvantages or which can provide a commercial choice in the marketplace.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a post comprising:

a base member and a cover member having corresponding snap fit formations by which the base member and the cover member are fastened to each other,

the cover member including an end wall with first and second buttressing walls projecting therefrom,

the base member comprising a base wall with first and second clamping legs extending therefrom for clamping a third member therebetween, the clamping legs converging outwardly and inwardly from the base wall to present a minimum space therebetween;

at least one opening formed through the base wall or the end wall for passage of a third member therethrough;

wherein the third member is oversized relative to the minimum space between the first and second clamping legs whereby forcing the third member through the minimum space urges portions of the clamping legs against walls of the cover member to thereby assist in retaining the cover member fast with the base member.

In a first embodiment of the invention the buttressing walls comprise sidewalls that extend over opposed sides of the base member. In this embodiment the at least one opening for passage of the slat is formed through the cover member. In this first embodiment the snap fit formations comprise inwardly projecting lips formed along the opposed sidewalls and corresponding rebates formed along outer edges of the base wall.

In a second embodiment of the invention the base wall further includes first and second sidewalls extending from opposed sides of the base walls with the first and second clamping legs being located between the first and second sidewalls.

Preferably, in the second embodiment remote ends of the first and second sidewalls are snap fitted to opposed sides of the cover.

It is preferred that in the second embodiment the buttressing walls and the clamping legs have portions that snap-fit together. For example, the clamping legs may be formed with outwardly disposed first grooves that receive corresponding inwardly projecting first lips of the buttressing walls.

Preferably the first and second clamping legs terminate in respective tapering portions to assist in guiding the third member there between in use. It is also preferable that the first and second clamping legs be formed with second outwardly disposed grooves that engage with corresponding inwardly projecting second lips of the buttressing walls during clamping of the third member.

In a third embodiment of the present invention first and second lateral wings extend from distal ends of the first and second sidewalls wherein outer edges of the lateral wings are formed with snap fit formations for receiving a balustrade or other cover. The snap fit formations may include a slot having a side formed as an undercut adjacent a tapering ridge whereby the tapering ridge assists in installing an edge of a balustrade into the slot.

A post arrangement according to an embodiment of the invention, such as that illustrated inFIGS. 1 and 2provides several advantages. Firstly, fitment of the panel to a surround is straightforward in that the base member can be easily screwed or otherwise fastened to the surround prior to attachment of the cover member. Secondly, if a slat is damaged and needs to be replaced, the slat and the cover member can be removed while keeping the base member fixed to the surround. That is, it is no longer necessary to remove the entire post to replace a slat. Thirdly, the openings in the cover member (through which the slats pass) no longer need to be routed or otherwise cut through the cover member using expensive machinery. Because the cover member can be substantially U-shaped or C shaped, a simple punch die can be used to form the openings as both sides of the interconnecting wall are now available for the punching operation. Fourthly, by having the clamping legs forming part of (and typically essentially the entire) side wall of the base member, the “hinge area” is much more robust and there is much less likelihood of fatigue and loss of memory.

Another advantage of the post according to the present invention is that the base member profile can remain the same for slats of different sizes as all that is required is to provide a different cover member with larger or smaller openings (depending on the size of the slats) and which can be snap fitted to the base member.

Another advantage is that should there be damage to a clamping leg on the base member; the base member can be replaced without requiring replacement of the entire post.

In another form, the invention resides in a panel comprising at least one post as described above and at least one slat.

Throughout the specification, the term “panel” will be used to include but not limited to fencing, gates, awnings, window screens, other types of screens, and fixed louvres.

The term “post” is meant to be interpreted broadly and to include any type of elongate member to which slats or other members can be fitted. The post may be positioned substantially vertically in use, substantially horizontally in use, or possibly at some other angle. The post may be an end post or an intermediate post.

The post will typically be formed of aluminum and typically from extruded aluminum as this is a common process. However, there may be circumstances where the post is made from materials other than aluminum such as plastics, or from metals other than aluminum, or from laminate materials and the like. If the post is formed from aluminum, the aluminum may be treated for corrosion resistance and the treatment may include anodizing, powder coating, painting and the like.

The length of the post can vary, typically, depending on the size of the panel to be formed. It is envisaged that the usual length of the post will be between 40 cm (for instance a screen for a small toilet window) up to 2 or 3 m for a larger fence screen. The post may comprise a single post member or may comprise a number of post members connected together by any suitable means. For instance, the post members may be connected using an internal sleeve type fixing, or an external socket type arrangement or using fasteners or welding and the like. If post members are to be connected together, it is highly preferred that this is done in an aesthetically pleasing manner.

The post will typically be formed from two parts being the base member and the cover member and that can be snap fitted together.

The base member may be of any suitable length and width and have any suitable thickness depending on the size and shape of the panel to be formed and whether the panel will subject to high wind loading, twisting or other types of forces on the panel. It is envisaged that the base member will have a width and a depth of between 10 mm up to 200 mm. Similarly, it is envisaged that the wall thickness of the base member (depending on material) will be between 1-10 mm.

The base member will typically be substantially U-shaped comprising a base wall and a pair of upstanding sidewalls. However, there may be circumstances where the channel member may have a curved base wall. There may be circumstances where the base wall may have other configurations, inter alia, for aesthetic reasons, for functional reasons (for instance the post may be used as balustrading) or for fitment reasons (for instance the support may include a recess or rebate in which the base wall fits).

The sidewalls preferably have a width which approximates the width of the sidewalls of the cover member such that when the base member is attached to the cover member, the sidewalls extend substantially through the cover member towards the base wall of the cover member. This can improve the clamping action to the slats since the side walls of the cover member may act as buttresses or buttress walls and assist in holding the clamping legs of the base member firmly against the slat.

The clamping leg may comprise a turned in portion of each side wall. It is preferred that substantially the entire side wall assists in the clamping action against the slat and this will be described in greater detail below. There may be circumstances where each side wall contains more than one turned in portion and may be circumstances where only one side wall contains a turned in portion.

The end wall of the cover member is formed with a plurality of openings through which the end of slats can pass. Because the cover member can comprise a simple U-shaped type profile, it is possible to form the openings using a simple punch die which greatly improves manufacturing speed and reduces manufacturing cost. The number of openings will depend on the number of slats that are to be accommodated. The shape of the openings will depend on the shape of the slats that are to be accommodated. It is envisaged that the openings will be substantially identical or, for decorative or strength purposes, some openings may be larger or smaller than others to provide a panel having larger and smaller slats.

Some form of snap fitting means is provided on the base member and/or the cover member to enable these parts to be snap fitted together. In one form, the snap fitting means may comprise small turned in lips on the cover member which engage into small rebates or recesses on the base member. Alternatively, the base member may be formed with small turned in lips and the cover member may be formed with small rebates or recesses.

The slats will typically comprise extruded aluminum members. Such members are well-known. These members are usually substantially hollow. It is however possible for the members to be filled with foam or other material to improve strength properties, insulation properties, sound deadening properties and the like. The slats may also comprise materials other than aluminum. For instance, the slats may be formed from solid or hollow plastics. It is envisaged that the slats may also comprise wood or wood laminate slats. The slats may comprise a number of smaller parts attached together to form the slat. The slat may be formed from laminated material or other built-up materials. It is envisaged that the slats may also be formed from a grid like or mesh like material to provide security and ventilation. The slats may be formed from substantially clear material. It is also envisaged that the slats may have end brackets or end pieces adapted to pass into the openings on the post.

