(Heavy duty screwjack system of joinery)

TECHNICAL FIELD

[001] The present invention relates to an improved system for joining structural elements that has been found to be particularly useful in advancing joinery of panels through a system of joint components with features for structure and adaptation to reinforce panel joins, facilitating innovative method and structural form.

BACKGROUND OF THE INVENTION

The present invention relates to building and construction of structures incorporating prefabricated units. Specifically, the erection of structures from prefabricated units has hitherto been restricted in practice to a limited variety of materials and methods of joining owing to the need to focus on a few basic types of structural elements susceptible to mass production, standardization that often require cutting to length and limited compatibility with available fixing methods. Thus, there has been little variation in style and only limited adaptability for DIY modular construction.

To meet these deficiencies my invention has the general object of providing an improved system of joinery that will offer access to a greater range of prefabricated structural units.

A further remedy is to provide a simple method for DIY enthusiasts to assemble prefabricated structural elements that are readily available, readily adaptable to outdoor environmental conditions (also fire resistant, flood proof) and generally more durable.

It is common knowledge that panel shaped materials need structural reinforcement when joining that is why panel shaped materials are usually limited to cladding, however a survey of the state of art bracket componentry for glass panels identifies pool fencing and shower screen glass joiners with a H section profile. The middle wall of the H profile creates a gap between materials being joined, due to the join due to the fixing bolt passing through the ‘H’ section wall; being made of precast material they are quite bulky for the capacity of the bracket that is restricted to 12mm thickness, and they are expensive. This form of panel joining componentry is available in ‘I’ straight join, ‘L’ comer joins, and a hinged join. Although this form of componentry is heavy duty, being made to withstand the weight of 12 mm thick glass. This form of prior art would not be compatible with joining pavers and tiles as articulated in this invention. The body configuring of these joiners and cost are impractical for joining pavers in a practical manner, therefor they are restricted to glass fencing application.

A survey of prior art identifies a “glass clips” that are available for glass display assembly, with a form of a C section embodiment for joining at the corner edge areas of structural elements. Consisting of components of configured C section profile, structural elements can join without a having gap between (as seen with H section joiners). The capacity range allows joining of material to a maximum of 14.5mm in thickness albeit for the straight join only (from one supplier) and are available in configurations of ‘T’, ‘X’ and ‘L’ joins with 12.5mm capacity between c-section walls from other suppliers that includes the full range of ‘I’, ‘L’, ‘T’, ‘X’.

This form of prior art uses a grub screw as a form of ‘Holding Bolt’ to apply pressure to the side of the glass pressing it against the side wall of the joining component. The use of a threaded grub screw in the context of applying pressure is termed in engineering a screwjack. A grub screw being a screwjack is more than just a threaded bolt. It allows the ability to adjust pressure to the surface of the material without penetrating the surface. The integrity of the wall structure of components that hold screwjacks require extra consideration. A noted feature of the preferred embodiment used in glass displays is that it features threaded holes placed near to the fold, as placing them further out from the edge would create extra flex on the wall due to leverage effects. Being close to the edge of the glass being joined is not such an issue as grub screws have a nylon tip that cushion surface contact. When joining concrete pavers, nylon tips may not be used, and the position of the grub screw ideally should be further from the edge of the paver, due to being more chalky type of material than hardened glass. Cast options are more prone to breaking (rather than bending), therefore requiring a bulkier body. This method of manufacture for joining 20mm or 40mm pavers would require a bulkier wall thickness, making it a less preferred option. The cast body maybe have benefits for mass production costing and maybe acceptable in a fixed position, however, under the strain of a heavy moving weight it would soon break. Cast being high tensile is less likely to flex and so is prone to breaking under pressure.

The ‘Glass Clip’ is made from folded sheet metal, a preferred option of material. The form of the body can be made slimline, and the body will flex, rather than break under heavy duty strain, a crucial function necessary for safe assembly of pavers or large panels for building temporary structures. One of the suppliers of the glass clip does not offer an ‘I’ straight join as glass panes are cut to size to suit the display cabinet assembly the system is primarily used for. Another supplier of the ‘glass clip’ does use utilize an ‘I’ -Straight join however the capacity (distance between c-section walls) is 14.5mm being slightly larger than the other X, L, T component in the range. (Not sure why it is different to others in the range. It is noted the side reference is ‘www.madeinchina.com)

The inclusion of a straight join to extend lengths would be necessary for joining homogenous units such as pavers and tiles used for landscaping application such as garden edging. More importantly the capacity of the distance between walls of the c-section would need to increase from 15-45 to be compatible with most standard paver thicknesses and the wall thickness of the componentry would need to be significantly increased to achieve the heavy-duty strength required to hold the greater size and weight of masonry pavers.

In systems theory it is known that a minor adjustment in the component’s features can have a disproportional effect on the emergent outcomes. Size as a catalyst to the proliferation of emergent outcomes relating to a system of joinery exemplifies this notion, as will be demonstrated in this proceeding specification.

Masonry is seen to be more practical for permanent immovable construction due to both the weight of the material and the current available methods of joining masonry being permanent fixing methods. Being able to disassemble and reassemble for transportation is an advantage for building with masonry structural elements that has not be perfected in the field of masonry yet. Prior art indicates that masonry self-supporting assembly using pavers and tiles has not emerged from the 2-Dimensional plane like glass (noting display cabinets and pool fencing) due to lack of an inventive step to facilitate such change.

As will be explained in the proceeding patent specification 3-DimensionalTiling and Paving along with advancing the art of assembly in general, particularly the art of assembling panels is achievable with a bracketed system of joinery that overcomes joining brittle materials and panels near the edges by use of a joining component that braces structural elements and a screwjack fixing mechanism that clamps structural elements as opposed to creating holes in the surface. (Note also panels also have extra strain due to the thickness to weight ratio)

Before ending this background section, it is worth noting more distant prior art relating to the art of joining RHS Rectangular Hollow Section brackets (for joining metal lengths) (Australian Registered Design 198704415, Design 201816824, Design 201816825) that lack appropriate dimensions, lack the feature of a screwjack for joining masonry and lack of a rigid wall to support a screwjack. These brackets, although they have configurative form of L and T joiners that resemble parts of the system to be described in the next section, they are designed for conventional tech screw fixings or bolt style fixing that require a nut on the other end of bolts and holes in the structural elements. The difference is walls are pulled inwards against the structural elements when this conventional style of fixing is used. Although at first glance these brackets may look similar in shape, functionally they lack structural integrity required of a screw jack joining system a key feature for joining materials such as masonry pavers and plywood panels.

Prior art shows that there is a lack of bracketed joining components not only based on size and robustness, but also in terms of complimentary hardware such as suitably configured hinges. There is a version of hinge that is designed to be used for joining 6mm glass to timber cabinet, consisting of a c-section type of leaf and a standard plate leaf that is joined by a pin to create the knuckle, however there is no prior art suitable for joining pavers to pavers (porcelain or natural stone pavers ranging from 15-20mm).

Prior art shows that there is a glass-to-glass hinge for 12mm glass but there is no 15-23mm bracketed hinge suitable for stone panels. Prior art shows that there is a straight c section hinge which takes the weight of the door as holds on the edge of the glass pane. A corner join with a modification to hold a hinge pin or pin holder for a hinge door to be attached would be a more robust design, there is no prior art that indicates that this has been done.

Another object is to integrate a pin hinge feature to a handle attachment that simplifies the process of DIY assembly and is made in such a way to protect the brittle masonry being repurposed into a functional furniture. There is no prior art of this apparatus to my knowledge.

Another object is to create a handle attachment that extends the paver dimensions for use in a chest or cabinet assemblies. When assembling rectangular prisms with standardised pavers the edges a preferred to overlap. When assembling a chest or cabinet for instance this creates an issue with the standard paver dimensions being too short to have the coverage Ithat is suitable for a door or chest lid. This is solved by installing a handle that extends the paver length. To my knowledge there is no prior art of this design.

The assembly of a chest requires a lid stay; lid stays need to be attached to the sides of the chest. Fixing can not be directly fixed with conventional mechanical fixing due to the brittle nature. Lid stay attachment plates solve this. To my knowledge there is no prior art of this design.

The DIY assembly of a table utilising a bracketed system of joinery requires a tabletop assembly to hold pavers. This tabletop assembly needs to be flat packable; it needs to be assembled with nuts and bolts without needing a welder and the tabletop assembly needs to be strong enough to support concrete pavers safely and importantly the tabletop assembly needs to be flat on the one level plane. This is achievable with the ‘Somerville’ tabletop assembly. No prior art indicates that this has been done.

Being able to use pavers (porcelain, natural stone, or concrete) to build a shelving set would be beneficial for the backyard as it would be strong, could be hosed down without rotting, warping or deteriorating from the sun. The bracketed system of joinery can do this. To date there is no prior art indicating that there is a DIY friendly system of joining pavers to build shelves. Currently masonry retainer walls in the garden are required to be assembled from masonry blocks for stability, as blocks are similar width and height. Blocks offer form that is of a self- supporting structure that is stable. A system of joinery that braces masonry panels such as pavers and tiles would allow pavers and panels to be applied to greater use in a vertical application in the assembly of low height garden retainers, garden beds and garden containers such as planter pots. The bracketed system of joinery can do this. To date there is no prior art indicating that there is a DIY friendly system of joining pavers to effectively achieve this.

Also note that not all technological advancement are best explained in terms of overcoming a problem. An advancement can come from sheer opportunity. For example, removing part of the wall of the bracket was an opportunity to expand the scope of use, providing enhanced versatility that has not been seen in prior art relating to I, L, T, X ‘glass clip’ joiners.

The ‘glass clip’ has threaded holes for the tension adjustable, screwjack - holding bolt. In the field of DIY or even in the manufacturing process, threads can be problematic, paint or galvanisation can cause issues by clogging threads. Also, threads installed directly into componentry adds a significant cost, especially on thicker sheet metal ranging from 2.5mm to 3mm. Finding a solution to overcome these issues is something that prior art (in the field of screwjack brackets used for joining) has not achieved. The present invention of componentry does solve this issue in the form of the detachable screwjack sub-assemblies.

SUMMARY OF THE INVENTION

The present invention provides a system of joinery based on a range of bracketed Joiners that has advantages for being able to join a range of building materials including, RHS metal tubing, timbers, timber panels, masonry elements such as pavers, tiles, cement sheet panelling and any other form of building material that can fit within the profiles of the heavy-duty joining brackets with adjustable screwjacks that hold structural elements together. Masonry units, such as sleepers, tiles and pavers generally come in industry standardized dimensions and are mass produced making them a suitable source of material for assemblage. Currently stone tiles and pavers have limited use outside of their intended purpose as floor and wall coverings. This is due to a general void in prior art characterized by a lack of foresight of others working in the field of the invention, primarily relating to the fields of landscaping architecture, furniture design and metal fabrication.

The bracket system of joining as described in this present invention solves the issue of size appropriateness for pavers with capacity space for structural elements ranging from 15mm to, for example, 110mm (and with no size limit specified); and the heavy-duty structure of joining components suitable for joining structural elements of this size category. Primarily the core components of the system consist of joining brackets with the form of a C or U- section channel providing a holding space for the application material. The joining of the application material is achieved by the inclusion of screwjacks positioned in the walls; the c- section walls brace each side of the structural elements. The integral feature along with the heavy-duty structure and form is the threaded hole in the wall of the bracket component and the threaded bolt that comprise the screwjack assembly. The screwjack exerts an adjustable form of pressure against the structural elements creating pressing on the surface, forcing the structural elements against the opposing wall, as opposed to penetrating the surface of the structural element as conventional mechanical fixing using screws and nut and bolts do, thereby avoiding damage caused to more brittle masonry panels or materials such as plywood timber panels, that have weight yet are relatively thin.

The nature of the screwjack and its gentle approach to fixing makes it also a suitable for repeat assemble and disassemble of temporary structures such as hoarding and partition walls.

This greater than 14.5 mm capacity and heavy-duty bracket system of joinery is configurable in use by the making of a broader range of componentry that provides greater degree of functionality to the joining system. The main four range of Joiners is described as the I - Straight, L- Corner, T-junction and X-Cross Junction. The joiners work in conjunction, being placed at opposing ends of the join as seen in the application of the ‘glass clip’. Prior art identifies that the ‘glass clip’ is compatible with materials up to 14.5mm. With reengineering this system of componentry can be useful with a wide range of application materials. For example, the system of joinery can be applied to 15mm - 50mm landscape pavers and concrete sleepers that have a standard size range of 70- 100mm, observing that the standout benefit of this compatible system of joining is the ability to join materials that are brittle at the edges particularly useful for joining masonry structures such as sleepers, pavers and tiles that have industry standardised sizing, a necessary requirement for a fully functional system of joinery of the bracketed type.

The main types of joins are achieved by four variations of c-section profile configured to facilitate (‘I’) straight Joins, (‘L’) corner joins, (‘T’) T - Junctions, (‘X’) cross junctions. The four configurations are used to assemble orthogonal structures. (Represented with the denotation I, L, T, X being self-explanatory).

‘Partial Wall’ Feature of Main Four Joining components

An improvement on prior art is the removal of part of the wall for the structural elements to pass through, expanding the scope of application beyond the convention join type for I, L and T joins, creating a space in the component wall between screwjacks also have added benefits associated with eliminating the negative effects of torsion particularly relevant to the ‘I’ straight join.

The ‘I’ Profile as the ‘Full Wall’ variation, straight join, is designed for joining two pieces of application material (tiles/pavers) in a butt join fashion. The modified ‘Partial Wall’ variation allows for use with a third piece of structural element to be slotted between two pieces of structural elements, which are butt joined. This allows for use as a rudimentary ‘T’ or ‘X’ junction. (Refer to figure 20 & 21 - ‘I’ partial wall application).

Over tightening one screwjack on the same wall as another creates a loosening effect because of torsion on the wall, creating a space between screwjacks has the added benefit of isolating the torsion effects, effectively eliminating this potential risk from occurring.

The ‘L’ Profile corner join provides brace profile for a right angle 90 degree join. The removal of part of the walls in the ‘partial wall’ variation allows for use as a rudimentary ‘T’ join, limited to joining two structural elements. Removing part of the wall allows the join to be placed along the edge of the structural elements as opposed to being limited to corner placement. (Refer to figure 27 - ‘L’ partial wall application.) The ‘T’ Profile allows for joining up to 3 pieces of application material in a perpendicular fashion. The partial wall variation allows for application material to pass through the wall, where the middle branch of the T profile intersects, therefore allowing the joiner to be positioned along the edge of the application material as opposed to the comer. This allows the ‘partial wall’ T to function as a rudimentary X cross join with a limitation to joining three structural elements. An improvement of the T configuration has been to provide screwjack positioning holes on both apposing side walls of the middle branch of the T profiled c-section to improve the alignment of the structural elements being joined. (Refer to figure 36 - ‘T’ partial wall application)

The ‘X’ Profile is designed for joining 3-4 pieces of application material in a four-way junction. There is no partial wall variation in this range. (Refer to figure 44 - ‘X’ junction application)

Partial wall feature possessing added benefits of using one set of tooling to fold each of the main four components.

Removing part of the wall also has the added benefit of allowing the components to be folded using the one set of ‘closed mould’ mass production tooling in the form of the ‘X’, as by removing the same part of the wall as described above the ‘I’, ‘L’ and ‘T’ components can fit within the ‘X’ mould. This saves on tooling change over costs and the costs of manufacturing tooling. So, in one context removing part of the wall has application benefits as described above and under another context the inventive step can be interpreted as an inventive step in manufacturing with the features identified as a ‘product by process’.

Alternative Screw Jack assembly

The direct thread screw Jack has issues relating to the DIY field and the Landscaping field in that the thread clogs easily with paint and galvanization. A detachable screwjack assembly s consisting of a threaded flanged nut and a threaded bolt or grub screw solves this issue, with the flanged nut acting as the thread installation that can be installed, removed, and replaced at will, allowing the body of the joiner to be painted, powder coated, galvanized or any other coating avoiding any defective thread issues.

Alternative thread installations also save on the efforts and costs for installing threads during the manufacturing process, especially when using more heavy duty sheet metal typically 2.5- 3mm thick. With the added consideration of the intention to utilize the joining brackets for semi-permanent assemblies the ability to avoid issues with defective threads does have benefits.

The spaces for the insertion of threaded nuts can be made during the manufacturing process which out extra cost therefore the seats spaces for the screwjack placement can be placed at optional locations on the joining components, providing choice for better alignment (e.g. on both side walls, which can have benefits during the assembly of for instance the ‘Zig Zag Retainer Wall’ where a preference is for the fixings to alternate placement of the screwjacks from internal comer and external comer.

There are three main alternative variations for creating a seat space for the threaded flange nut that acts as a thread installation: 1.) Hexagonal Hole (‘Hex-hole’ space) seat, 2.) Slotted space seat (‘Slot-space’) 3.) Hexagonal Slot Space seat (‘Hex-slot’ space).

The hex-hole version consists of a hexagonal space for placement of the threaded hex headed flanged nut that is place with the hexagonal head fitted into the matching hexagonal hole in the side wall of the joining component, the flanged acting as a thread installation for a threaded bolt to be threaded into. When the bolt is threaded through the flanged nut and presses against the structural element loaded into the joining component the resistant force that increases as tightened, hold the screwjack assembly in place, with the stop the nut from passing through the wall and the hex shape stop the nut from rotating as the bolt is tightened. (Refer to figures 5 & 7 - Hex-hole - screwjack assembly)

An issue with the hexagonal hole screwjack placement seat variation of componentry occurs with the smaller sized components, as it can be difficult to get fingers in between the walls of the c-section for the placement of the flanged nut, especially with the components with less than 15mm between c-section walls. A solution to make the flanged nut installation easier is to install a ‘Slot space’ in the wall, so the flanged nut can slide into position from the outer edge of the wall of the component, with the slot spacing being of appropriate width to engage the hex head of the nut (refer to figure 6 & 8 - ‘slot space’ screwjack assembly) . Pending there being adequate space (approx 2mm) between the the inner side wall and the stuctural element posisioned in the joining component, the slot space allows the flange nut to be installed after the stuctural elements have been placed into position which has benefits when using bracket joints with larger structural elements. Although the straight slot space variation solves issue of inserting the flange nut into position for the smaller components where it is difficult to get finder between c-section walls. There is a risk of the flange nut potentially sliding out perhaps under certain scarios or over time. An added featur to reduce the the chance of this happening is to create an indentation in the wall where the flange nut is to be seated. This would lock the flange nut in place to a degree but depending on how tight the screwjack was done up it may still be possible to slide under certain circumstances. Creating a recess however has other benefits of reducing the interference with the structrual elements in the holding space, the flange takes up about 2mm of the capacity space, the indentation reduces or eliminates this interference. Creating the indendation all the along the slot space further allows the flange nut to be inserted when the structural element has already been palced in the holding space of the joining component, potential leading to an easier and safer assembly process.

The ‘Hex-Slot’ variation; is a merge of the previous two designs (Hex-hole & slot space) mentioned, whereby the side wall of the component freatures a hex hole that matches the hexhead flange nut to be insertered, further, there a slot is formed between the hex-hole and the edge of the side wall, in such a way that the slot space is slightly wider than the grub screw or threaded bolt yet narrower than the hex nut so that the flanged nut is locked into position when seated in position. By threading the grub screw or bolt into the flange nut just a few turns the protruding length of the threaded bolt can act as a handle to position the flange nut in the hex hole where it locks into position (Refer to figure 9 - ‘Hex-slot’ screwjack assembly). This design further addresses any concern of the screwjack assembly sliding out, whilst also providing a method for easy installation of the flange nut in the smaller sized components where it is difficult to acces between c-section walls (less than ~15mm).

Althought the alternative screwjack assemblies are presented as an inventive step relating to a removable thread installation in the componentry, it is slightly more complicated for the user for user of the componentry. With consideration of methods for easier assembly it should be noted that second temporary nut can be threaded onto the thread of grub screw (does not work with hex bolt) and tightened to hold the flange nut in poision, in component wall. The nut can be removed once the scrub screw is tightened against the structural element being joined and tension takes hold of the flange nut keeping it in its position.

Reingineering to suit Application By upscaling the body of the components and the inceasing structural integrity for heavy duty application the bracketed system of joinery has a never seen before explosion of application potential. Much like adding oxygen to petroleum. The oxygen is not dramatic on its own yet adding oxygen to particular combination of environmental factors can lead to a highly reactive outcome. It should be noted the the inventive step is not in the design of the I, L, T, X components but rather the re-egineering for heavy duty applications in construction, leading to new materials that can be joined which further leads to new assembled concepts that can be built as a consequence.

By increasing c-section walls the components gain capacity for holding larger structural elements. By enhancing the strength of the wall the components have the structural integrity for the screwjack to be position further down the wall where leverage and flex of the wall is increased due to the dynamics of the screwjack force putting pressure on the wall unlike other convention fixing methods that tend to fix directly into the structural elements being joined. When assessing the ‘glass clip’ prior art, the closest relative it can be noticed that the screwjacks are placed close to the fold of the sheet metal where the wall is most rigid, it should also be noted that this position translates to being closer to the edge of structural elements being joined. This is not so much of an issue with hardened glass (glass clip application) as it would be with other types of material such as plywood or cementious panels which is more brittle. Therefore the reingineering to position the screwjacks further away form the edge of the structural elements, meaning to move further way from the fold line of the componenet wall is a significant inventive step to meet the requirements for the alternative applications that form the demonstrate the inventive step.

Understanding this dyunamic in relation screwjack use, and the need to increase strength to counter wall torsion is the key to understanding the inventive step, which can be overlooked by appearances. Like wise, over looking the context of the inventive step involving a system of componentry as osppposed to a one component. It should be noted that the uniquness of the inventive step should considered in regards to the system as a whole. When evaluating against prior art the examiner should remind them self that they are not comparing one component against another single component in prior art but rather comparing systems consisting of a range of compatible co-operative components that form a dynamic apparatus with varying, or one might say infinite potential, (eg, a computer is a system with infinite potential, that is not that same as saying that the system does not have limitations. I say this as the limitations of the prior art should be noted.) The re-engineered bracketed system of joinery overcomes the limitation of distantly related prior art to faciliate the joining and assemblage of structural elements such as:

• Masonry tiles, such as Ceramic and porcelain floor and wall tiles.

• Plywood timber panels

• Natural stone tiles.

• Masonry / Stone pavers

• Stone pavers

• Concrete pavers

• Porcelain pavers

• Hebei panel / Aerated panels

• Extra thick structural elements for civil or large construction applications

• RHS (Rectangular Hollow Section) Metal

• Timber lengths.

Layering back-to-back to achieve double sided prime surface or increased strength of structural elements.

Having a larger more heavy-duty bracket range will allow greater possibility in construction as a result. For instance, 9mm floor and wall tiles can be laminated together to achieve a thicker and stronger application material with a prime surface on both sides of the application material. This process of laminating can be achieved by using silicone /adhesive to bond the tiles back-to-back. The masonry tiles can then be used with the heavy-duty bracket system to build hard wearing masonry elements, recalling the superior durability that is associated with stone and gloss finishes from tiles. A similar method of laminating can also be applied to plywood timber with the standard plywood panels.

The bracketed system of joinery used to advance the art of concrete formwork Pushing the boundaries of the art of form-work concreting this upscaled componentry can be used to assemble form-work boxing made plywood or the form work could be mad of tiles or pavers with the possibility of the form work becoming a permanent feature of cladding on the finished concrete structure, effectively saving time of tiling over later if tiling the surface is desired and saving time on disassembling form work. (Refer to figure 116 & 119 concreting form work). (Note: wire can be tied between brackets to reinforce wall structure. Refer to figure 120)

Easily joining plywood and masonry panels to create multi-material panels.

The upsized bracket range of joiners could also be used to build temporary formwork, partition walls for exhibitions or cubicles (Refer to figure 109 & 118 - panels walls) made from panels of timber plywood panels with the possibility to integrate large format masonry tiles into the wall structure. Tiles are easy to clean, ideal for application where sanitation is of importance for example, kitchen and toilet facilities at temporary facilities. The system of joinery allows for the integration of tiles into wall temporary wall structures, previously unachievable. (Hand fastening knobs can be applied to screwjack to enhance ease of use).

Creating larger panels from smaller sub-panels

By integrating the use of screwjacks into extended lengths of ‘C’or ‘H’-section profile (effectively long linear ‘I’ joins made from folded sheet metal or extrusion) the system can join multiple panels into larger panel structures. (Refer to figure 109-117 - multi-panel rail system).

A new context of combining screwjacks with C or H section (extrusion or back-to-back c- section) can be achieved with the objective to create larger panels out of smaller sub-units of panelling. The side walls of the C-section can feature threaded holes for screwjacks or alternative screwjack placement spaces in the form of ‘Hex-hole’, ‘Slot-space’ or ‘Hex-slot’ screwjack placement spaces (as previously described), spaced along the length of the c- section wall. With c-section rails and screwjacks holds the multiple sub-panels together to form a larger panel that can be used to assemble partition wall structures using the main four joining components (I, L, T, X).

The rail joiners can run horizontal or vertical.

Further, assembled structures can be reinforced with RHS (rectangular hollow section) reinforcement members, providing structural support to temporary wall structures. Handles, hinges & stays; solutions for the DIY bracketed system of joinery:

The presented system of joinery also includes improved peripheral components and accessories for more ease of use and enhanced effectiveness:

1.) handles that integrate hinge features for easier assembly (refer to figure 97, 102 & 103 -

Handle hinge).

2.) corner join integrates features of a hinge assembly for easier assembly (Refer to figure

98 and 99 - Comer join hinge).

3.) bracketed handle that extends the dimensions of pavers or tiles for use as chest lid or cabinet door (refer to figure 67-72 - chest handle attachment).

4.) bracketed attachment plates for the installation of lid/door stays (refer to figure 73-76 - lid stay attachment).

With the intention to be a DIY system of joinery with componentry and assemblies that are that are fit for purpose and easy to assemble. The ‘Long Hinge Handle’ combines a handle embodiment that attaches to the bottom of the tile door, extending along the length of the bottom edge to protect the masonry tile edge from being knocked and chipped during regular use; and integrates the features of a pin hinge assembly, that can be attached in one easy install. (Refer to figure 97 & 102-103). The ‘Long Hing Handle’ consists of a length of c-section with screw jacks to create the hold to the tile door panel edge; a pin fitted into a hole in the centre wall, on the hinge side of the c-section; a reverse c-section fold to create a protrusion for a handle hold.

A similar approach to simplification and enhanced functionality was taken with the development of the ‘hole & pin’ corner join hinge, with a fold in the wall creating a tab at the apex of the comer join to hold a pin or to feature a hole to hold a pin for a hinge assembly. (Refer to figure 97-101). When installed at the top and bottom comers of an open-ended rectangular prism a door can be attached via the pin hinge assembly to form an enclosed cabinet that can be opened via the door.

Like the above pin hinge is the ‘sleeve & pin’ corner join hinge includes the feature of hinge assembly wherein the corner join component featuring screwjacks is made with either a sleave or pin feature on the external wall of the corner join component with either the pin or sleeve to fit in mating fashion with a straight c-section hinge component that has pin or sleave feature on the external face of the wall of the c-section component that is to fit to the edge of a lid or door with screw j acks. (Refer to figure 62-65) Lid/Door handle assembly tuned to solve issues with assembling with pavers and tiles (for chest and cabinet assemblies)

As briefly mentioned in the background getting the door or lid to fit when assembling chest and cabinets using standard sized pavers and tiles can be problematic due to overlapping of tiles or paver in the chest or cabinet structures, creating a shortfall in coverage for the lid or door using the standard size paver or tile. For example, when creating a chest using 15-20mm pavers the rectangular open-ended prism is usually created by assembling pavers over lapping at the edge face where the pavers meet at the corners. When using homogenous sized pavers in assembly, a paver uniform in width and length will not fit completely to enclose the top. This is solved by attaching a handle to the length of the edge, continuing with the contours of the paver to extend the coverage to the edge of the chest. Preferably made from sheet metal with the sheet metal walls fitting to the face and edges of the paver with furniture bolts that tighten a bottom and top face together to clamp the handle component to the paver when tightened. Further it allows for extending the length of the lid, and the hollow cavity provides space for a recess to act as a handle hold, facilitating dual functionality. (Refer to figure 66 - 72). The same concept can be applied to cabinets as it can for chests (with the cabinet effectively being a vertical standing chest).

Stay attachment plates

Attaching lid stay to a stone paver or tile lid is an avoided art due to the brittle nature of masonry panels. A solution is a set of attachment plates that facilitate fixing the stay to the lid and the reticular box structure.

The attachment plate for attaching the stay to the lid consists of a component made from folded sheet metal configured into a length of c-section that features screwjacks on the side wall and the wall extends further with a slight bend inward after the first two screwjack placement holes, the extended section features holes for the attachment of the stay arm which has an attachment plate with matching holes for a threaded bolt to pass through. The distance between apposing c-section side walls are of a distance being suitable to fit over the edge of a paver or tile and the slight bend is such that when the screwjacks are tightened the flex of the wall from the torsion creates a parallel plane with the face of the paver. (Refer to figure 73 & 74) The box attachment plate, for attaching the stay to the reticular box side wall consists of a plate between the comers of the box; with the attachment plate having holes in each end of the plate for attaching to the ‘L’ - corner join components by utilising the screwjack threaded bolts with an extended length if necessary, either by using a bolt with a head or a grub screw with a threaded nut for fastening the attachment plate at each corner. The attachment plate features appropriately placed holes for attaching the stay arm to, with the stay arm having suitably matching holes for use of threaded bolt for attachment, the holes could be threaded or bare (without thread), if bare a nut will be required on to be threaded on to the threaded bolt at back of the plate to fix the stay arm the plate. (Refer to figure 75-77)

Engineering componentry to the counter torsion created by Screw Jack fixings

As previously mentioned, the screwjack approach to fixing requires a greater degree of structural integrity from the body of the componentry (to counter torsion) than conventional nut and bolt fixings or screw fixings that pull the bracing tight against the structural element. The heavy-duty strength of the componentry walls necessary to meet the heavy duty demands of larger structural elements using screwjacks, can be achieved by increasing wall thickness of the component body.

Finding the right balance in tensile strength and ductility is the key to optimising the structural integrity of the componentry, simply increasing wall thickness of mild steel componentry is the simplest approach to increasing structural integrity as the ductility is not compromised. Hardening can be achieved by altering the carbon composition of metal and treating the metal by four known metal fabrication methods including 1.) Cold Working, 2.) Solid-solution hardening, 3.) Transformation hardening, 4.) Precipitation hardening. Although the characteristic of hardening the metal is an advantage when using screwjack fastening, on the other hand hardening the metal does reduce the ductility, finding the right balance high tensility does increased risk of cracking which can be a hazardous risk when used in a diverse range of applications such as furniture assembly.

Adding rib contours, indentations and pressing holes in the metal contributes to stressing the metal in a way that can increase the tensile strength of the metal. The consequence of punching hex-holes or slots in the sheet metal for the alternative screwjack assemblies (previously mentioned) for the placement of the threaded flange nut has added benefits associated with increasing rigidity of the wall, a benefit to maintaining tension when tightening the screwjack against the application material. This aspect is often overlooked as most people associate reductionism with a general overall loss of structural integrity.

Lattice of hex holes in the body walls to increase tensile strength and offer diverse range of screw jack thread placements.

In the context of the installation of the reverse flange nut for alternative thread installation, the bracket can be further improved by punching a lattice of hexagonal holes or slots over the entire body of the joining component. With the hexagonal hole dimensions being of a size that match the reverse flange nut hexagonal head. Therefore, such lattice of hexagonal holes would offer greater variation of where the flange nut can be placed (e.g., Further form edge may be of benefit with some structural elements than others) and further facilitating attachment points expanding the range of possibility in the art of customisable bracketed joinery.

Demonstrating practical outcome because of the instrumental changes to components.

As acknowledged in Systems Theory, minor adjustments to the components of a system can greatly enhance the range of emergent outcomes. Increase the component sizing, more specifically the space between opposing c-section walls for the Main Four range of joining components, introducing new componentry for greater functionality with the system of joinery, and enhancing the rigidity of the walls allows the bracketed system of joinery to work in combination with a new range of material elements to assemble an innovative range of practical concepts.

Below are some stand-out assembly DIY concepts that demonstrate the practical value of being able to easily assemble concepts using standard materials often without needing to cut or drill holes:

• Outdoor Table assembled with tiles or pavers (Figure 85 -88)

• Fire resistant Stand assembled with pavers or tiles (Figure 54)

• Shelving assembled out of pavers or tiles. (Figure 57, 58, 90-95)

• Firewood storage shelving assembled with pavers or tiles. (Figure 58) • Containers / Planter Pots / Laundry Container/ assembled with tiles or pavers. (Figure 55, 59-6)

• Garden Beds assembled with tiles and pavers. (Figure 56)

• Retainer walls / Garden edging assembled with tiles, pavers or timber or concrete sleepers. (Figure 105, 106 & 107)

• Concrete Form Work assembled with tiles and pavers. (Figure 117, 120)

• Hoarding/ partitions walls using plywood and/ or tiles/ panels as structural elements. (Figure 110 - 116)

• Walls using Hebei (Aerated) panels

• Work benches constructed with timber or masonry panels. (Refer to stand, in larger size)

• Cabinets made from masonry tiles (Figure 96-97)

• Outdoor Chests made from stone pavers. (Figure 76)

• Drain Pit made from pavers (Figure 78)

Table-top Assembly:

The Table-top assembly is a tabletop that is designed to hold standard sized pavers or tiles. Consisting of components that can be assembled by DIY users, requiring a low level of skill the structural elements do not need cutting, welding, or drilling When un-assembled, the parts consist solely of modified angle iron rails with a series of cut-outs and counter sunk holes for bolts and nuts. The angle railings are manufactured with cut-outs and assembled in such a way that the tabletop is flat, so pavers or tiles rest flat on the level plane that forms the tabletop. The dimensions of the tabletop can be modified to suit variable sizes of pavers or tiles yet the same principles of componentry consisting of angle iron with cut-outs and counter sunk nut and bolts for assembly remains.

Comprising of a perimeter of support rails (with the L stems facing vertical and horizontally inwards) of either folded or extruded angle (right angle L-section profile) lengths of metal rail of a thickness being suitable, (2mm and greater) typically 3mm. A second layer of right-angle L-section profile is attached to the said right angle with wall facing up, in such a way that the flat faces come together and the perpendicular walls of the L section profile face away from each other in such a way that the lengths when bolted together form a T section profile, with a wall facing up and wall on the second length facing down. Either the top or bottom rail has a space in the wall that sits flat against the other part removed, these cut-out spaces in the wall equivalent to the thickness and width of the wall of the angle iron, are located at each end and along the rail. With 8 rails of L-section profile lengths joined in pairs to form a T section profile and with alternating cut-outs at the ends, the lengths can be fitted together perpendicular at the ends and joined to create a rectangular perimeter rail of T profile, with the mid stem of the T facing in wards (Refer to figure 87 & 88). The L angle lengths are joined to form the T rails by way of holes that align when the paired rails are paired together. Nut and counter sink bolt fixings are then used to fix the two parts together. Tapered counter sink holes for counter sink bolts are spaced along the longitudinal length and when tightened the tapered counter sunk style bolt heads sit flat level to the surface of the rail. The Joined L lengths forming T lengths that form the four side to the perimeter of the tabletop assembly are fitted in such a way that the cut outs at the ends interlock with apposing protrusions and cutouts so that the lengths join in such a way that the surface of the rails maintains a flat level plane without the appearance of overlapping at the joins. In effect the cut-outs in the rails create a counter sink effect for the rails joins. Under support rails consisting of L-section profile with one stem facing horizontally flat and other facing down are position in pairs that are parallel and distanced apart to fit mattingly with a leg structure. The perimeter rails are connected to the perimeter rail, at counter sunk cut-outs located the underside of the double layered stem of the T on opposing sides, with the cut outs positioned accordingly along the length of the T formed rail. The cross rails support rails are attached the perimeter T rail with counter sunk bolts and nuts used for fixing. These cross rails act as support for attaching to a table leg structure (made from the main four rang of component: refer to figure 85 & 89) and as a secondary support for a perpendicular cross rail that fits into the top layer of the double layered T stem, with the rail running between the other two sides of the perimeter rails. Once fitted the top surface of this rail sits level with the top surface of the perimeter rails and is supported by crossing over the previously mentioned cross support rails and is positioned in such a way to support standard or homogenous sized tiles, pavers or panels at the joins when laid on the tabletop assembly. With the counter sunk cut-outs positioned to provide support and lengths of L-section suitable for use with standard sized panel units whereby the table top assembly consists of a flat even plane suitable for laying plates, panels, pavers and tiles in way that can be assembled from nut and bolts using minimal materials to build the supporting structure, without requiring use of a welder, angle grinder or drill for assembly, and more importantly generally suitable for DIY assembly of a paver or tile table-top assembly. (Refer to figure 85, 86 &89) Stand Assembly:

The stand is an easy DIY assembly consisting of three panels (e.g., tiles or pavers or timber panels) that are joined together by four ‘L’ -Corner Joins.

The method of assembling a stand using of pavers as outlined below:

Materials: 3 concrete pavers, 4*40 Series comer join brackets

1.) Place a ‘L’-Comer Join on the ground with the two opposing walls of the c-section profile facing up.

2.) Fit a paver in between the c-section walls with the paver perpendicular the ground.

With the paver position in place tighten the screwjack on the side. (Assuming the joining component has threaded holes directly featured into the side wall the process will include placing a grub screw or threaded bolt into the threaded hole and tightening to apply pressure to the side of the paver as it pushed the paver into the apposing wall. Holding it in place. (If the joining bracket features a ‘Hex-hole’ as opposed to a threaded hole the grub screw (or threaded bolt) can be threaded into the flange nut supplied as part of a sub-assembly, screwing in only a few turns so the rest of the grub screw sticking out of the flanged nut can be held with fingers as a form of handle. The flanged nut with the grub screw (the opposite end from the flange) is place into the ‘Hex-hole’ in the joining bracket wall with the grub screw poking through to the outer side of the bracket wall where it can be held in place as a paver is fitted to the joining component ( two people may be required to assist on first occasion), to assist in holding in place a second flange nut can be to the other end of the grub screw bolt to hold the screwjack assembly in place while a paver is loaded into joiner. With the right length grub the grub screw can be tightened so that it sits flush with the bracket wall when tightened against the paver and the holding nut removed once tightened. This process of installing the screwjack can be similar applied to ‘slot-space’ version however those versions have the added benefit of sliding the flanged nut with grub screw in from the edge of the bracket after the bracket is loaded with a structural element, pending there being enough space between structural element and bracket wall. )

3.) The second paver is placed is place the other branch c-section and the screwjack tightened. 4.) Another comer join with appropriate distance between c-section walls is placed on the join mirroring the comer join at the apposing comer of the join. And the screwjacks tightened on each branch.

5.) With one paver being the stand top and the other being the stand leg a third join comer bracket is placed on the other side of the stand top for a second leg to be installed and the screwjacks tightened.

6.) A fourth comer join is placed on the opposite comer mirroring the previous bracket installation and the screwjack tightened.

7.) With three pavers joined with 4 comer joins the stand consists of a paver top with two paver legs.

8.) The stand is now complete and can be used as a fireproof and weatherproof BBQ stand.

Paver Container: (Materials: 5 pavers (4 pavers and paver for bottom), 8* Comer join brackets)

A method for assembling a container out of pavers as outlined below:

• Place pavers in a comer join. (The comer joins should be of the appropriate size having a space between walls of the c-section that is equal to or wider than the paver thickness.)

• Tighten screwjacks: (If the bracket is of a version that has direct threaded hole, install a grub screw or threaded bolt into the threaded hole and tighten against paver to firmly hold in position.

• If the screwjack uses a threaded flanged nut instead of threaded hole in the component wall, the flanged nut is place into the ‘Hex-hole’/ ‘Slot-space’/ ‘Hex-slot’ flanged nut mounting space in the component wall by placing the head of the nut in to the mounting space form the inside of the component walls with the flange on the facing the inside stop the nut from passing all the way through the space. It can be easier to thread a bolt into the head of the flanged nut only few turns so the bolt pokes through the wall providing a point to hold the screwjack sub-assembly in position whilst a paver is positioned in the joining component. If using a grub screw as a threaded bolt, to assist in holding in screwjack sub-assembly in place, a second flange nut can be threaded on to the to the other end of the grub screw and tightened against the wall of the component (this is not necessary after joining a few times).

• This process of installing the screwjack can be similar applied to ‘slot-space’ version however those versions have the added benefit of sliding the flanged nut with grub screw in from the edge of the bracket after the bracket is loaded with a structural element, pending there being enough space between structural element and bracket wall (min 2mm space required).

• Once 2 joining components are installed at the top and bottom of a paver join with screwjacks tightened the 90-degree wall structure becomes self- supporting.

• If want to install a base the walls are spaced apart with the internal comer edges of the pavers not overlapping, either touching or spaced slightly apart. This allows enough room for the floor / base tile to be installed.

• Once 3 pavers are installed into the corner joining components at the bottom and top of the joins a base tile can be installed into the open-sided rectangular prism to create a floor. With enough space between perimeter pavers the base panel/paver should rest level on top of the bottom brackets.

• Once the base is installed the fourth side can be installed.

• Adding 90-degree corner edging to the assembly protects the masonry edges from being knocked and chipped and completes the assembly by closing off any gaps on the joins where a minor separation (e.g., 1mm) may have been required to fit base tile. (The edging also provides a more finished completed look). The corner edging can be installed before the top comer joins. The Angle lengths fit into the top and bottom joins at each comer join.

• Containers made from pavers or tiles can be used as laundry containers, filled with potting mix to be used as a plant pot or a range of other purposes.

Retainer wall / Garden Edging:

Materials: Pavers, L-Corner Joins, I-Straight Joins, T-joins

Method of assembling a Garden Edging out of pavers: 1.) Level ground in the line that the garden edge will take.

2.) Place two pavers into a straight join with a straight join placed at the bottom and top comer ear of each join, install screwjacks, and tighten at each join.

3.) Repeat process for the linear length of garden edging.

4.) To make corner to edging, place a corner join between pavers, install screwjacks and tighten.

5.) Either a T join or partial wall comer join can be installed long length of long linear garden edge to create stability. To Create stability, the bottom part of the pavers can also be partially buried in the ground.

Garden Bed:

Materials: Pavers, Corner joins, Straight joins, T joins.

Method of assembling a Garden Bed out of pavers:

1.) Ensure ground is flat and on a level plane along the lines of the garden bed walls. To assist in doing this lay the pavers out along the line or measure the pavers gauge the wall lengths.

2.) Start with the comer join with two pavers is self-supporting and stands upright. Place pavers in each branch of the right-angle joins, install screwjacks and tighten. (If using a hex hole version of screwjack installation, install screwjacks, before place paver into the joiner.)

3.) Extend the perimeter of the garden bed using straight joins at the top and bottom edge of the joins, ensuring to install screwjacks and tighten.

4.) Use the corner joins to create a 90-degree branch corner in the wall assembly.

5.) Use the T joins or Partial Wall Corner Join (a substitute form of T join) to install perpendicular mid-walls to branch off with another wall along the line of the wall. (Mid walls connecting to apposing walls act as a reinforcement member, to provide support and stability to the perimeter garden bed walls.

6.) To ensure the cross member mid-walls fit correctly, the pavers on the ends of the garden bed should be of the same dimensions as the mid-wall pavers and the over lapping of the pavers at the ends should be consistent with the pavers along the wall.

7.) Once the structure is complete and the screwjacks are tightened the garden bed can be filled with garden soil and planted with plants. Pit Drain Made from pavers:

Materials: 5 pavers, 8 Comer Joins

Method of assembling a Drain Pit out of pavers:

1.) Use four pavers and comer join paver brackets to create an open-ended rectangular prism out of pavers by installing the pavers into the joins and tightening screwjacks. If installing a base paver join pavers with the inside edges touching or just short of touching to allow space between walls for the paver to be installed in the base, (if not using a base paver concrete can be installed into the base at later stage)

2.) The paver can be installed in the base by placing straps under the base paver to pick it up and lower into the rectangular pit. With enough space between walls of the pit the paver should be able to be lowered to the bottom of the pit where it rests on top of the brackets and the straps can be removed by letting go of one and pulling the other end.

3.) The holes in the wall of the pit can be installed before pipes being connected are laid, so that the pipes are laid to the hole in the pit wall or if laying pipes before installing the pit the pit the holes can be made to match the position of the pipe. It is preferred to position the hole in the pit wall in the middle of the paver or as close as possible to the centre maintain optimal wall strength. The pipes can be connected directly to the pit walls or pipe joiners can be use suit the approaching angle of the pipe.

4.) Prior to back filling behind walls the pavers joins can be sealed with caulking to ensure the structure is watertight (however this is not necessary if back filling pavers with concrete).

5.) The space between the paver walls and the excavated hole that the pit sits in can be back filled with concrete to add extra support to the walls and seal the joins.

6.) Optionally the cavity behind walls may be back filled with the earth that was removed from the hole, however back filling with concrete is a superior method as it provides extra strength and assists in sealing joins.

7.) A grate can be installed at the top of the pit using a grate holder and grate with dimensions and structure to suite standard paver dimensions and structure for fitting between brackets.

8.) The Paver Drain Pit is now complete. Retainer wall: (Sleeper assembly)

Building retainer walls out of sleepers currently requires the use ‘Uprights’ consisting of lengths of configurations of C or H section that are first installed into the ground and usually by concreting, this requires careful measurement, alignment and spacing during the installation of the uprights, then the sleepers are slotted between the walls of the C or H section in a two-part process of installation.

Under limitations governed by use, the Bracketed system of joinery can assemble retainer walls using sleepers reducing or eliminating the need to install uprights into the ground and simplify installations without delay between stages of the assembly process.

The presented Bracketed system of joinery has two ways of doing this:

1) by using plates that are fitted between the upper and lower joining brackets (any of the main four joiners I, L T, X) (Refer to figure 106-109).

2) or by using lengths of C or H section with screw jack installations spaced along the length as described in the in the previous section under the heading: "Creating larger panels from smaller sub-panels ’ (refer to page 14) (refer to figure 111 -118)

To hold multiple layers of sleepers using side plates the side plates are of the length of the height of the retainer wall based on the number of sleeper layers; the plates are fitted between the upper and lower joining brackets (either of the Main Four: I, L, T, X, as described on page 8) on each side of the sleepers (or structural elements). The side plates can be either flat or have a longitudinal right-angle fold. The right-angle side plates have greater structural integrity and can be used in a straight join by using two of the right-angle plates with the comer fold fitted between the ends of the sleepers butted together. The folded plates can also be used on each side of a comer. (Refer to figure 106-109).

The second method of holding layers of sleepers is to assemble the sleeper wall using lengths of C section that has screw jacks fitted into the c-section side walls that hold the sleeper in position (like what is described in the section ‘Creating larger panels from smaller subpanels ’ (refer to page 14). By combining the use of the Main four joiners (as described on page 8), the sleeper walls can be configured into a straight join (I), right angle (L) or a T junction (T), or Cross junction (X). A demonstration of the form of assembly combining layers of structural elements using C-section lengths with straight joins (I) and corner joins (L) is depicted in figures 106-109 whereby a retainer box is assembled albeit using tiles. With larger spacing between c-section walls and heavy-duty sheet metal the same method can be applied to sleepers. Stability of this method of assembly can be furthered by extending the c- section into the ground where it can optionally be concreted.

BRIEF DESCRIPTION OF DRAWINGS: Examples of Sizes

Figure 1 The Main Four Joiner components, partial wall type, made from 3mm sheet metal, with 43mm spacing between c-section walls (suitable for concrete pavers)

Figure 2 Main Four Joiner Components, partial wall type, made from 2.5mm sheet metal, with 22mm spacing between c-section walls. (Suitable for porcelain pavers)

Figure 3 Main Four Joiner Components, Partial wall type, made from 2.5mm Sheetmetal with 16mm spacing between c-section walls. (Suitable for floor and wall tiles)

Examples of screw jack installation types

Figure 4 The ‘Comer Join’ depicting the ‘Direct threaded holes’ in the walls of the C-section that have been tapped for the insertion of a Grub Screw that functions as a ‘ Screw Jack’ to apply and release holding pressure when tightened and unscrewed.

Figure 5 A ‘Comer Join’ displaying the Hexagonal Holes in the side walls that function as a seat for Flange Nuts, an alternative thread installation for the Screw Jack assembly.

Figure 6 A 'T- Join' depicting the ‘Slot Space’ Version with the space in the wall removed for sliding the Flange Nut in to position from the edge.

Figure 7 A side view of ‘Comer Component' depicting the process of installing the Screw Jack assembly.

Figure 8 A T-Join depicting a range of views of the ‘Slot-Space’ version, making it is easier to install the screwjack assembly in the small components. Note: top right figure showing the grub screw that functions as a handle to hold on to whilst sliding the flanged nut into position. (Also note: the position of the flanged nut can be recessed from inside out (unable to draw. The recess does two functions, it reduces interference with stmctural elements and in theory it reduces chance of sliding out of position).

Figure 9 The ‘Hex-slot’ Screw Jack placement depicted on the 10 Series X-Cross Junction. The Hexslot has the benefits easy installation and hex hole seat locks the screwjack assembly in position when loaded under pressure.

Figure 10 A Comer Join depicting a 'Slider Space - Comer Joining Component' with installation of a Nut and Bolt in a conventional way.

Figure 11 A back view Comer Join depicting the bracket being adaptable to varied approaches of fixing. Figure 12 A Front view of the Comer Joiner Component showing versatility with the slot space on both side of the joiner. Being suitable for both screw jack fixing and conventional nut and bolt fixing suitable for non-masonry.

Figure 13 A Comer Joiner Component with Screw Jack Fixing on the external facing wall of the Comer.

‘I’- Straight Joins

Figure 14 Full Wall - T-Straight Join components for joining stmctural elements in a Linear Butt Join fashion.

Figure 15 Straight Join with ‘Slot Spaces’. Note the space removed in the middle of side walls for independent Jack tensioning. (Without isolation, overtightening on screwjack can theoretically undo the tension of the other screw jack on the same wall via the effects from torsion on the wall).

Figure 16 10 series Straight Join with hex holes for screwjack assembly. Note length of wall reduced on one side for easier insertion of flanged nut.

Figure 17 20 series straight join T with- hex holes for screwjack assembly - partial 1 wall' variation

Figure 18d the T - straight join - 'hex-slot' variation - allows for a removable screwjack assembly that lock into the hexagonal seat. (Hex Seat)

Figure 19 80 Series T - straight join - suitable for joining concrete sleepers (with M8 Hex-seat)

Figure 20 'Full Wall' I- Straight join limited to a linear butt join. Note also without a space between screwjacks the torsion caused by over tightening one more than the other can cause a release effect.

Figure 21 Partial wall - straight join demonstrating application with pavers. Removing part not only isolates torsion of the wall it also provides functionality as a form of T junction or X Junction with limitations.

L-Corner joins

Figure 22 Comer Joint without holes

Figure 23 comer joint with direct thread and dome head bolt. The length governs depth and potentially the tension.

Figure 24 Full Wall - 20 Series comer join - ‘Slot Space’ flat pattern. Figure 25 the 'Hex-slot' version. The slot for easy installation the hexagonal seat secures the screw jack assembly in place.

Figure 26 Comer Join demonstrated using 40mm concrete pavers.

Figure 27 Partial -wall - Comer Join - demonstration with pavers.

Figure 28 Comer Component suitable for use with 16mm Ply-wood timber panels and masonry panels (cement sheet, double layered tiles, natural stone pavers). Screw Jack ‘Slot-spaces’ (M6) on both sides for fixing on either the external or internal of the comers. (Note: unable to show recessed indentation from inside out for flange nut seat due to technical drawing limitations)

Figure 29 10 Series - Full wall - comer joint - with 12mm spacing between walls. Size is suitable for joining floor and wall tiles. Full wall feature is suitable for insertion of comer edging when assembling a rectangular open prism (container). (Refer to assembly figure 58).

Figure 30 40 Series- partial wall - comer joint - suitable for joining concrete pavers or double layered porcelain pavers, features ‘slot spaces’ for insertion of screwjack assembly. Partial for greater versatility in use.

Figure 31 40 series- hexagonal hole (M6 size) - Partial Wall - Comer Joint demonstrating flat pattern and folds. The wall removed at the apex allows for greater versatility in use.

Figure 32 10 Series (12mm capacity) - ‘Slot-space’ (M5 size) - Partial wall - comer join - Flat pattern. (Refer back to figure 8 for demonstration of screwjack installation in ‘Slot-space’ version.)

Figure 33 80 Series- full wall - comer join with ‘hex-hole’ screwjack seat. 80 Series rage us suitable for joining concrete sleepers that typically have thickness of 75-80mm. (refer to figure 105 for assembly demonstration)

Figure 34 80 Series comer join - with ‘Slot-spaces’ for Screw Jack Insertion.

Figure 35 20 series - hex hole (M6)- comer join-partial wall, suitable for joining pavers and double layered-laminated tiles.

T - Junction Joins

Figure 36 40 Series - Full wall - 'T' join - demonstration with concrete pavers

Figure 37 T Join - ‘partial wall’ component demonstrating extra versatility with pavers Figure 38 40 Series - Partial Wall 'T-Joint' with Hexagonal Hole screwjacks seats.

Figure 39 20 Series - Partial Wall T Joint - suitable for 20mm porcelain pavers and 19mm plyboard.

Figure 40 20 Series - T join with ‘slot spaces’ - flat to fold

Figure 41 20 series T joint - has 4 threaded holes (creating threaded holes can be labour intensive process and threaded holes can be problematic when painting or galvanizing the joiners)

Figure 42 10 Series T joint with ‘Slot spaces’ - flat to fold. (Note: the square space in the comers allows for the caulking of joins.)

Figure 43 the 'Hex-slot' locks the screwjack assembly in the hex space to it cannot slide out. The head of the flange nut mounts into the hexagonal space.

X-Cross Junction Joins

Figure 44 40 series X - Cross Join demonstrated with Pavers.

Figure 45 10 Series Cross Joint with direct thread holes for screwjacks - flat to fold (suitable for tiles) (note: the cross component with holes on both all walls have 8 threaded holes, adding a significant portion to the cost. Having holes on one side of each branch, reduces cost however it does compromise the ability to align the structural elements in assembly)

Figure 46 20 Series - X Cross Joint component with hex holes for screwjack installation. (Note this version in not practical for the 10 series range as the distance between walls is too small for placement of the flange nut)

Figure 47 The 10 series X Joint with ‘slot space’- Screw Jack slide in pattern for easy insertion of flange nut.

Figure 48 10 Series 'Hex-slot' variation - for easier installation of removable screwjack assembly. The Hex hole locks the screwjack in its place.

Figure 49- 20 Series - X Cross Joint with round holes - flat pattern

Partial Wall Feature

Figure 50 1- Straight Join featuring part of the wall removed for more versatile application and to isolate screwjack torsion.

Figure 51 'L-comer join’ - Partial Wall demonstrated with pavers. Useful for type of join for stabilising garden bed walls or for assembling shelving, as a substitute T junction. Figure 52 series T Join - partial wall demonstrated with pavers. Not as stable as a X cross join, however it can be useful substitute in a shelving installation.

Figure 53 10 series T Join - Partial Wall - demonstrated with tiles.

Assemblies

Figure 54 Paver stand, table, or seat

Figure 55 open ended rectangular prism assembled with porcelain pavers (container I planter pot)

Figure 56 Garden bed assembly - assembled with concrete pavers.

Figure 57 Shelf set assembled with porcelain pavers - a self that is made for in the garden

Figure 58 Matrix structure assembled with double layered (laminated) porcelain pavers - (firewood storage unit)

Figure 59 over lapping of edges does not allow paver/tile to be used as base.

Figure 60 joining pavers/tiles at edge comers allows paver/tile to be inserted as base. (Example: Tile: 600 *300 & 300*300. Or Pavers: 600*400 &400*400)

Figure 61 installing a corner trim finishes the assembly. (Comer trim installation requires full wall comer join to hold it in place, not the partial version)

Figure 62 20 series hinges separated.

Figure 63 20 series hinges assembled.

Figure 64 ‘open ended rectangular prism’ assembled with pavers, 20 series comer joins and hinge components.

Figure 65 A 20mm porcelain paver hinged to an ‘open ended rectangular prism’ assembled from 20mm porcelain pavers.

Figure 66 top perspective showing gap due to overlap of pavers in the box assembly.

Figure 67 bottom part to 600mm chest lid attachment.

Figure 68 Top part of chest lid attachment showing recess as a handle. Figure 69 exploded view of chest lid attachment with ‘nut and bolt’ fixings. (‘Furniture bolt and nuts’ are preferred)

Figure 70 Assembled view of lid with attachment installed on 600*400*20 mm porcelain paver.

Figure 71 20 series 600 * 400 mm Chest with assembled lid attached.

Figure 72 Lid open view of chest

Figure 73 Top lid stay attachment plates including holes for stay attachment and threaded holes for screwjacks.

Figure 74 Top stay attachment plates attached to lid.

Figure 75 Base Stay Attachment Plate

Figure 76 Stay fitted to attachment plates, taking the weight of the stone lid.

Figure 77 dissected perspective of lid stay installed. Note that the screwjack on the comer hinge becomes a fixing point for the attachment when extended grub screw is installed.

Figure 78 Pit Drain assembled with pavers and screwjack Comer Join components.

Figure 79 example 40 mm concrete pavers. 2 with holes cut for pipes.

Figure 80 Skeletal view of joiner components utilised.

Figure 81 Box assembled with a paver in the bottom.

Figure 82 grate holder

Figure 83 grate

Figure 84 Drain Pit assembly completed with grate fitted. (The seams can be caulked, and the pit can be back filled with concrete.)

Figure 85 Sommerville Table perspective view. Note: legs assembled using 40 Series, straight and comer joiners.

Figure 86 Sommerville table bottom view perspective view

Figure 87 Sommerville tabletop assembly assembled from angle iron using nut and bolts

Figure 88 An array of rail parts with cut-outs allows the tabletop to be assembled with rails flat and spaced to support pavers. Figure 89 Metrino Table assembled with porcelain pavers using 20 series joiners and a tabletop frame assembled by a similar method to the Somerville table shown in previous drawings.

Figure 90 10 series Shelf unit assembled from porcelain tiles and 10 series joins. Note: the partial wall comer join is used for the comer and as the shelf holders. (No cutting or drilling required)

Figure 91: Shelf unit made from 450mm x 450mm tiles, assembled with Partial wall - Comer joins. The Screw Jack clamp style fixing allows shelves to be adjusted to any position, added or removed with out damage to stmctural elements.

Figure 92 A double shelving unit (correction: note - L joint at join of wall should be a T join)

Figure 93 20 series quadrant shelf set assembled with porcelain pavers.

Figure 94 shelf set assembled with concrete pavers using 40 series joiners.

Figure 95 Multi sized garden shelf sculpture utilising the 10 series I-Straight join that has been designed with a spacing between the partial walls to integrate with 20 mm pavers. And the 20 Series straight join has a 40mm gap between partial walls to integrate with concrete pavers.

Figure 96 10 series cabinet assembled with gloss porcelain tiles.

Figure 97 10 series cabinet with doors open.

Figure 98 cabinet door with hinges attached (note: the bottom pin hinge component also functions as a handle and a protection guard to the bottom of the door.

Figure 99 10 series standard hinge assembly. Note the comer hinge component also function as a comer join to the cabinet.

Figure 100 separated comer hinge component featuring threaded holes and grub screws. (Alternative thread installation consists of spaces in the wall of the component for the insertion of a flange nut.)

Figure 101 10 series comer hinges without pin. (The pin can be installed as a separate component, held in place with flange at base of pin and a circlip)

Figure 102 series hinge set with pin installed.

Figure 103 handle and hinge embodiment

Figure 104 10 series handle and hinge embodiment in multiple views

Figure 105 landscape retainer wall assembled with concrete to form a recessing matrix for an embankment in a garden (zig zag wall structures are renowned for stability) Figure 106 80 Series Joints demonstrating use with concrete sleepers.

Figure 107 Plate components used to assemble a double layer concrete sleeper garden wall.

Figure 108 80 series components

Figure 109 plate components used to in combination with joins to for bracing stacked structural elements.

Figure 110 cubicle panel assembly using 16 series Joiners and rails to stack sub-panels to make larger wall structures. Note: cross member integrates to stabilise the partition walls.

Figure 111 the comer joint screwjacks engage with the panels directly (correction: rail is missing screwjacks that hold the tiles in the rail.)

Figure 112 top view of tile engaging the comer joint

Figure 113 Top view of comer joint with rectangular hollow section (RHS) to fdl the space on a return when there is no wall.

Figure 114 c-section capping with Hex-slot spaces for placement of screwjack assembly and slots between screwjacks for isolating wall torsion. Utilised for making large panel out of smaller subpanels.

Figure 115 Hex-Slot C section rail with screw jack fixings - nuts can be used to keep screwjacks in place temporarily until stmctural elements are fitted.

Figure 116 the hex-slot rail showing a tile fitted and the different stages of fitting screwjacks, showing a nut holding screwjack in place, then removing the nut once stmctural element fitted and screwing the grub screw flush.

Figure 117 A multi panel rail system used to assemble a large container out of 600 by 300mm tiles. Straight Joins and Comer Joins are used to configure the panels. Note that the joining components have a partial wall space that fits either side of the rail.

Figure 118 side view showing the screwjack that press against stmctural elements to hold them in place.

Figure 119 Multi material joining. 1200 x 1200 plywood panel joined to a 1200 x 1200 porcelain tile (part way through assembly - missing bottom comer joint) Figure 120 An open-ended rectangular prism can be used as utilised as concreting form work. Note the T Joint can be used with reinforcement wires fixed to the T branch of opposing side for reinforcement.

Figure 121 The Screwjack can be utilised as a fixing point for a wire attachment bracket for reinforcing walls when utilising the joining system for form work construction. Brackets on each comer can be used to connect wires that restrain the outward pressure.

DETAILED DESCRIPTION OF EMBODIMENTS

The preferred embodiment entails cutting a I, L, T or X profile joiner component pattern out of sheet metal using either laser cutting or stamp press. The preferred sheet metal is 2mm to 3mm thick. For 40 mm concrete pavers the preferred thickness is 3mm, for 10mm large format tiles the preferred format is 2.5mm. For 20mm porcelain pavers the preferred thickness is 2.5mm. (refer to diagram section to see the flat patterns) Depending on the type of screwjack installation, the holes may be threaded before bending or a screwjack sub-assembly may be provided with the joiner for installation during assembly.

The AutoCAD flat patterns are fed into a computer that automatically reads where fold lines are. Modern laser cutting machines read and the cut lines and modem folding machines read and fold the fold lines.

In general terms the range of brackets consists of C-section channel with the centre plane between walls taking the form of a I, L, T, X and side walls are fold at 90 degrees.

The preferred choice of flat patterns come in what is called the 10 series range with a 10- 12.5mm space between opposing walls, the 20 series range with a 22-23 mm distance between walls, 40 series range with a 40-43 mm distance between walls or 80 series range with a 75 to 85mm distance between walls. The distance between varies on the type of screw jack installation. If providing detachable screwjack assemblies an extra 2mm allowance between internal side wall and structural element is required to provide space for the flange of the nut that is inserted.

A preferred option is the Partial Wall Version of the range of joining brackets that allows application material to pass through the wall of the bracket further expanding the scope of dynamic use by allowing the bracket to be placed midway along the application material and the partial allows the assembler to better align the pavers or tiles into position.

If using the L comer joiners assemble a box shaped container with four sides and a base the preferred corner join is of the ‘Full Wall’ variety that facilitates holding the corner trim in place.

The preferred screwjack assembly for the 10 Series is what is termed the ‘Hex-slot’ cut-out version consisting of a hex hole with a slot cut-out to the edge for easy installation of the reverse flanged nut and grub screw that can slide through the slot into position. This version of screw of joining bracket is cheaper to produce and can be DIY painted without issue with paint get in the thread causing thread defects and the flanged nut can be installed with limited space between the walls of the 10 Series range that has space between c-section side wides of 12mm or less, making it difficult to insert a threaded flanged nut for the alternative screw jack assembly.

If producing high volume, the preferred method of manufacture is to have the joining component flat patterns made into a flat that is provided in a coil that is fed by a feeder into a mechanical press that both cuts and folds the components. Using a ‘closed’ folding consists of a negative and positive mould, this process of manufacturing is faster, although it is more expensive to set up therefor requires higher volume.

If assembling multiple layers of structural elements, the preferred method of joining is to use lengths of C-section rails with screwjacks featured in the side wall and use the main four joiners to configure the assembled walls. The C section lengths are preferably made of 2- 3mm folded sheet metal, with space between opposing c-section walls to allow for the structural elements being joined and the flange of the flange nut if using detachable screw jack assemblies.

Sheet metal of 2-3mm is a preferred sheet metal thickness, mid steel with either galvanized or zinc coating, as it can be easily folded by most machines, is ductile compared to cast, therefor less likely to break, yet is rigid enough for the screwjacks to hold firmly. (Stainless may also be a preferred option however it is expensive) Stainless does have superior weather resistance however mild steel is more ductile than stainless therefore less likely to break when under strain.

The preferred pin and sleeve hinge is made with 2-3mm sheet metal folded into c-section components with a sleeve or pin welded on to the outer wall of the c-section. The side wall can feature hole cut-outs for installation of screwjacks or holes with threads directly installed in the walls for fixing. The straight c -section with pin or sleeve fits a door or lid whilst the comer L configured c -section with a corresponding pin or sleeve welded to the outer wall fits the open-ended box side comers that the door is to be hinged to.

All the handles and hinges are preferred to be made from folded sheet metal.

The bracketed system of joinery is preferred method joining as it allow the assembler to assembler to easily dismantle structures. The preferred structures to be assemble are outdoor furniture and garden constructs such as:

• Paver or tile Garden Beds

• Paver, tile, or concrete sleeper Retainer walls

• Paver or tile Shelving

• Paver Fire-wood storage units

• Paver or tile Plant Pots

• Paver or tile Tables and stands.

• Paver Chest

• General Containers

• Tile Cabinets

• Partition walls

• Aerated concrete walls.

The good thing about being able to join stone tiles and pavers is that to build furniture is that is weather resistant, fire resistant, flood resistant, snow resistant, sun resistant, UV resistant. I won’t fade, doesn’t need regular coatings for weather protection like timber.

The good thing about building with tiles and pavers is that they come in a range of sizes that are generally industry standard so designs can be thought out with tile and paver size references for configurations without needing to cut the structural elements. And with the bracketed system of joinery the joins have a reinforced brace and the structural elements do not need to have holes drilled for fixing.