COUPLING SYSTEM

Background of the Invention

The present invention relates to a method and apparatus for coupling first and second members, and in particular to a method and apparatus for coupling members by deforming at least one of the members or a fastener passing therethrough.

Description of the Prior Art

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Many assemblies, such as walls, barriers, fences and louvre systems consist of a combination of supporting members and cross-members.

For example, louvre systems are generally composed of a plurality of parallel blades mounted on two or more vertical posts. The blades may be attached to the posts in a^variety of ways and are usually angled with respect to the posts. In the case of metallic components the blades are usually attached by individual welds or screws at each junction between a blade and a post. The points of attachment can be visually unattractive or prone to corrosion.

Similarly, barriers such as fences for swimming pools typically have a number of aluminium panels that are formed separately and then placed in position end to end. Each panel has two or more horizontal rails that support a series of vertical pickets. The panels are assembled by passing the pickets through apertures in the rails. Each picket is then usually welded or crimped to the rails and the assembled structure is painted. The rails and pickets come in many forms and may be assembled in a wide variety of structures.

Existing methods of construction generally require each picket to be individually handled and fastened to the rails. Each panel typically has 20-30 pickets so the methods are generally

slow with a significant cost of manual labour. The need ^' to paint the panel after the pickets have been fastened to the rails can also be a disadvantage. Structural weaknesses are sometimes experienced in panels where the pickets do not extend beyond the top rail. In these systems the top ends of the pickets lie within the top rail and can be difficult to fasten sufficiently strongly to the rail.

When fabricating these assemblies, arranging supporting and cross-members with respect to one another, and subsequent fastening between those members, can be time consuming.

Some fastening methods have been developed to reduce fabrication time, for example WO 2005/059279 describes a crimping tool which passes through the rails to deform the pickets within the rail. However, such methods require rails with sufficient structural strength to resist crimping forces as pickets are deformed by a crimping tool that engages the rail to provide the crimping force. This often means at least one member is stronger than required during later use of the assembly, and this member comes at a greater weight and material cost than necessary.

Summary of the Present Invention

In a first broad form the present invention provides apparatus for coupling a number of first members to a second member, wherein the apparatus includes: a) a number of arms, each arm being for insertion into a respective first member; b) a deforming tool provided on each arm; and, c) an actuator for actuating the deforming tool to secure the first members to the second member by causing each deforming tool to deform at least one of: i) the second member, the second member extending at least partially through the respective first member; and, ii) a fastener extending through the respective first member and the second member.

Typically each deforming tool includes a pair of jaws, the actuator causing the jaws to at least partially close and thereby deform at least one of: a) the second member; and, b) the fastener.

Typically the jaws are coupled to the body by arms.

Typically the deforming tool includes a guide, the actuator urging the arms into engagement with the guide to thereby selectively move the jaws between open and closed positions.

Typically each deforming tool includes an aperture for receiving the fastener and jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the fastener and wherein the actuator is for urging the arm, so that the jaws deform the fastener as the fastener passes through the opening.

Typically each deforming tool includes an aperture for receiving the second member and jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the second member and wherein the actuator is for urging the arm, so that the jaws deform the second member as the second member passes through the opening.

Typically the jaws are substantially immovable.

Typically the actuator includes: a) an arm support for supporting the arms; b) a piston coupled to the arm support for: i) positioning the arms in the respective first members; and, ii) biasing the arms away from the first members.

Typically the actuator includes a member support for supporting at least one of the members, the piston being coupled to the member support to bias the arm support relative to the member support.

Typically the jaws are adapted to deform at least one of the second member and the fastener without engaging the first member.

Typically the arms are coupled to an arm support.

Typically the deforming tools are rotatable relative to the arm support, to thereby allow at least one of the second member and the fastener to be deformed at a selected orientation.

Typically the deforming tools are movable relative to the arm support to adjust a separation between the deforming tools, to be adjusted to thereby the arms to be inserted into first members having a range of relative spacings.

Typically the actuator is an hydraulic actuator.

In a second broad form the present invention provides a method for coupling a number of first members to a second member, wherein the method includes: a) inserting each of a number of arms into a respective first member, a deforming tool being provided on each arm; and, b) actuating the deforming tool to secure the first members to the second member by causing each deforming tool to deform at least one of: i) the second member, the second member extending at least partially through the respective first member; and, ii) a fastener extending through the respective first member and the second member.

In a third broad form the present invention provides apparatus for coupling a first member to a second member, wherein the apparatus includes: a) an arm for insertion into the first member; b) a deforming tool provided on the arm, the deforming tool including a pair of jaws; and, c) an actuator for causing the jaws to at least partially close thereby securing the first member to the second member by deforming at least one of: i) the second member, the second member extending at least partially through the respective first member; and, ii) a fastener extending through the first member and the second member.

Typically the jaws are coupled to the body by arms.

Typically the deforming tool includes a guide, the actuator urging the arms into engagement with the guide to thereby selectively move the jaws between open and closed positions.

Typically the jaws are adapted to deform at least one of the second member and the fastener without engaging the first member.

In a fourth broad form the present invention provides a method for coupling a first member to a second member, wherein the method includes: a) inserting the arm into the first member, the arm including a deforming tool including a pair of jaws; and, b) actuating the jaws to thereby cause the jaws to at least partially close securing the first member to the second member by deforming at least one of: i) the second member, the second member extending at least partially through the respective first member; and, ii) a fastener extending through the first member and the second member.

In a fifth broad form the present invention provides apparatus for coupling a first member to a second member, the second member extending at least partially through the first member, wherein the apparatus includes: a) an arm for insertion into the first member; b) a deforming tool provided on the arm, the deforming tool including: i) an aperture for receiving the second member; and, ii) jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the second member so that as the arm is urged the jaws deform the second member as the second member passes through the opening.

Typically the aperture can receive only a single second member.

Typically the jaws are substantially immovable.

Typically the jaws are adapted to deform the second member without engaging the first member.

In a sixth broad form the present invention provides a method for coupling a first member to a second member, the second member extending at least partially through the first member, wherein the apparatus includes: a) an arm for insertion into the first member; b) a deforming tool provided on the arm, the deforming tool including:

i) an aperture for receiving the second member; and, ii) jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the second member; and, c) urging the arm, so that the jaws deform the second member as the second member passes through the opening.

In a seventh broad form the present invention provides apparatus for coupling a first member to a second member using a fastener extending through the first member and the second member, wherein the apparatus includes: a) an arm for insertion into the first member; b) a deforming tool provided on the arm, the deforming tool including: i) an aperture for receiving a fastener extending through the first member and the second member; and, ii) jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the fastener so that as the arm is urged the jaws deform the fastener when the fastener passes through the opening.

Typically the aperture can receive only a single second member.

Typically the jaws are substantially immovable.

Typically the jaws are adapted to deform the fastener without engaging the first member.

In an eighth broad form the present invention provides a method for coupling a first member to a second member using a fastener extending through the first member and the second member, wherein the method includes: a) inserting an arm into the first member, a deforming tool provided on the arm including: i) an aperture for receiving the fastener; and, ii) jaws defining an opening extending from the aperture to a perimeter of the deforming tool, the opening being smaller than the fastener; b) inserting the fastener through the aperture; and, c) urging the arm, so that the jaws deform the fastener as the fastener passes through the

opening.

In a ninth broad form the present invention provides a barrier including: a) a number of first members extending through at least one second member; and, b) a number of fasteners, each fastener extending through a respective first member and the at least one second member, wherein each fastener is deformed within the respective first member, thereby securing the first members to the at least one second member.

Typically the at least one second member including pairs of apertures for receiving respective ones of the first members.

Typically the at least one second member and each first member include pairs of fastener apertures for receiving a respective fastener.

Typically each fastener allows rotational movement of the first member relative to the at least one second member.

Typically each fastener includes a first pin coupled to a first head and a second pin coupled to a second head, wherein the pins are for insertion into the first and second members, the first pin being hollow and having a diameter larger than that of the second pin, thereby allowing the second pin to be received by the first pin.

Typically each first and second pins are deformed with the second pin positioned inside the first pin.

Typically the barrier is at least one of: a) a louvre system; and, b) a fence panel.

In a tenth broad form the present invention provides a louvre system including a number of posts, each post extending through a number of blades, the posts being deformed within each blade to thereby securing the posts to the blade.

Typically each post is deformed at an angle offset to an axis of the post.

In an eleventh broad form the present invention provides a fence panel including: a) a rail; b) pickets passing through the rail; and c) fasteners passing through the rail and the pickets, wherein each fastener is deformed within a respective picket, thereby securing the pickets to the rail.

Typically the yield force of the rail is less than the deformation force required to deform respective ones of the fasteners.

Brief Description of the Drawings

Examples of the present invention will now be described with reference to the accompanying drawings, in which: -

Figures IA to ID show a schematic perspective views of an example of a fence panel;

Figures 2A to 2E are schematic plan views showing an example of the formation of a junction between a rail and a picket in the panel;

Figure 3 is a schematic side view showing an example of relative movement of the junction; Figures 4 A to 4E are schematic views of an example of a tool for deforming fastening elements in the junction;

Figure 5 is a schematic diagram of an example of apparatus for assembling the panel of

Figures IA to ID;

Figures 6A to 6D are schematic diagrams outlines operation of the apparatus; Figures 7A and 7B are schematic perspective and side views respectively of an example of a louvre system;

Figures 8 A to 8G show how a blade may be fixed on a post of the louvre system of Figure 7;

Figures 9 A to 9E are schematic perspective views of an example of a process for constructing the louvre system of Figure 7; Figures 1OA to 1OD are schematic views showing an example of the construction sequence for the louvre system of Figure 7;

Figures HA and HB show a deforming tool with moveable jaws, in open and closed positions;

Figure 12 shows a further deforming tool with moveable jaws;

Figures 13A and 13B show a louvre arrangement, the blades of the louvre being deformed within the posts;

Figure 14 shows a ladder formed from a louvre type arrangement; Figures 15A and 15B show a fence panel having an internal partition; and Figure 16 shows an arrangement of members forming a more complex product.

Detailed Description of the Preferred Embodiments

Referring to the following figures it will be appreciated that the invention may be implemented in a variety of ways for a range of different structures. The embodiments described here are given by way of example only.

Figures IA to ID show the main components of a fence panel having a bottom rail 10, mid rail 11, a top rail 12 and a number of pickets 13. The pickets pass through the rails and are fastened in place by fasteners 14. In this example the rails and pickets are shown as tubes which are interconnected by fasteners at junctions, however any suitable arrangement of members may be used. The terms junction, rail and picket are therefore for the purpose of explanation only, and are not intended to be limiting.

These components are typically formed from aluminium or steel, although any suitable material may be used, depending on the intended use. The components may be provided in a wide range of numbers, shapes, and sizes, and may be combined in different ways depending on the purpose and style of the fence.

Figures 2A to 2E show a sequence of steps in coupling a first member in the form of a picket 21 to a second member in the form of a rail 20, when creating a typical fence panel. Figures 2A to 2D are provided as cross sectional views through the junction along a vertical axis of the picket 21.

In Figure 2A, the picket 21 passes through an aperture 22 in the rail 20. A pair of apertures 23 are provided on either side of the picket, with a corresponding pair of apertures 24 on either side of the rail. Once the apertures 23, 24 are aligned, the fasteners, which in this case are formed from a pair of rivets 14, are passed thereinto until portions of those fasteners are within the respective picket 21. In Figure 2B, the two rivets are shown during passage

through the apertures 23 and 24. Each rivet has a head 25A, 25B and a hollow pin 26A, 26B joined to a base 27A, 27B of the head 25A, 25B.

Two types of rivets are used in this example, each having a slightly different diameter, with the larger diameter pin 26A being hollow to allow the smaller diameter pin 26B to be received therein as shown in Figure 2C. The heads 25A, 25B of the rivets abut outer surfaces of the rail 20 while the bases 27A, 27B of the rivets abut the picket 21, which holds the picket

21 separate from the rail 20. The pins 26A, 26B are then deformed inside the picket 21 so that the picket 21 and rail 20 are coupled together thereby providing a junction. Figures 2D and

2E show plan and end views which highlight the deformation as a flattening which narrows the pins 26A, 26B in one direction and extends the pins 26A, 26B in another direction, preventing further passage through the apertures in the rail and picket.

Figure 3 is a cross-section view of a junction between the rail 20 and picket 21 of Figures 2A to 2E, from one side of the panel. Particular types of fastener, such as the aforementioned rivets 14 which have a generally cylindrical pin 26A, 26B, allowing rotational movement of the first and second members 20, 21, as highlighted by the picket 21 shown in dotted lines. The amount of rotation is governed by the size of the aperture 22. This enables a degree of flexibility in the panel to suit a range of requirements during installation, such as in the construction of balustrades, wherein the first members may form substantially vertical stanchions and the second member, or second members, form a rail, or rails, provided at a desired angle. In this example the picket is shown oriented a few degrees from vertical, but it will be appreciated that any angle may be accommodated.

Figures 4A to 4E show aspects of a fastening tool which may be used when forming a junction between first and second members, such as a rail 40 and a picket 41. A tool of this kind operates inside the picket 41 and deforms a fastener, such as a pair of rivets 42, which fastens the picket 41 to the rail 40. The tool may form part of an apparatus having multiple tools which operate simultaneously in relation to a plurality of pickets, typically in relation to all of the pickets in a panel.

In one example, the apparatus includes a load bar LB which supports a set of parallel tools in alignment with the pickets which have been put in place to form the panel.

As shown in Figure 4A the apparatus includes an arm 43 which undergoes movement inside the picket 41, through a junction with rail 40 containing the pair of rivets 42 to thereby deform the rivets 42 and couple the picket 41 to the rail 40. A similar action may also be performed with respective to the rail 46 (shown in Figure 4C). The pickets 41 and rails 40, 46 are temporarily supported by restriction bars 45, 47 which hold the picket 41 and rails 40, 46 in place during movement of the arm 43 and deformation of the rivets 42.

In one example, the arm 43 includes a deforming tool 31 which is shaped to deform the rivets 42. Figures 4B and 4D show a first example deforming tool having a keyhole configuration.

In this example, the deforming tool 31 includes an aperture 32 that can receive only a single "second member", such as a picket 41, or single fastener, such as a rivet 42. The aperture 32 is connected to an end of the deforming tool 31 by an opening 32, defined by respective jaws

34. In this example, the jaws 34 defining the opening 32 are static or substantially immovable so that as the second member or fastener passes through the opening 32, the second member or fastener deforms, without the jaws 34 engaging internal walls of the first member.

A twinset configuration is shown in Figure 4E. In this example, each fastening tool, or arm, consists of two elongate members such as rods 35. A deforming tool is defined by the end of the rods 35, the deforming tool including two opposing jaws 36 rigidly mounted to the rods 35 so as to define an opening 37. The jaws may be cast from the same mould and simply installed on the rods at an angle of 180° offset from one another (or cast simultaneously with the rods and otherwise oriented at that offset).

The rods 35 may be extended into the rail, or "first member", in a non-synchronised fashion to avoid premature deformation of the second members or fasteners by both jaws 36 impacting opposite sides simultaneously. Alternatively, the rods 35 may be inserted from the side of the first member opposite an actuator, connected through the first member to the actuator and drawn through thereafter.

Typically however, the actuator extends the arms 43 into the first members. The second member or fastener is then inserted into the deforming tool 31, such as between the rods 35,

before the actuator withdraws the arms 43 simultaneously past each second member or fastener. As the jaws 36 pass a second member or fastener, they are restricted in their outward movement by an internal wall of the first member. Accordingly, this limits outward movement of the jaws 36 causing the opening 37 of a predetermined size to be defined by the jaws 36 as they pass respective second members or fasteners. Therefore, as the second members or fasteners pass through the opening they are deformed. The advantage of this configuration is that multiple second members and fasteners may be deformed with one movement of the actuator.

However, this requires that the jaws 36 engage the rail or picket, which can be disadvantageous. For example, this requires that the rail or picket which is engaged is stronger that the picket or rail being deformed. The need for additional strength can result in an increase in material, and hence an increase in the weight and expense of the fence components. Accordingly, in some examples it is preferred to use an arrangement in which jaws are substantially immovable, such as the arrangement of Figures 4B and 4D.

Figure 4C shows the picket in relation to supports, such as the rail supports 45, 47 which may be required in the overall machine, and also highlights movement of arm 43 between different positions.

Figure 5 shows the general layout of an apparatus for coupling a number of first members to a second member, such as rail 40 and picket 41 combinations as described above. The apparatus includes a number of arms 43, each arm 43 being configured for insertion into a respective first member 41. A deforming tool 31 is provided on each arm 43, for securing the respective first members to the second member.

An actuator causes the deforming tools to secure first and second members together. Securing may be achieved by deformation of the second member by the deforming tool, with the second member extending at least partly through, and being deformed within, respective first members. Alternatively, or in addition, the actuator may cause the deforming tool to deform a fastener and thereby couple the first and second members together. In this alternative case, the fastener extends through the first and second members, the deformed portion being within the first member.

Each arm of the apparatus is a generally solid, circular rod secured at one end to the actuator and at the other end to a deforming tool, by any appropriate securing method. The arms are adapted to be received within the first members and, therefore, the cross-section of the arms is less than, or equal to, the internal cross-section of the respective first members.

The actuator includes an arm support, or load bar LB, for supporting the arms 43 of the apparatus, and pistons 50 having a piston chamber 51 and shaft 52 coupled to the load bar LB, for positioning the arms 43 in the respective first members. The load bar LB moves in a vertical direction, through a cycle or half cycle, under the action of drive pistons 50.

The pistons 50 are connected to feet 53, which are in turn connected to a frame formed from upright and lateral frame elements 55, 54. The frame 54, 55 can be used to support the pickets and rails in use, as will be described in more detail below.

The arm support LB is an elongate bar of rectangular cross-section. The arms are connected with the arm support LB by a C-channel and locking pin 60. The C-channel receives the elongate bar and the pin is passed through an aperture in either side of the C-channel and a corresponding aperture 61 in the arm support LB, thereby securing the arms to the arm support. Many other means of securing may be applied without venturing outside the scope of the invention.

In addition, the channel and locking pin arrangement allows easy relocation of deforming tools, relative to the arm support, to account for variations in arrangements of, or distances between, respective first members. This simply requires additional corresponding apertures 61 to be placed at intervals along the arm support.

The piston 50 of the actuator extends to bias the arms 43 away from the first members. The piston 50 is hydraulically or pneumatically actuated, and is connected to the frame 54, 55 to bias the arm support LB relative to the first members as desired.

When coupling a number of first members with a second member, each of a number of arms 43 is inserted into a respective first member. The deforming tool 31 on each arm 43 is then used to deform either a fastener or the first or second members, thereby securing the first members to the second member.

In performing the above coupling of first and second members, the deforming tool may take various shapes depending on the application. In particular embodiments, such as those of Figures 4B and 4D, the deforming tool 31 includes jaws 34 that are substantially immovable or rigid, the jaws 34 defining the opening 33 that extends from the aperture 32 to a perimeter or end of the deforming tool 31.

The aperture 32 has a cross-section equal to, or greater than, that of a fastener such as the rivets 42, allowing these to be received therein. Accordingly, in this example, the coupling process typically involves actuating the piston 50 so as to align the aperture 32 with apertures in the first and second members. A fastener is then inserted into each of the apertures, 32, before the piston is used to urge the load bar LB away from the frame member 54, thereby causing the fasteners to pass through the opening 33. As the width of the opening 33 is smaller than width of the fastener 42, the fastener 42 is deformed as it passes through the jaws 34.

Methods of coupling the first and second members together using a fastener may therefore include the steps of: a) inserting an arm into a first member, the arm having a deforming tool including; i) an aperture for receiving the fastener; and ii) jaws defining an opening extending from the aperture to a perimeter of the deforming tool, wherein the opening is smaller than the fastener; b) inserting the fastener through the aperture; and c) urging the arm, so that the jaws deform the fastener as the fastener passes through the opening.

Alternatively, the aperture may be aligned with corresponding apertures in the first member, wherein the second member is passed into the aligned apertures. In this embodiment, the width of the second member is less than the width of the opening and, as the actuator urges the arm, the jaws of the deforming tool cause the deformation of the second member as it passes through the opening, again causing the second member to be coupled to the first members.

Figures 6A to 6D shows a series of stages in the process of creating a panel using a machine similar to that indicated in Figure 5. In Figure 6 A, a row of pickets 41 are located on one or more supports in the machine. Figure 6B shows how a pair of rails 40, 46 are then dropped onto the pickets 41 and located at required heights using the rail supports 45, 47. The number of rails 40, 46 defines the number of junctions requiring rivets on each picket 41. Therefore, there are two such junctions per picket in this example.

In Figure 6C, the fastening tools (not shown) attached to the bar LB are lowered into position, with one tool inside each of the pickets 41. Rivets 42 are then put in place at each of the junctions. In Figure 6D, the row of tools is urged upwards by the pistons 50 so as to deform the rivets 42.

If the deforming tool of Figure 4C is used this allows each of the rivets 42 for both of the rails 40, 46 to be deformed in a single process. However, alternatively the deforming tool of Figures 4B and 4D are used, in which case the fasteners for the rail 46 are deformed before the deforming tool is realigned with the rail 40, allowing further fasteners to be inserted therein and deformed, to thereby couple the pickets to the rail 40.

Accordingly, the above described example is a specific example of the construction of a barrier in the form of a fence panel. In this example, the fence panel uses pickets and rails, although this is for the purpose of example only, and in practice similar construction techniques could be implemented using any first and second members that are joined using the deformation techniques described above.

In one example, the technique uses a fastener, such as a rivet, inserted through the first and second members, and being deformed therein, to thereby secure the first and second members together.

In one example, this is achieved using a tool for connecting the first and second members. Connecting may be achieved either by using the tool to deform a fastener, as described, or alternatively by having the tool deform either one of the first and second members, in which case a fastener may not be required.

In one example, the tool includes jaws defining an opening extending from an aperture to a perimeter of the tool. The aperture is adapted to receive a single fastener or member to be deformed. The tool is urged so that the fastener or member, passes through the opening, thereby deforming the fastener or member.

By ensuring that the jaws are substantially immovable, or at least are not urged against an inner surface of the rail, deformation may be performed without force being applied to the rail, which in turn allows the rail to be of a reduced strength or thinner cross-section, thereby using less material than in prior art arrangements. In particular, the yield force of the rail may be less than the deformation force required to deform respective ones of the fasteners. The rail may, therefore, be fabricated from a weaker material, or the same assembly may be rated to take higher loads (i.e. safety barrier systems and retaining walls).

A further example of the construction of a barrier such as a louvre system will now be described.

In this example, as shown in Figures 7A and 7B, the louvre system includes a plurality of blades 710 mounted on a series of posts 711. Each blade 710 is typically hollow and has a cross-section roughly in the shape of an airfoil, although a range of shapes are possible.

Similarly the posts 711 are typically hollow with a rectangular cross section, although again a range of shapes are possible. They are preferably formed from aluminium of steel. In one example the blades are angled downwards from horizontal and are set at an acute angle with respect to the posts as also indicated.

Figures 8A to 8G show how a blade 820 may be fixed in place on a post 821. In this example the post has a hollow rectangular section with a pair of long sides and a pair of short sides, and internal ribs 824. The post includes deformations 822, 823 which form internal engagements with the blade 320. A range of one or more different deformations are possible, formed by tools of various shapes and configurations (as hereinafter discussed).

Figure 8A shows an exploded view of cross-sections of a post 821 and blade 820. In Figure 8B, the post passes through apertures 825 in the blade 820 and is fastened, as shown from external and internal views in Figures 8C and 8D respectively, by deformation 822, 823 of

the blade 820. Figure 8D shows the deformations on the short sides in the form of indents lying on a line at the same angle to the post as the blade. Figure 8E is a view from one of the short sides showing how the each of the indents 822, 823 causes a corresponding bulge 826, 827 on the long sides of the post. Figure 8F is a view along the axis of the post showing the bulges. Figure 8G shows jaws 828 of a deforming tool in a position of retraction from the post 821 after deformation, as will be described in more detail below.

Figures 9A to 9E show a sequence in the manufacture of a louvre system using a machine which positions a set of blades in relation to a set of posts and then enables multiple deformations to be carried out simultaneously. In this example, the machine includes a frame having a group of stationary upright supports 930 linked by a pair of hydraulic rams 931. Pistons 932 for the rams carry a number of supports 933 which in turn rest on a track (not shown). Additional equipment required to drive the rams has also been omitted for clarity.

In Figure 9A the machine is shown in an open configuration, without blades, posts or a set of tools which cause the deformations. In Figure 9B a set of blade holders 934 are mounted on the supports 930 and set of tool holders 935 are mounted on the supports 933. The required angle of the blades is reflected in the configuration of the blade holders 934. In Figure 9C a set of blades 910 has been positioned on the holders 934 and set of corresponding deformation tools 936 has been positioned on holders 935. The multiple tools in this example are pairs of parallel rods which are aligned with end portions of the blades and can be cycled back and forth inside the blades to deform the posts.

In Figure 9D the pistons 932 have been moved into the rams 931, and posts 937 are located in the blades. Following this, the rams 931 are actuated to withdraw the deforming tools 936 from the blades 910, deforming the posts and thereby fastening the posts within the blades. The panel can then be removed from the blade holders 934.

Figure 9E shows detail of the tools 936 in supports 935, before withdrawal from the blades. The tools are dragged out of the blades 910 to deform portions of the posts 937 inside the blades. One of the supports 935' opposes horizontal movement of the blades as the posts are deformed by the tools.

Figures 1OA to 1OD provide further details of the construction process. Figure 1OA shows pairs of blade holders 934 in the fabrication apparatus. Figure 1OB shows two posts 911 about to be positioned in relation to blades 910, typically by insertion through apertures (not shown) in the blades 910. Figure 1OC shows the posts 911 in place. The blade holders 934 are provided in pairs with one holder on each side of a post, but slightly spaced from the post to prevent marking during action by the tools 936. Figure 1OD shows a preferred form of one of the tools 936, having a pair of rods 941 with jaws 942. The rods are held in a fixed orientation by holders 935 on a line which corresponds to the required angle of the respective blade 910 in the louvre system.

It can be seen in Figures 1OA to 1OD that movement of the tools through the blades creates multiple deformations of the posts inside the blades. The tools can be moved through half a cycle into the blades 910 before the posts are put in place, and then withdrawn, or through a full cycle after the posts are put in place.

Each deformation forms a local engagement at the junction of a blade 910 and a post 911. This avoids the need for additional fasteners such as screws or rivets, or the need for welding. Deformation in this example takes the form of an indent with a corresponding bulge in the post. However, a range of different crimps, swages or other forms are envisaged.

Accordingly, the above described example allows a number of first members, in the form of blades, to be coupled to one or more second members, in the form of the posts. In one example, this is achieved by inserting a deforming tool into each of the first members to thereby deform the second member passing therethrough.

In one example, this could be achieved using a tool similar to that described above with respect to Figures 4 to 6 above. Thus, for example, the deforming tool could be of a similar form to that shown in Figures 4B and 4D. In this example, the aperture 32 or each deforming tool, is aligned with apertures in respective ones of the blades. The post is then inserted into the apertures, before the deforming tools are withdrawn, thereby deforming the post, so as to couple the blades to the post. In this example, it will be appreciated that each post is inserted and deformed before the deforming tool is aligned with the next set of apertures, allowing a next post to be received and deformed.

Altematively, this could use jaws that are capable of compressing and thereby deforming the second member, as will be described in more detail below. Again, in this example, the jaws are not urged against an inner surface of the rail, the deformation to being performed without any forces being applied to the blades, which in turn allows the blades to be of a reduced strength.

In one example, the jaws are moveable, and may be actuated by a guide mechanism, as shown in Figures 1 IA and 1 IB. The deforming tool 1100 includes first and second portions 1101, 1102 defining a body and a slide respectively. The slide 1102 is received in a groove in the body 1 101 so that movement of the slide 1102 causes the actuation of jaws 1114 of the deforming tool. In one example, the jaws 1114 are connected to jaw arms 1115, which engage a guide 1 1 16, for example via a guide wheel 1 1 17. The guide 1 116 causes the jaw arms 1115, and hence the jaws 1114, to open or close, as the slide moves between extended and retracted positions.

In one example, the slide 1102 is moved by a drive that forms part of the deforming tool. In this instance, the arm is used to provide power to the drive, which may be a hydraulic drive, electric drive or the like. In this example, if the deforming tool is lowered substantially vertically into the first members, the arms do not need to be rigid, allowing flexible arms carry any required power to be used.

In use, the arm is extended into the first member until the second member or fastener is received in the opening between the jaws. The second portion 1102 of the arm 1100 then remains stationary while the first portion extends further into the first member. This causes the slide to retract from the groove, closing the jaws, as shown in Figure HB, and thereby deforming the second member or fastener between the jaws.

Once deformation has occurred, the second portion of the arm is retracted from the first member slightly, and then both first and second portions are retracted together. As the jaws are biased in the open position by resilient members, such as springs 1118, they will automatically release the second member or fastener when the second portion has made the slight retraction.

Again, the jaws 11 14 can be caused to deform the second member or fastener without engaging the internal wall of the first member. Further combinations, such as one jaw being moveable and the other being rigidly attached to the body, as described in previous embodiments, may also provide this advantage.

Further tools with moveable jaws are envisaged, such as jaws being connected with the body 1211 of the deforming tool 1210 by movable jaw arms 1212, 1213 as shown in Figure 12. In this example, the jaws 1214 are mounted on the arms 1212, 1213, which are in turn movably mounted to the body 121 1 by a pivoted cantilever actuator 1215 mounted to the body 1211 and jaw arms 1212, 1213 via pins 1216.

In order to secure the first and second members together an arm 1200 to which the deforming tool 1210 coupled is inserted into the first member. In one example, the jaws 1214 can be caused to close by urging the jaws 1214 against the second member or fastener to be deformed.

In this example, the jaw arms 1212, 1213, are biased away from one another by resilient members, in this case springs. However, as the jaws 1214 contact the second member, supports 1215 rotate about the pins 1216, bringing the jaw arms 1212, 1213 and hence the opposing jaws 1214, closer together, thereby causing the jaws 1214 to deform the second member or fastener. At this stage, further deformation can be prevented by having the jaw arms 1212, 1213 abut against each other to thereby prevent further jaw movement.

In one example, the deforming tool 1110, 1210 may be mounted to the arm 1100, 1200 by a rotatable coupling, thereby allowing the deforming tool to deform second members or fasteners in various orientations relative to the apparatus.

Thus, the above described examples provide an apparatus for coupling a first member to a second member. In particular examples, the apparatus includes an arm, for insertion into the first member, a deforming tool, provided on the arm and including a pair of jaws, and an actuator. The actuator causes the jaws to at least partially close, thereby securing the first member to the second member.

Typically each of the first and second members is an elongate, hollow tube of generally

circular cross-section, although any suitable arrangement may be used.

In one example, the second member is deformed, in which case the second member is made from a plastically deformable material, such as steel, aluminium or the like. In this example, the jaws of the deforming tool close around the hollow second member, which extends at least partially through the respective first member, thereby deforming it to secure it to the first member.

Alternatively, or in addition, the jaws may close around a fastener, extending through the first member and the second member, deforming the fastener in order to secure first and second members together.

Accordingly, the above described examples allow the formation of a barrier, such as a fence panel or louvre system, including a number of first members, at least one second member and a number of fasteners. The first members extend through the second member and the fasteners extend through respective first members and the second member, each fastener being deformed within the respective first members. This deformation causes the first and second members to be secured to one another. However, this is not essential and alternatively the fastener may be omitted with the second member alternatively being deformed.

The second member may be formed from any elongate item, and in one example could be an open channel. However, more typically it is formed from a closed-section tube having pairs of apertures for receiving respective ones of the first members. In this manner, a portion of each first member is received within the second member.

The barrier may be useful for the purposes of forming fencing or louvre systems, as shown in Figures 13A to 14B. Particularly with regard to louvre systems, the first members may form the horizontal blades of the louvre, the second members forming the posts. Generally in louvre systems, the posts will be deformed within each blade to thereby secure the posts to the blades. It will be appreciated that a single post may be suitable for some purposes, as may a single blade.

A deformation tool is inserted into each blade, the jaws of the deformation tool having an angular surface, or being introduced at an angle, to allow deformation of the posts at an angle

offset from the axis of respective posts. This angular deformation encourages the blades to rest upon respective deformed portions of posts at an angle. Alternatively, the jaws may take many different shapes or orientations depending on the shape of the deformation required.

In addition, the apertures provided in the blades are larger than the external cross-section of respective posts. This allows rotation of the blades about the posts to open and close the louvre.

In an alternative embodiment, as shown in Figures 13A and 13B, a louvre system may be fabricated wherein the blades 1300 are deformed within posts 1310. Thus, in this example, the posts 1310 correspond to the first member, whilst the blades form the second members as opposed to the second members or fasteners. In this embodiment, as shown in Figure 13 A, the deforming tools have a smaller cross-section than the posts 1310 and the actuator extends those deforming tools down respective posts 1310 by movement of arms as hereinbefore described. Deformation of the blades 1300 occurs in the same manner as deformation of the posts 911 in the above examples.

Figure 13B shows a side view of one of the posts 1310. Apertures 1311 in the posts 1310 are diagonal and approximately the shape and size as the cross-section of the blades 1300. The angle of the diagonal apertures 1311 prescribes the angle of the blades in the louvre system. Alternatively, the apertures may be made larger than the cross-section of the blades. In this configuration, individual blades of the louvre system may be angularly adjusted. This may be useful, for example, in window shades, where more light will be required at times earlier in the morning and later at night. Accordingly, the louvres can be adjusted to let in extra light or, conversely, dim the room.

Figure 14 shows a louvre system formed using the same method as the louvre system of Figures 13A and 13B, but with the blades 1400 not extending beyond the post 1410. The blades are deformed at their ends using the deforming tool in a manner as hereinbefore described. Various materials can be used in fabrication of these louvre systems and using a tool that does not contact the second members while deforming the first members, ensures that the structural integrity of the system is maintained.

Figures 15A and 15B show an alternative example of a fence panel constructed in accordance with the above described techniques. In previously described examples, a pair of apertures is provided in the rail 1500, through which pickets 1510 pass, and between which deformation of the pickets 1510 occurs in order to secure the -picket to the rail. Contrastingly, in the example shown in Figure 15 A, the rail 1500 includes only a single aperture, so that the pickets 1510 terminate therein. In one example an internal wall having an aperture therein is provided so that deformation occurs as described above, between the aperture in the rail and the aperture in the internal wall. In this example, the cross-section of the deforming tool and that of the arm must be less than the cross-section of the internal cross-section of the rail minus the portion of that cross-section partitioned off by the internal partition.

The fence panel of Figure 15A is shown in side view in Figure 15B. As can be seen the picket extends into the top rail but not through that rail, deformation of the picket occurring between the aperture in the rail and the aperture in the internal partition.

This configuration allows a fence panel to be constructed without exposing the ends of pickets. This is useful in ^' circumstances where such ends would be inconvenient. For example, safety hand rails, where there should be no obstacles to allowing a hand to grip the rail.

Figure 16 shows that techniques as hereinbefore described may deform second members 1610 within first members 1600 to provide any desired configuration of connected members. In one example, the configuration shown in Figure 16 may, for example, be useful for forming small bridges, wherein the horizontal bars at the top of the configuration are provided as hand rails, and the horizontal bars at the bottom of the configuration can support a walkway.

Many variations of embodiments described herein are possible. For example, the deforming tools could be used individually to deform individual fasteners or second members, and it is not therefore necessary to perform multiple deformations simultaneously. Other variations include: using first and second members and arms may have cross-sections that are not circular; limiting movement of cantilever elements such that they do not reach a state of being substantially in parallel before deformation is completed (i.e. limiting movement of the

jaws towards the body); the slide and groove arrangement on the deformation tool may allow movement of the first portion of the arm while keeping the second portion of the arm stationary; arms may not be connected with the arm support but may be configured to be urged thereby using some other means (i.e. receiving the arm support in the C-channel at the end of the arms without using a fastening pin, allowing the arms to still be extended into the first member by movement of the arm support); moveable jaws may be connected to the body of the deformation tool by a mechanism other than the cantilever elements, such as a cam mechanism; the actuator need not include a piston but may, for example, comprise a motor and cam shaft wherein the arms are mounted on consecutive lobes on the shaft; the first and second members may not have a closed cross-section; the second member may not be hollow but instead have a compressible core; and many other variations, all of which are within the scope of embodiments of the invention.

Persons skilled in the art will appreciate that numerous other variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.