FENCE POSTS

The invention relates to fences and particularly relates to components of fences of a post and rail construction.

Traditionally, a fence is constructed of two basic components, posts and rails, the aim being to provide a barrier or an enclosure.

Posts are upstanding supports which are normally fixed firmly in a ground surface and provide the stable foundation for a fence. They are generally constructed from concrete reinforced with steel rods which extend along the length of a post.

Rails are the generally level components that connect one post to the next post to span across the open space therebetween. Conventionally, top and bottom rails are provided. Other fences may have middle rails. Alternatively, the rails can be replaced with a panel.

Rails can be attached to external faces of posts, using nails extending through the rail and the post, where the posts are wooden. Alternatively, cut-away hollow sections can be provided in a post to provide a type of open mortise joint between the post and rail, an external face of the rail therefore lying flush with the external face of the post.

Multiple rails will often extend in different directions from the same post, depending upon the location of the post (corner, end, middle). In some cases, the post may act as an intersection post, for example providing a junction for three or four posts where the post is common to adjacent enclosures. In these cases, posts can be tailor made for the specific use as shown in Figure 1, where different cut-away hollow sections are provided in the post for receiving a rail. These posts can be cast in concrete and can be unsightly. Furthermore, different casts are required for each

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different type of post.

An object of the present invention is to provide a universal member which can be used to make fence posts for all applications, thereby reducing manufacturing costs and improving manufacturing efficiency and flexibility. Another object of the invention is to provide fence posts which are adaptable to the environment in which they are being used, by providing a suitable external appearance.

A further object of the invention is to provide a universal member which can be used in post and rail fence construction. Another object of the invention is to provide a method of manufacturing fence posts.

According to a first aspect of the invention therefore there is provided a universal member for use in a making an upstanding support for a fence, the fence comprising upstanding supports spaced from one another on a surface and at least one connecting component which extends between upstanding supports, wherein the upstanding support comprises at least one cavity for receiving an end of at least one said connecting component, characterised in that the member is adaptable to be used to make a variety of upstanding supports, each of which has a different number of cavities to receive a particular number of connecting components for a specific application.

With this arrangement, a universal member can be used to make all kinds of upstanding supports or fence posts as opposed to having different tailor-made members. The use of this single adaptable member means that the cost of manufacturing different casts for different post types are significantly reduced and

there is a greater degree of flexibility in producing the relevant components on demand. In this latter respect, the single adaptable member can be transported to a construction site to be used to create upstanding supports as required.

The universal member preferably comprises a main section which is an elongate section. The main section preferably provides at least one cavity on an external face. The at least one cavity is preferably in the form of a channel. The channel may extend the whole length of the face of the main section or alternatively, may be interrupted by members extending thereacross at intervals. Most preferably, the main section comprises a plurality of channels on a number of external faces. The main section may provide connection points on at least one of the external faces for attachment of an additional section. Most preferably, all of the external faces are provided with connection points. The connection points are preferably provided in pairs. The connection points may be provided along the whole length of the faces of the main section or alternatively, may be provided at intervals. The universal member therefore comprises additional sections. These additional sections preferably comprise expansion sections and blanking sections. The expansion sections may be attached to an external face of the main section where an additional channel is required, whereas a blanking section may be attached to an external face to cover a pre-existing channel. Accordingly, the expansion sections are preferably elongate and comprise a channel. The channel may extend the whole length of the expansion section or alternatively, may be interrupted by members extending thereacross at intervals, as described in relation to the main section. The expansion sections preferably provide connection members for engagement with the connection points on the main section.

The blanking sections are preferably elongate and provide a plain outer face. The blanking section may be in the form of a thin spine with outer and inner faces. The blanking sections preferably provide connection members on the inner face for engagement with the connection points on the main section. The connection members of both expansion and blanking sections may be provided in pairs for use with the pairs of connection points.

The connection points preferably comprise a retaining means to retain the connection members. The retaining means may comprise a space beyond an overhang. Therefore, the connection members preferably comprise a Hp for engagement with the space beyond the corresponding overhang.

The connection members may comprise resiliency flexible parts to enable a snap-fit engagement with the connection points.

Where the respective face of the main section comprises a channel, side walls of the channel may provide the respective overhangs as the connection points. Alternatively, where the respective face of the main section comprises a planar face, the overhangs of the connection points may be inset into cavities cut into said face.

In both cases, the overhangs may be provided by an aperture cut into the respective side wall of the channel or cavity respectively, or a projection provided by the channel or cavity respectively. Most preferably, a pair of connection points comprises one cut-away aperture and one projecting overhang.

At least one of the connection points may comprise a guidance means for aiding the snap-fit engagement of the respective connection member. The guidance means may be in the form of an inwardly tapering guide provided by the overhang to

guide the respective connection member beyond the overhang.

The sections of the universal member are preferably hollow casings. The casings may be partitioned by incoiporating cross-walls to improve the stability of the sections. Each section may be made out of aluminium, glass fibre or other suitable material.

The main section may be provided with any number of external faces. For example, the main section may be substantially triangular, square/ rectangular, hexagonal, octagonal, etc., in cross-section.

Each section is preferably manufactured in long lengths for cutting to an appropriate size. This allows a member, to be cut to the required length as necessary to create an upstanding support to a required height.

Most preferably, the sections are filled with an appropriate filling material. The filling material may comprise concrete or resin or other suitable material to create the upstanding support. According to a second aspect of the invention therefore, there is provided an upstanding support for a fence comprising a universal member as described above, filled with a filling material.

According to a third aspect of the invention there is provided a method of manufacturing an upstanding support for a fence using a universal member, wherein the upstanding support is substantially hollow and comprises at least one cavity for receiving an end of at least one connecting component, the method comprising the steps of: a) cutting said universal member to an appropriate length for the upstanding support;

b) adapting the universal member to comprise a required number of cavities; and c) filling said adapted universal member with a filling material.

The step of adapting the universal member to comprise a required number of cavities preferably comprises the further steps of: i. attaching blanking members to the main section to cover un-required pre-existing cavities; and ii. attaching expansion members to the main section to add required cavities. With this arrangement, the upstanding support is much lighter before filling than conventional posts, making it much safer for transport and lifting. When filled, the strength and weight of the upstanding support is increased to result in a post, the filling of the upstanding support being performed at a construction site if appropriate.

The cavities may be in the form of channels. The blanking members and the expansion members preferably comprise connection members and the main section may comprise connection points as described in relation to the first aspect of the invention for the adaptation of the main section.

The filling of the universal member may comprise blocking one end of the adapted main section and pouring the filling material in through an open end. The filling material may comprise concrete or resin or other suitable material.

This method may be performed at a site where construction of a fence is taking place. hi all previous aspects of the invention, the member is preferably formed

from a hollow aluminium extrusion.

According to a final aspect of the invention, there is provided an upstanding support for a fence, characterised in that the upstanding support is hollow and can be filled with a suitable filling material. With this arrangement, the hollow member can be made so that it is attractive in appearance whilst providing a solid fence support, with unattractive filling being enclosed within the hollow member. Again, the upstanding support is much lighter before filling than conventional posts, making it much safer for transport and lifting. In this aspect of the invention, the upstanding support is preferably formed from a hollow extrusion.

The filling material may comprise concrete or resin or other suitable material.

It is to be appreciated that the upstanding support or hollow member can be made in a variety of finishes, colours and textures to be appropriate to a particular surrounding.

The invention will now be described further by way of example only and with reference to the accompanying drawings in which: Figures Ia - If are plan views of prior art fence posts;

Figure 2a is a diagrammatic plan view of a universal member according to the present invention;

Figure 2b is a perspective view of the universal member of figure 2a;

Figure 3 a is a diagrammatic plan view of an expansion member for use with the universal member of the present invention; Figure 3b is a perspective view of the expansion member of figure 3a;

Figure 4a is a diagrammatic plan view of a blank member for use with the universal member of the present invention;

Figure 4b is a perspective view of the blank member of figure 4a;

Figure 5a is a diagrammatic plan view of the universal member of figure 2a in use with an expansion member and blank member; and Figure 5b is a perspective view of the arrangement of figure 5a.

As shown in figures Ia - If, a conventional fence comprises a number of fence posts 1 which receive the ends of fence rails 2 in cut-away channels 3 of the posts 1. With such fences, the posts 1 are made specifically for a particular use, be it to receive one rail 2 (figures Ie and If), two rails 2 (figures Ia ₃ Ic and Id) or three rails 2 (figure Ib). Such posts 1 are cast in concrete using different moulds (not shown) as appropriate and are reinforced using steel rods which run the whole length of the post 1. The universal member 4 as shown in Figure 5, comprises a main casing 5, expansion sections 10 and blanking sections 18. The expansion sections 10 and blanking sections 18 can be attached as required to adapt the main casing section 5 to have a required number of channels 7 depending on the intended use of the eventual post. The casing 5 comprises a section of elongate, hollow casing 5. The casing 5 can be made from aluminium or other suitable material, such as fibre glass or plastics. The casing 5 can be manufactured in any suitable length, which can then be cut to an appropriate length suitable for a particular post. Once cut to a suitable length, the casing 5 is filled with an appropriate material, for example, resin or

concrete to complete the fence post.

The casing 5 has four upright faces 5a - 5d, which comprise two opposing channelled faces 5b, 5d and two opposing other faces 5a, 5c and two open ends 5e, 5f, for access to the inside of the casing 5. The casing 5 comprises an elongate, substantially rectangular, hollow main body section 6 made up of four walls 6a - 6d. A number of elongate v-shaped projections 6e are provided along the inside of the opposing walls 6b, 6d which act to aid adherence of the eventual filling (not shown) and reduce movement of the same within the casing 5. Four elongate, substantially rectangular, hollow extension arms 8 project in pairs from the main body section 6 along opposite walls 6b, 6d so as to define open channels 7 in the channelled faces 5b, 5d, which run along the length of the casing 5. The extension arms 8 are positioned adjacent to the edges of the main body section walls 6a, 6c and contribute to the two faces 5a, 5c of the casing 5, respectively. The wall 6a of the main body section 6 is slightly outwardly domed towards the extension arms 8 and the extension arm walls continue the line of the dome, so as to define an outwardly domed face 5a.

The casing 5 can be used in the arrangement of figures 2a and 2b to provide a post 1 with two opposing receiving channels 7, in which rails can be disposed once the casing 5 has been filled with an appropriate filling material, as discussed above.

The casing 5 is also adaptable to receive the additional members 10, 18 to create a universal member 4 with the appropriate number of channelled faces (figures 5a, 5b), by blanking off the existing channels 7 using a blanking member 18, or by adding a further channel 17 using an expansion member 10.

In this respect, the faces 5b, 5c, 5d are adapted to receive one of these two types of members as described further in detail.

The wall 6c of the main body section 6 and the corresponding extension arms

8 provide a substantially in-line face 5c. Where the main body section 6 and the extension arms 8 are joined, the face 5c provides a pair of narrow connection channels

9 for the attachment of an expansion member 10 (figures 3 a and 3b) or a blank member 18 (figures 4a and 4b). The connection channels 9 comprise first 11 and second 12 channels spaced from one another. The first channel 11 has a narrow neck 1 1a, which opens up to provide an internal overhang l ib which protrudes into the hollow space of the respective extension arm 8. The second channel 12 has a neck 12a which provides an inwardly tapering guide protrusion 12b, which terminates to provide an overhang therebehind.

In addition, the channelled faces 5b, 5d provide expansion and blanking options by providing the same structures in opposing inwardly facing walls of the extension arms 8, which define the pre-existing channels 7 of the casing 5 as described above. An internal overhang 7a is provided opposite an inwardly tapering guide protrusion 7b in the channel 7 side walls.

With regard to the expansion member 10 and the blanking member 18, both have cooperating first and second connector members 13, 14 which are received by the connection channels 11, 12 or channel 7 respectively. The connector members 13, 14 extend along the length of the members 10, 18 at a distance from one another which allows the members 13, 14 to cooperate with the connection points. Therefore, the spacing of the members 13, 14 equals the length of the distance between outer edges of the necks 1 1a, 12a or the width of the channel 7. The members 13, 14 are

disposed centrally of a longitudinal axis of the members 10, 18. These distances between the edges of the necks 11a, 12a and the width of the channel 7 are kept the same where possible for universal application.

In both of the members 10, 18, the first connector member 13 comprises an upstanding spine 13a with an outwardly projecting lip 13b extending along the length of the spine 13 a. The second connector member 14 comprises an upstanding spine 14a at the end of which is a small tapered overhang 14b. The spines 13a, 14a of the connector members 13, 14 are resiliently flexible so as to allow deflection away from and towards the longitudinal axis of the respective member 10, 18. For connection of the appropriate member 10, 18 to the appropriate face 5b,

5c, 5d of the casing 5, the lip 13b of the first connector member 13 is manoeuvred behind the appropriate overhang 7a, l ib. Once the first connector member 13 has been connected with its receiving connection channel 11, the second connector member 14 is manoeuvred into connection channel 12. The tapered protrusion 12b and the tapered overhang 14b, act to gradually deflect the second connector member inwardly until the end of the protrusion 12b has been reached, after which point, the overhang 14b springs outwardly beyond the protrusion 12b to firmly connect the member 10, 18 with the casing 5. Alternatively, the members 10, 18 can be slid into position on the casing 5 from one end where the connector members 13, 14 can access the necessary overhangs 7a, l ib and protrusions 7b, 12b.

The expansion member 10 comprises an elongate, substantially hollow c-shaped member, comprising a narrow elongate spine section 15 made up of two side-by-side elongate rectangular hollow sections 15a, 15b and supplementary extension arms 16 which comprise two elongate, substantially square hollow sections

16a, 16b. The extension arms 16 extend from opposite ends of the spine section 15 to provide a supplementary channel 17, which can be added onto the main casing 5 via the connector members 13, 14. The connector members 13, 14 are provided along the spine section 15 of the expansion member 10 for engagement with the connection points 9 as previously described.

The blanking member 18 comprises an elongate slightly domed spine 19 having a concave face 19a and a convex face 19b. The connector members 13, 14 are provided on the concave face 19a such that when the blanking member 18 is connected to the casing 5, the receiving face of the casing 5 takes the same domed shape as the face 5 a.

In use, the casing 5 is adapted as appropriate for the intended use by adjusting the number and arrangement of channels and cutting the casing and any additional attached members to the required length for the post 1. The casing 5 is capped at one end before being then filled with an appropriate filling of, for example, resin or concrete, with the appropriate hollow sections created or provided by any blanking or expansion members also being filled.

With this arrangement, a single casing can be adapted and used for a range of different applications, which, in addition to reducing the difficulties with the requirements for numerous different castings, can improve the appearance of the resultant fence posts which are tailor made and more attractive than the conventional concrete posts. Furthermore, as the casing is substantially lighter than most conventional posts before filling, it is safer for this support to be lifted and transported, the post acquiring its weight and strength from being filled thereafter, which can be done at the site of fence construction if so appropriate. Posts

constructed in this way can have a longer lifespan.

It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiment, which is described by way of example only. Thus, it will be appreciated that in a different embodiment, face 5a can take the form of face 5c to provide additional expansion options.