The present invention concerns fence panels, fences, methods for assembling fences and kits for assembling fences.

Fences are free standing structures designed to restrict and/or prevent movement across a boundary. One type of fence often used for civilian boundaries due to its aesthetic qualities is the picket fence. In general, picket fences include at least one, but often two or more, rails spanning across at least two adjacent fence posts embedded in the ground. Picket fences also include a number of upright members, usually evenly-spaced, extending across and connected to the rails and oriented generally parallel to the posts.

Fences are often used on terrains that are not flat but are inclined. In such scenarios, welded picket fences are unsuitable. Instead, one must use a picket fence that is rackable. Rackable fences work by adjusting the upright members relative to the rails of the fence, such that the angles between the upright members and the rails can be varied. This cannot be done if the joints are welded together. For many civilian applications it is therefore desirable to have a fence which is rackable.

It is also desirable for the fence to be manufactured in a cost-effective and facile way, and be easily installed on site at a different location to where it was manufactured and/or assembled. Furthermore, it is also desirable for the fence to be manufactured from material with high weatherability and with a low chance of corrosion.

Various ways of connecting upright members to the rails are known in the art. For example, WO2021164923 describes a fence panel comprising a plurality of upright members and at least one rail connected to each of said upright members, wherein the at least one rail comprises an external casing defining a rail channel and comprising at least one aperture, wherein each of the upright members extends through an aperture into the rail channel, and an inner plate that extends along at least part of the length of the rail channel, wherein the inner plate is at least partly enclosed by the external casing, wherein the inner plate comprises a flat portion comprising a plurality of openings that rests against the upright members and two angled portions connected to opposite sides of the flat portion and extending away from said upright members and wherein the plurality of upright members each comprise a projection that extends into one of said openings to connect said upright member to the rail. US6824123 describes a rackable fence with a rail, picket carrier, and plurality of pickets wherein the rail defines a rigid inverted U-shaped cross-section, the picket carrier includes a top span residing within and extending across the interior of the rail and the pickets are pivotally attached to the picket carrier and pivotable toward the rail.

It is also known to include additional components within the rail, in order to strengthen the arrangement and to attach the upright members. For example, US2006081828 describes a picket fence system wherein pickets are supported by a system which includes a picket support and strengthening bar and rail system.

US2002175321 describes a picket fence and rail mounting system. The system comprises at least an upper and a lower elongate rail. Each rail has a hollow interior defining a substantially l-shaped crosssection including at least a first slot and a second slot. A plurality of pickets are transversely slidable through openings in an upper surface of the rails and a channel in a lower surface. The pickets each have at least a first notch or indentation near a first end and a second notch or indentation near a second end. An elongate retaining rod slidable within at least one rail cooperates with a notch or indentation on each picket to secure the picket to the rail. Rather than the retaining rod, spring clips, threaded fasteners or the like may cooperate with a hole in each picket to secure the picket to the rail.

The arrangements of the art typically include additional inserts or components that are made from material that are susceptible to corrosion. Additionally or alternatively, inserts of the art are typically required to be a specific shape in order to provide the sufficient stability required to hinder the rotation of an upright member.

Thus, there remains a need for rackable fencing which is cost-effective, easy to manufacture, and simple to assemble and install. It is also desirable for the fencing to be made from material that provides structural integrity with reduced risk of corrosion.

According to a first aspect of the present invention, there is provided a fence panel comprising: a plurality of upright members, and at least one rail connected to each of said upright members, wherein the at least one rail comprises: an external casing defining a rail channel and comprising at least one aperture, wherein each of the upright members extends through an aperture into the rail channel, a first plastic insert that extends along at least part of the length of the rail channel and is at least partly enclosed by the external casing, wherein the first plastic insert comprises a plurality of openings, a plurality of pins, wherein each pin extends through an opening in a first plastic insert to rotatably connect the upright members to the first plastic insert, and a second plastic insert that extends along at least part of the length of the rail channel and is at least partly enclosed by the external casing, wherein the second plastic insert is positioned on the side of the plurality of upright members opposite to the first plastic insert, wherein the thickness of the first and second plastic inserts increases along the axis perpendicular to the length of the rail channel, such that the rotation of each of the upright members around the pin is hindered by a first and second plastic insert.

The term "fence panel" is to be construed in accordance with the normal use of the word to relate to a panel that can be used in combination with fence posts to create a fence. The fence panel is therefore not self-supporting and is not sufficient to create a fence or other barrier alone, without some form of support.

The inventors have found that the fence panel of the present invention is straightforward and cheap to manufacture, with minimal and simple component parts (and fewer components than similar arrangements of the art), whilst still providing excellent structural security. Furthermore, the fence panel is rackable.

As the fence panel of the present invention is rackable, the angle between the upright members and the rails can be varied. In the present invention, this angle can preferably be up to 40° from the perpendicular in either direction. Thus, the fence panel can be used on a sloped surface.

The first and second plastic inserts of the present invention create an inward force against the upright members when the inserts are positioned in the external casing, thereby restricting the ability of the upright members to freely rotate. The inventors have advantageously found that that the use of a plastic material provides the necessary friction between the inserts, external casing and upright member to hinder the free rotation of the upright member. Additionally, the inventors have advantageously found that the arrangement of the present invention eliminates rattling of the upright members in the fence panel structure.

Therefore, the first and second plastic inserts according to the present invention may have the ability to provide the necessary force against the upright member such that rotational movement is hindered. The force may be greater than the force of gravity, such that the upright members are retained in a position in which they are placed, but can still be re-positioned by a user.

The inventors have advantageously found that the use of two separate plastic inserts according to the present invention provides the necessary friction to prevent the upright members from being loose and freely rotating. This is in contrast to arrangements in the art, for example, that utilise one insert that may surround either side of an upright member, as well as the top of the upright member in order to provide the necessary support. Therefore, the arrangement according to the present invention is more cost-effective than similar arrangements in the art.

Additionally, the shape of the inserts can decrease the flexibility of the inserts, thereby providing improved stability to the fence panel, while also increasing the ease of positioning the inserts within the rail channel.

In particular, the inventors have found that the use of a plastic material for the first and second inserts, for example PVC, gives the inserts a sufficient degree of resiliency that creates the necessary friction between the plastic inserts and the upright member to hinder rotation of the upright member. While rotation of the upright member is important for the fence to be rackable, the upright members should remain in the position in which they are placed, rather than being able to rotate freely.

The present invention has been found to be advantageous compared to similar arrangements in the art that include the use of non-resilient materials, for example steel, which require a specific shape in order to provide the force necessary to hinder rotation. In contrast, the present invention uses the inherent resilience of the material itself, thereby increasing the ease of manufacturing the component parts as a variety of shapes can be used. Additionally, the materials of the present invention are less susceptible to corrosion.

The first and second plastic inserts may therefore be made from a resilient material or a material having a degree of resiliency. The terms "resilient" and "degree of resiliency" are to be construed as requiring that the material can be deformed under the application of a force and can subsequently return to its original shape on the removal of said force. It will be understood that any deformation in shape is not permanent. In contrast, a non-resilient material is to be understood as a material that either cannot be deformed or will not return to its original shape after deformation.

The first and second plastic inserts may be made from PVC. This is advantageous because of the inherent resilient properties of PVC and the reduced propensity for corrosion compared to other conventional inserts or plates used in the art, for example, those made from steel.

The first and/or the second plastic inserts may have a tensile strength of over 7 MPa, preferably between 7 MPa and 200 MPa. The first and/or the second plastic inserts may have a hardness of lower than 80 HA, preferably lower than 60HA. The first and/or the second plastic inserts may have a Break Extend Rate of over 250%, preferably over 300%.

A low hardness and/or a high tensile strength allows the plastic inserts to be more deformable and resilient. This means that the tolerances can be improved, along with the friction exerted by the inserts on the upright members.

The first and second plastic inserts may be the same length. The first and second plastic inserts may be different lengths. The second plastic insert may be longer than the first plastic insert. The first and/or second plastic insert may extend the entire length of the rail channel, preferably more than 80% of the length of the rail channel and more preferably more than 90% of the length of the rail channel. The arrangement where the first and second plastic inserts are different lengths has been found to be advantageous because it is cost-effective, as less material is required, whilst also maintaining the necessary structural integrity.

The first and second plastic inserts of the invention are cheaper to manufacture compared to similar arrangements in the art, as no separate shaping process is required after the inserts have been created. Further, the inclusion of one plastic insert that is shorter than the other has been found to improve structural integrity of the fence panel, as shorter plastic inserts are less flexible in nature. Furthermore, the inventors have found that the use of first and second plastic inserts according to the present invention yields fencing that is easier to assemble and is simpler compared to fences in the art. The first and second plastic inserts may have one thick portion which tapers down to a thinner portion, thereby forming a wedge-like shape. The change in thickness is along the height of the inserts, i.e. the dimension parallel to the length of the upright members. The first and/or second plastic inserts may have thinner portions at each end thereof, with a thicker portion in between. The thicker portion is preferably closer to one end than the other. Additionally or alternatively, there may be a bend or curve at one end of the first and/or second wedges. This shape for the first and second plastic inserts is advantageous because it can be easily inserted into the arrangement of the present invention and therefore construction is simple. The thicker portion of the plastic inserts can apply a pressure against the upright member, creating the necessary friction to hinder rotation.

The thicknesses of the first and second plastic insert may be the same. The thicknesses of the first and second plastic insert may be different.

The thickest portions of the first and second plastic inserts may be in contact with both the upright member and the external casing. The thickest portions of the first and second plastic inserts may therefore provide the necessary force to hinder the rotation of the upright members.

The thickest portions of the first and second plastic inserts are preferably opposite one another, at the same height along the upright member. The thickest portions of the first and second plastic inserts may be positioned away from the upper side of the external casing. This shape has been found to result in easy insertion of the first and second plastic inserts, while still providing the necessary force to hinder the rotation of the upright members.

The thickest portion of the first and second plastic inserts may be positioned towards the upper side of the external casing. This shape has been found to provide the greatest amount of friction and contact between the insert and upright member, thereby improving the stability of the upright members.

The terms "upper" and "lower" herein are to be construed with reference to the surface on which the fence panel is to be placed. Thus, the lower side is that closest to the surface, while the upper side is that furthest from the surface.

The skilled person would understand that the term "external casing" includes any protrusions that also may be present in the external casing. The external casing may comprise at least one first aperture and at least one second aperture opposite the at least one first aperture, wherein each of the upright members extends through a first and second aperture and thereby extends through the rail channel. This allows the rail to be positioned at any point along the length of each upright member (for example along the top, middle or bottom of the upright members). Thus, multiple rails can be positioned at different heights of the fence panel.

Preferably, the external casing comprises a plurality of apertures such that each upright member extends through a different aperture. Said plurality of apertures may be a plurality of first apertures. The plurality of apertures ensures that each upright member is held in place and limits the extent to which the upright members have rotational freedom. The extent of the rotational freedom is at least partially dictated by the size of said apertures. The first apertures are preferably on an upper side of the external casing.

The external casing may comprise one aperture extending along at least part of the length thereof, such that all of the upright members extend through the same aperture. This aperture may be the second aperture. This aperture may extend along the entire length of the external casing. This aperture may be on a lower side of the external casing.

The combination of the plurality of first apertures and the single second aperture increases the ease with which the upright members are positioned relative to the rail, as each upright member only needs to be aligned with a first aperture. Such an arrangement is also cheaper and easier to assemble, whilst maintaining the stability of the upright members, which is provided by the first apertures.

The cross-section of an aperture may be greater than the cross-section of the upright member extending therethrough. For clarity, the term "cross-section" is used in this context to refer to the cross-section parallel to the side of the external casing comprising the aperture. This may be the case for all apertures in the external casing and is particularly important for the plurality of first apertures, if present. The cross-section of the aperture may be greater than the cross-section of the upright member in one dimension, or in all dimensions.

This permits rotation of the upright members around the pin, which would be impossible if the crosssections of the apertures were equal to the cross-sections of the upright members, as the upright members would then fit tightly in the apertures with no room for movement. This also allows for insertion of the upright members into the external casing and through the rail channel, as it accounts for the size of the pin. The ease of assembly is also increased.

The external casing may have a rectangular cross-section. The external casing may comprise two sides parallel to the upright members and two sides perpendicular to the upright members. However, at least one of the sides perpendicular to the upright member includes an aperture. In an embodiment in which the aperture extends across some or all of this side, the external casing may be described as generally having an inverted U-shaped cross-section. The dimensions of the external casing may be such that the sides of the external casing parallel to the upright members are longer than the side(s) of the external casing perpendicular to the upright members.

The external casing may comprise a lip adjacent to an aperture and extending into the rail channel. The lip may be connected to the external casing at the boundary between said external casing and the aperture. The aperture may be the one second aperture and the lip may extend along at least part of the second aperture. Preferably, the lip is connected to the side of the aperture closest to the first plastic insert.

The lip may be connected to the lower side of the external casing, which extends perpendicular to the upright members. Alternatively, the lip may be connected directly to the side of the external casing that extends parallel to the upright members. The lip may comprise a section angled towards the inside of the external casing, away from the lower side. The lip may extend partly over the aperture.

Advantageously, the lip may provide a channel in which an end of the first plastic insert can rest. Therefore, the height of the first plastic insert may extend the majority of the height of the rail channel, for example, from the upper side of the external casing to the lip of the external casing. The lip may also ensure that the size of the cross-section of the aperture in the dimension perpendicular to the length of the rail channel is similar to the size of the cross-section of the upright members in the same dimension. This prevents movement of the upright members in this dimension, and thus improves stability of said upright members. Alternatively, the lip may be on the side of the second plastic insert and these features apply equally in this case.

The lip may be angled at about 0° to about 80°, preferably about 20° to about 80°, more preferably about 20° to about 70°, most preferably about 30° to about 70°, relative to the side of the external casing comprising the aperture. The inventors of the present invention have found that such an angle provides optimal positioning of the plastic insert inside the external casing to maximise stability and security, especially compared to arrangements of the art which are absent the lip, or have an angle greater than about 80°. A lip having this angle makes it more difficult to remove the top rail from the arrangement. The inventors of the present invention have also found that the external casing comprising a lip having such an angle is cheaper and easier to manufacture compared to arrangements of the art which have an angle greater than about 80°.

The first plastic insert may contact the external casing between a side of the external casing extending parallel to the upright member and the lip. Additionally or alternatively, the first plastic insert may contact the external casing between the upright member and the external casing. This provides extra stability and security to the first plastic insert inside the external casing, particularly in view of the forces applied to the first plastic insert by the pins as the upright members are rotated.

A thinner end of the first plastic insert may be positioned between the lip and a side of the external casing extending parallel to the upright member. In this embodiment, a thicker portion of the first plastic insert may contact both the upright member and the external casing. Alternatively, an end of the first plastic insert closer to the thicker portion may be positioned between the lip and a side of the external casing extending parallel to the upright member. In this embodiment, the thicker portion may contact both the upright member and the external casing just above the lip. A bend in the first plastic insert may help to provide the necessary force on the upright member.

The external casing may be formed from metal, preferably aluminium. This material has been found to provide a fence panel with improved weatherability and reduced corrosion compared to fence panels made from other materials conventionally used in the art, for example steel. The external casing is preferably extruded, and may be formed from extruded aluminium. This means that protrusions can easily be formed on the inside of the external casing, extending into the rail channel.

The external casing may comprise one or more protrusions extending into the rail channel. There may be one or more protrusions on one or both sides of the external casing parallel to the upright member. The external casing may comprise a plurality of protrusions extending into the rail channel on the side positioned closest to the second plastic insert. The protrusion may extend perpendicular to the upright member. Thus, the second plastic insert may be in contact with one or more protrusions. Additionally or alternatively, there may be one or more protrusions on the side of the first plastic insert and so these features apply equally in this case. The external casing may comprise at least two protrusions or at least three protrusions extending into the rail channel of the external casing. The external casing may comprise two protrusions extending into the rail channel of the external casing. The protrusions may protrude into the rail channel to different extents, therefore the protrusions may be different lengths. Each protrusion may be a different length. Alternatively, the protrusions may be the same length.

The length of the protrusion may be complementary to the thickness of the plastic insert at the height of the protrusion in the external casing. For example, the thinner the section of the plastic insert that is in contact with the protrusion, the longer the corresponding protrusion may be.

An upper protrusion may act to hold the second plastic insert against the upright member, thereby applying the necessary forces to hold the upright member in place and hinder rotation of the upright member. This can also reduce the friction created when the second plastic insert is pushed along the rail channel, as it is only in contact with the protrusion rather than the entire surface of the external casing. Thus, the protrusions in contact with the surface of the second plastic insert, that act to hold it against the upright member, must have a length such that the plastic insert can slide past them, between the external casing and the upright member. A thicker portion of the second plastic insert may be in contact with the upper protrusion, in order to increase the force applied to the upright member. A thinner portion of the second plastic insert may be in contact with the upper protrusion, in order to increase the ease of assembly.

Additionally, or alternatively, the second plastic insert may be in contact with and abut a lower protrusion, which may be perpendicular to the upright member. Advantageously, an end of the second plastic insert may rest on the upper surface of a lower protrusion. The upper surface may provide a channel in which the second plastic insert is positioned. Therefore, the second plastic insert may extend between the upper side of the external casing and the lower protrusion. This arrangement means that the height of the second plastic insert (perpendicular to the length of the rail channel and parallel to the upright member) can be reduced, which improves the ease of assembly and the stiffness of the second plastic insert, as well as reducing costs as less material is required. It may be an end furthest from the thicker portion of the second plastic insert that rests on the lower protrusion. Alternatively, it may be an end closest to the thicker portion of the second plastic insert that rests on the lower protrusion. Advantageously, the position of the lower protrusion on which the end of the second plastic insert may rest may depend on the intended height of the plastic insert. The distance between the upper side of the external casing and said lower protrusion may be shorter than the distance between the upper side of the external casing and the lip.

The external casing may therefore include a lower protrusion wherein the second plastic insert rests on the upper surface of said lower protrusion. The external casing may also comprise an upper protrusion that is positioned between the upper side of the external casing and the lower protrusion. The upper protrusion may not extend as far into the rail channel as the lower protrusion. The upper protrusion may be in contact with a thicker portion of the second plastic insert. The upper protrusion may be in contact with a thinner portion of the second plastic insert.

The term "inner" herein is intended to be construed with reference to the external casing surrounding the rail channel. Thus, the inner side is that closest to the upright member, while the outer side would be that furthest from the upright member and facing the surroundings.

The first plastic insert is rotatably connected to the upright member via a pin. The pin may be part of the upright member or may be a separate component. Thus, the upright members may comprise a pin connected thereto, or a hole through which a pin can extend.

The upright members may each comprise a pin irreversibly attached thereto. Said pin may be fixed and immovable on the upright member. The pins may be welded to the upright members. This is simpler and cheaper than the spring-loaded pins in the art, as it is more expensive to manufacture an upright member comprising a spring loaded pin than an upright member comprising a fixed pin. However, the pin may be a spring-loaded pin.

Alternatively, the upright member may comprise a hole and the pin may not be fixed on the upright member and may be loose. A loose pin may not be attached to the upright member and instead, may extend through a hole in the upright member and then through a hole in the first plastic insert.

The second plastic insert may be absent of holes.

The external casing may further comprise one or more stoppers to hold one or both of the plastic inserts in position. The one or more stoppers are preferably positioned within the rail channel, extending away from the external casing. Preferably, the stoppers prevent the movement of the plastic insert in the direction parallel to the length of the rail channel. There may be stoppers at both ends of the plastic insert, at opposite ends of the rail channel, particularly for the first plastic insert. There may be a stopper at one end of the second plastic insert. There may be no stoppers in contact with the second plastic insert and stoppers at both ends of the first plastic insert. The stoppers may be L-shaped stoppers, which may be welded onto the external casing or formed integrally thereon.

This can increase the stability of the rackable fence panel, as the plastic inserts do not move during racking. Thus, preferably at least the first plastic insert is held in position by one or more stopper. This also provides a simple way in which to assemble the fence panel in a manner that holds the plastic inserts in position, without requiring additional tools to connect the plastic inserts to the external casing.

The fence panel may comprise at least two rails, optionally at least three rails, optionally at least four rails. Additional rails provide extra support and stability to the fence panel, as well as improving its aesthetics. The fence panel may comprise two rails. The fence panel may comprise three rails. The fence panel may comprise four rails.

The fence panel may comprise an upper rail extending at or towards the top of the upright members. The fence panel may comprise a lower rail extending at or towards the bottom of the upright members. This improves the stability and the aesthetics of the fence panel.

Preferably, when the fence panel comprises at least two rails, the external casing of at least one rail comprises apertures on only one side of said external casing. In fence panel arrangements comprising at least two rails, one of the rails may be located at the top of the fence panel, and thus be connected to the upper ends of the upright members.

Alternatively or additionally, one of the rails may comprise apertures only on one side of the external casing and may be located at the bottom of the fence panel, and thus be connected to the other end of the upright members. The rail may also be in contact with a surface. For the benefit of aesthetic appearance, in these embodiments the upright members do not extend all the way through the rail channel of the at least one rail located at the top and/or bottom of the fence panel, such that the ends of the upright members are located in the rail channel, thereby creating a flat surface along the top and/or bottom of the fence panel. Furthermore, in these embodiments, the end of the upright members that is present in the rail channel may be in contact with the side of the external casing which is opposite the side comprising the at least one aperture. Alternatively, the end of the upright members may not be in contact with said side of the external casing, to permit rotation of the upright members about their pin.

The cross-section of the upright members may increase in size towards the end of said upright members. Preferably, the cross-sectional dimension perpendicular to the length of the rail channel increases.

The inventors have surprisingly found that the arrangement of the present invention prevents the arrangement from rattling and does not allow free rotation of the upright member, whilst maintaining the property of rackability. This is as a result of the shape and material of the plastic inserts in combination with the use of pins. This is in contrast to conventional arrangements in the art which require additional structural modifications to maintain the position of the upright members. The arrangement of the present invention is therefore simpler and easier to assemble.

According to a second aspect of the present invention, there is provided a fence comprising at least two adjacent fence posts and a fence panel as discussed above, wherein the fence panel comprises a plurality of upright members located between adjacent fence posts and at least one rail extending between the adjacent fence posts and connected to each of said upright members.

The external casing may be clamped to at least one of the fence posts. This may be achieved by having corresponding slot holes on both the external casing and a clamp, which are then screwed or bolted together. The clamp is then affixed to the fence post. The clamp may be screwed onto the fence post. The use of slot holes on both the external casing and the clamp permits rotation about this connecting joint, which allows for the fence to be racked.

Additionally or alternatively, the external casing may be bolted to at least one of the fence posts. The external casing may be bolted using self-drilling screws. All of the rails may be clamped to at least one of the fence posts and preferably are clamped to both fence posts. This is to ensure maximum strength and stability of the fence. The fence posts may be metal and may be formed from a corrosion-resistant metal, such as aluminium. The fence posts may be extruded. The upright members may be formed from the same material and may be extruded.

The fence posts may have a rectangular or square cross-section. The fence posts may have a circular or oval cross-section.

At least one end of at least one of the fence posts may be connected to a surface. Both ends of the fence posts may be connected to a surface if the fence is used as part of a larger structure, for example to block an entrance in a building. Preferably, at least one end of all of the fence posts is connected to a surface. Preferably, the surface is terrain. The surface may be flat or inclined.

The end of at least one of the fence posts may be embedded in the surface. The fence posts may be embedded by any reasonable method, for example pushing the fence post into the surface or digging a hole for the fence post to be inserted into.

The end of at least one of the fence posts may comprise a base plate for affixing said fence posts to the surface. The base plate may be attached to the fence post using any reasonable means. The base plate may comprise a plurality of holes for screwing or bolting the base plate to the surface.

At least a portion of the fence may be racked. In particular, the fence may be racked when used on an inclined surface. The upright members may be rotated about the pins so that the upright members remain parallel to each other and parallel to the fence posts. However, the upright members are no longer perpendicular to the at least one rail in this embodiment. The racked fence may comprise a plurality of rails, wherein the distance between said rails is maintained upon racking, and the plurality of rails remain parallel to each other.

According to a third aspect of the present invention, there is provided a method for assembling the fence panel discussed above, comprising the steps of: a) inserting a pin through a corresponding opening on the first plastic insert, thereby connecting a plurality of upright member to the first plastic insert; b) passing the plurality of upright members through the aperture of the external casing, such that the first plastic insert is moved inside the rail channel of the external casing; and c) inserting the second plastic insert along the rail channel, between the external casing and the side of the upright member opposite that in contact with the first plastic insert.

As discussed above, the pin may be attached to the upright member, or may be a separate component. Thus, step (a) can involve inserting the pin that is connected to the upright member through the corresponding opening on the first plastic insert. Alternatively, step (a) can involve inserting a pin through an opening both in the first plastic insert and in the upright member. Each pin may connect one upright member to the first plastic insert.

The upright members may be partly inserted through the apertures on the external casing before the pins are inserted through the opening on the first plastic insert. The upright members may therefore extend through the rail channel before step (a) is conducted. Thus, step (b) may comprise passing the upright members further through the aperture of the external casing. In this embodiment, the external casing helps to hold the upright members in position to aid the connection to the first plastic insert. Alternatively, the upright members may not extend through the apertures of the external casing before step (a) is conducted.

The stoppers may be attached to the inside of the external casing after the plastic insert has been positioned within the external casing. In an embodiment in which the stoppers are positioned at either end of the first plastic insert, they may be attached to the inside of the external casing after step (b) or after step (c). The stoppers may be attached to the external casing by welding. This allows the plastic insert to be in close contact with the stoppers, thereby ensuring that the plastic insert is firmly held in the desired position.

According to a fourth aspect of the present invention, there is provided a method of installing a fence as discussed above, comprising the steps of: a) installing a first fence post; b) attaching the fence panel as discussed above to the first fence post; and c) installing a second fence post and attaching the second fence post to the fence panel, or attaching a second fence post to the fence panel and installing the second fence post.

According to a fifth aspect of the present invention, there is provided a method of installing a fence as discussed above, comprising the steps of: a) installing a first and a second fence post; and b) attaching the fence panel as discussed above to the first and second fence posts.

Thus, the fence panel of the present invention can be used in installation methods in which two or more posts are installed first and the panels are subsequently fitted to the posts. The fence panel of the present invention can also be used in installation methods in which the posts and panels are installed in an alternating manner, along the length of the fence.

The methods of installation of the present invention are straightforward, require no complex tools or machinery (such as welding equipment), and can be done at a different location to that of manufacture and/or assembly.

According to a sixth aspect of the present invention, there is provided a kit for assembling the fence discussed above, comprising: at least two fence posts, a plurality of upright members, and at least one rail, wherein the at least one rail comprises: an external casing defining a rail channel and comprising at least one aperture, and a first plastic insert capable of extending along at least part of the rail channel wherein the first plastic insert comprises a plurality of openings, a plurality of pins capable of extending through an opening in the first plastic insert, a second plastic insert capable of extending along at least part of the length of the rail channel, wherein the thickness of the first and second plastic inserts increases along the axis perpendicular to the length of the rail channel, such that in use, the rotation of each of the upright members around the pin in hindered by a first and second plastic inserts .

For the avoidance of doubt, all features relating to the fence panel also relate, where appropriate, to the fence, the methods for assembling the fence and the kit for assembling the fence and vice versa.

The invention will now be more particularly described with reference to the following examples and figures, in which: Figure 1 illustrates a perspective view of a section of the fence in accordance with one embodiment of the invention;

Figure 2 illustrates a cross-section of an upright member and a rail in accordance with one embodiment of the invention;

Figure 3 illustrates a cross-section of an upright member and a rail in accordance with another embodiment of the invention;

Figure 4 illustrates a cross-section of an upright member, a pin and rail in accordance with another embodiment of the invention;

Figure 5 illustrates a cross-section an upright member and a rail in accordance with another embodiment of the invention; and

Figure 6 illustrates a cross-section an upright member and a rail in accordance with another embodiment of the invention.

Figure 1 illustrates a section of a fence 10 according to an embodiment of the present invention. The fence 10 comprises a plurality of fence posts 11 (only two of which are shown), a plurality of upright members 12 and a rail 13. The rail 13 extends between the adjacent fence posts 11 and connects each of the upright members 12. In this embodiment, the upright members do not extend through the rail. Thus, the fence 10 has a flat top, defined by the rail 13.

The plurality of upright members 12 are parallel to the fence posts 11 and are perpendicular to the rail 13. Thus, in Figure 1 the fence is not racked. However, the upright members can rotate around the pin and so the angle between the upright members and the rail can be varied.

Figure 2 illustrates a cross-section of the joint between an upright member 22 and a rail according to an embodiment of the present invention. The rail comprises an external casing 23, which has an aperture 24 on the bottom side of the casing. The size of the aperture 24 is such that the upright member 22 can pass through. In this embodiment, the external casing 23 only comprises a single aperture and so the upright member 22 does not extend all the way through the rail channel, such that the end of the upright member 22 is located within the rail channel. This creates a flat surface along the top of the fence panel.

The rail also comprises a first 25 and second 26 plastic insert. The first and second plastic inserts 25, 26 are interposed between upright member 22 and the external casing 23, and are shaped such that the thickness of the first and second plastic inserts 25, 26 increases along the axis perpendicular to the length of the rail channel. The first and second plastic inserts 25, 26 therefore have a thick portion which tapers down to a thinner portion, thereby forming a wedge-like shape. However, both inserts also taper to a thinner portion at the upper end thereof and therefore have thinner ends and a thicker portion between the two ends. Both inserts also have a slight curve at the end closest to the thickest portion.

The thickest portions of the first and second plastic inserts 25, 26 are located towards the top of the external casing 23, opposite the side of the aperture 24 and closest to the upper side of the external casing 23. The first and second plastic inserts 25, 26 are positioned on opposite sides of the upright member 22.

The external casing 23 comprises a plurality of protrusions 27a, 27b extending into the rail channel on the side positioned closest to the second plastic insert 26. The thinner portion of the second plastic insert 26 rests on the upper surface of a lower protrusion 27a, which is angled perpendicular to the upright member 22 into the rail channel. The second plastic insert 26 is therefore interposed between lower protrusion 27a and the upper side of the external casing 23.

The external casing 23 also includes an upper protrusion 27b extending into the rail channel. The upper protrusion 27b is angled perpendicular to the upright member 22 and is positioned between the upper side of the external casing 23 and the lower protrusion 27a. The upper protrusion 27b does not extend as far into the rail channel as the lower protrusion 27a and is located adjacent the thicker portion of the second plastic insert 26. The thicker portion of the second plastic insert 26 is interposed between upper protrusion 27b and the upright member 22, thereby increasing the friction applied to the upright member 22.

The lower side of the external casing 28a extends perpendicular to the upright member 22 and defines one side of aperture 25. The first plastic insert 25 comprises at least one opening (not shown). The first plastic insert 25 is connected to the upright member 22 by at least one pin (not shown) on the upright member 22, which extends into the corresponding opening on the first plastic insert 25. The upright member 22 has a corresponding hole (not shown) through which the pin can also extend, thereby rotatably connecting the upright member and the first plastic insert 25.

The thicker portion of the first plastic insert 25 is in contact with both the upright member 22 and the side of the external casing 23. The thinner portion of the first plastic insert 25 is in contact with and abuts lip 28b, which is angled upwards at 45°, away from the lower side of the external casing 23. The first plastic insert 25 is therefore held in place in the external casing by lip 28b. The first plastic insert 25 is therefore interposed between the lip 28b and the upper side of the external casing 23 parallel to the upright member 22. The height of the first plastic insert 25 is greater than that of the second plastic insert 26. The length of the first plastic insert 25 extends the majority of the length of the rail channel.

Figure 3 illustrates a cross-section of the joint between an upright member 32 and a rail according to another embodiment of the present invention. The rail comprises an external casing 33, which has a first aperture 34a on the bottom side of the casing, and a second aperture 34b on the top side of the casing. The upright member 32 extends all the way through the external casing 33 via opposed apertures 34a, 34b.

Bottom aperture 34a is a single aperture that extends along the entire length of the external casing 33. There are a plurality of top apertures 34b, with a single upright member 32 extending through each. The cross section of the top apertures 34b is larger than the cross section of the upright members.

As with Figure 2, the rail also comprises a first 35 and second 36 plastic insert, along with protrusions 37a, 37b, lip 38b and bottom surface of the rail 38a. The arrangement of these components is the same as discussed above in relation to Figure 2.

Figure 4 illustrates a cross section of the connection between an upright member 42 and a first plastic insert 45 via a pin 49 according to an embodiment of the present invention. Also shown is fence post 51, to which the external casing 43 is connected via clamp 50. The first plastic insert 45 comprises a plurality of openings 45a. The pin 49 extends through the opening 45a on the first plastic insert 45 and extends into a corresponding hole 42a on the upright member 42, thereby rotatably connecting the upright member 42 and the first plastic insert 45.

As with Figure 2, the rail comprises an external casing 43, which has an aperture 44 on the bottom side of the casing. The size of the aperture 44 is such that the upright member 42 can pass through. The rail also comprises a second plastic insert 46, along with protrusions 47a, 47b, lip 48b and bottom surface of the rail 48a. The arrangement of these components is the same as discussed above in relation to Figure 2.

Figure 5 illustrates a cross-section of the joint between an upright member 62 and a rail according to another embodiment of the present invention. The rail comprises an external casing 63, which has a first aperture 64a on the bottom side of the casing, and a second aperture 64b on the top side of the casing. The upright member 62 extends all the way through the external casing 63 via opposed apertures 64a, 64b.

Bottom aperture 64a is a single aperture that extends along the entire length of the external casing 63. There are a plurality of top apertures 64b, with a single upright member 62 extending through each.

As with Figure 3, the rail comprises a first 65 and second 66 plastic insert, along with protrusions 67a, 67b, lip 68b and bottom surface of the rail 68a. However, the orientation of the first 65 and second 66 inserts is different, in that the thickest portion of both of the plastic inserts is away from the upper side of the external casing 63. Thus, the end of the second plastic insert 66 closest to the thicker portion rests on the lower protrusion 67a. The upper protrusion 67b presses a thinner portion of the second plastic insert 66 into the upright member 62.

The thicker portion of the first plastic insert 65 is in contact with and abuts lip 68b, which is angled upwards at 45°, away from the lower side of the external casing 63. The first plastic insert 65 is therefore held in place between the lip 68b and the upper side of the external casing 63 parallel to the upright member 62. The shape of the first plastic insert 65 and its inherent resilience provides a force on the upright member 62 that hinders the rotation thereof. Figure 6 illustrates a cross-section of the joint between an upright member 72 and a rail according to an embodiment of the present invention. The rail comprises an external casing 73, which has an aperture 74 on the bottom side of the casing. As with the embodiment in Figure 1, the external casing 73 only comprises a single aperture and so the upright member 72 does not extend all the way through the rail channel, such that the end of the upright member 72 is located within the rail channel. This creates a flat surface along the top of the fence panel.

As with the arrangement of Figure 2, the rail also comprises a first 75 and second 76 plastic inserts, interposed between upright member 72 and the external casing 73 and shaped such that the thickness of the first and second plastic inserts 75, 76 increases along the axis perpendicular to the length of the rail channel. However, the thickest portions of the first and second plastic inserts 75, 76 are located towards the bottom of the external casing 73, closer to the side of the aperture 74 and away from the upper side of the external casing 73.

Thus, the end of the second plastic insert 76 closest to the thicker portion rests on the upper surface of lower protrusion 77a, which is angled perpendicular to the upright member 72 into the rail channel. The thinner portion of the second plastic insert 76 is interposed between the upper protrusion 77b and the upright member 72, thereby making assembly of the fence panel easier while still maintaining the necessary force on the upright member 72.

The arrangement of the first plastic insert 75 is the same as that in Figure 5. A stopper 79 is shown at one end of the first plastic insert 75. The stopper 79 is connected to the external casing 73 by a weld and extends into the rail channel, thereby preventing the movement of the first plastic insert 75 in the direction parallel to the rail channel.