TECHNICAL FIELD OF THE INVENTION

The invention relates to a modular construction composed of rod-like elements. More particularly, the invention relates to a modular fencing, gate, railing and security system comprising a plurality of space posts arranged in parallel and a plurality of fence segments located between the posts.

BACKGROUND OF THE INVENTION

There is an ever growing demand for robust fencing systems particularly for improved security of properties, and to keep the public safe, for example fences to keep children out of swimming pools or to keep people away from cliffs or the edges of buildings and bridges. Furthermore, people would like to have a fence around their property with a real "wrought iron" appearance.

Picket type fences are particularly suitable for these applications as they can be difficult to climb over. Fences having long vertical pickets with widely spaced rails are not easily climbed as they do not provide convenient stepping points. In addition the tops of the pickets can be pointed to make the fences more difficult to scale.

Currently in the art, "wrought iron" fencing, railing, and security systems constructed of solid components are typically either prefabricated as complete units or custom fabricated at the installation site by skilled craftsmen using welding equipment and other specialized tools.

Alternatively, many modular fence, railing, and security systems have been developed which simulate solid wrought iron, but are constructed of hollow tubing or similar materials, and can require rather complex installation procedures. Thus, the expense and complexity of installation of the most routine fence, gate, railing, or security system with their component parts become very burdensome for the average person- particularly for those who are required by law to build such systems (such as fencing in swimming pools and the like).

While steel and aluminium fences can be welded, this construction method is not always convenient, particularly in the field. In addition, welding can destroy protective coatings; such as galvanising, meaning that welded sections of fence often require re-protection, for example galvanising after assembly. Prefabrication of fence segments is not always convenient. A buyer has to use a van or trailer to transport the segments from the store to the location of installation. Alternatively, he could request the warehouse employee to deliver the segments at home. This results in additional delivery time. Another disadvantage of prefabricated fence segments is that they require a relative large storage space in the warehouse.

Consequently, the variation in design of segments will be limited.

US4006885 discloses a modular fence and hand rail designed to be assembled into connecting modular segments. The modular fence can be economically tooled and manufactured and is shipped in a knocked-down condition. An unskilled individual can assemble the components with the simples of tools such as a screw driver and pliers. However, couplings with screws have the disadvantage that they form the weakest part of the construction with respect to corrosion.

WO2009067027 discloses a fencing system having one or more rails that are generally aligned with a length of the fencing system. Each rail has an internal passageway along its length. The fencing system further includes upright members that are adapted to be connectable to the rails, and at least one elongated locking member that is configured to fit within the internal passageway and to pass through an opening in each upright member to secure each upright member to the rails. Both the rails and upright members are hollow elongated bodies in which moisture can become a source of corrosion.

SUMMARY OF THE INVENTION

The object of the invention is to provide a modular construction which overcomes at least one of the disadvantages mentioned before.

According to the invention, this object is achieved by a modular construction having the features of Claim 1 and a modular fencing system having the features of claim 8. Advantageous embodiments and further ways of carrying out the invention may be attained by the measures mentioned in the dependent claims.

According to the invention, the modular construction is composed of solid rod-like elements. The construction comprises first rod-like elements wherein each first rod-like element comprising at least one hole. A first rod-like element is fixated in longitudinal direction of the first rod-like element by a second rod-like element which passes through a hole of the first rod-like element. The first rod-like elements is fixated in a direction perpendicular to the longitudinal direction by passing a first rod-shaped part of the first rod-like element through a hole of one or more third rod-like elements.

These features provide a construction which enables one to assemble the construction without need of additional tools. The respective rod-like elements having one or more openings are fitted together by shifting rod-shaped parts of rod-like elements through one or more openings of other rod-like elements. In this way, a rigid structure is created wherein solid rod-like elements are secured without additional locking means. The elements of the structure are positioned such with respect to each other, that they are fixated with respect to each other and form a stable construction.

In an embodiment, the first rod-like element is further fixated in a direction perpendicular to the longitudinal direction by passing a second rod-shaped part of the first rod-like element passing through a hole of a third rod-like element wherein the at least one hole of the first rod-like element is positioned between the first and second rod-shaped part. This feature improves the attachment of the first rod-like element in the construction.

In an embodiment, the solid rod-like elements are forged elements from one piece. This feature improves characteristics of the rod-like elements, such as stiffness, as the rod-like element does not comprise welds. Another advantage is that no process steps such as welding and riveting are necessary to produce the solid rod-like elements. This reduces the production costs of the individual elements.

In an embodiment, the solid rod-like elements are individually pre- processed by at least one of the following processes: abrasive blasting, metalizing, priming, anodising, hot dip galvanizing, powder coating, patinating, chroming, polishing and wet painting. In this way the surface properties of the elements are improved, such as appearance, adhesion, wettability, corrosion resistance, wear resistance, and scratch resistance. By fitting the elements together, by shifting rods through corresponding openings, the protective coating will not be damaged and the construction does not require some post treatment to protect the basic material of the rod-like elements against corrosion. A subsequent treatment after assembly is necessary when the elements are coupled together by welding, riveting and/or screwing. These coupling methods damage the protective coating. Furthermore, if a subsequent treatment after assembly is necessary, it would not be possible to coat the surfaces of the rods-like elements in the openings.

Moisture between the rod-like elements in the openings will become a source for corrosion. In an embodiment of the invention, the modular construction is demountable into the rod-like elements. This feature allows one to reuse the rod-like element.

In an embodiment of the invention, the rigid rod-like elements are metal elements. Metal has the advantage the system will be stiff and the element could economically be manufactured by induction heating, forming, punching and cutting long rods. The rigid rod-like elements could be manufactured with a cold forging process when low carbon steel or aluminium is used.

According to a first aspect, there is provided a modular fencing system. The fencing system comprises fence segments. A fence segments is composed of horizontal and vertical rod-like elements. Each vertical rod-like element comprises at least one hole. The vertical rod-like element is fixated in vertical direction in the structure of the fence segment by a first horizontal rod-like element which passes through a hole of the vertical rod-like element and is fixated in a horizontal direction by passing a first rod-shaped part of the vertical rod-like element through a hole of one or more second horizontal rod-like elements.

It will be clear that the various aspects mentioned in this patent application may be combined and may each be considered separately for a divisional patent application. Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, various features of preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE FIGURES

These and other aspects, properties and advantages of the invention will be explained hereinafter based on the following description with reference to the drawings, wherein like reference numerals denote like or comparable parts, and in which:

Figure 1 shows schematically a first embodiment of a fencing system according to the invention;

Figure 2 shows schematically a second embodiment of a fencing system; Figure 3 shows schematically a gate having the modular construction of the invention;

Figure 4 shows schematically an embodiment of a coupling between two fence segments; and, Figure 5 shows some exemplary embodiments of decorative rod-like elements.

DESCRIPTION OF EMBODIMENTS

Figure 1 shows schematically a first embodiment of a fencing system 1 according to the invention. The fencing system 1 comprises a plurality of spaced posts 2 arranged in parallel and a plurality of fence segements 4 located between the posts 2. A fence segment 4 is an assembly of solid rod-like elements 6A, 6B, 6C forming an embodiment of a construction according to the invention. Solid in the context of the present application means entirely of one substance with no cavities inside. A rod-like element could be in the form of a rod with or without one or more holes 8. In figure 1 each vertical rod-like elements 6A comprises one hole 8. A vertical rod-like element 6A comprises a first rod-shaped part 61, a second rod-shaped part 62 and an eye part 63 positioned between the first and second rod-shaped part 61, 62. The eye part 63 includes hole 8.

The construction of the fence segment 4 comprises two types of horizontal rod-like elements 6B, 6C. The first type of horizontal rod-like element 6B is a rod without holes. The second type of horizontal rod-like elements 6C is a rod with a plurality of holes. The number of holes corresponds to the number of vertical rod-like elements 6A. Each holes of the second type of horizontal rod-like element 6C has an opening configured to pass a rod-shaped part 62 of the vertical rod-like elements 6A. The opening formed by a hole of rod-like elements has a cross section which essentially corresponds to a cross section of the rod-like parts of a rod-like element. When the openings of the rod-like elements have a size which essentially corresponds to a cross section of the rod-shaped parts of the rod-like elements, the elements will form a rigid construction/fence segment with minimal free movement or deformation.

In the embodiment shown in Figure 1, distal ends of the three horizontal rod-like elements 6B, 6C are positioned in corresponding openings 2A in the posts 2. However, other coupling structures are commonly known to the skilled person, for example by using bolts and/or nuts.

A modular fencing system shown in figure 1 is assembled in the following way. In a first step, the distal ends of the second rod-shaped part 62 of the vertical rod-like elements 6A are inserted through the holes of one of the horizontal rod-like elements 6C. In a second step, the distal ends of the second rod-shape part 62 of the vertical rod-like elements 6A are inserted through the holes of the other one of the horizontal rod-like elements 6C. The vertical rod-like elements 6A are now positioned parallel. In a third step, a distal end of the horizontal rod-like element 6B without holes is inserted through the holes 8 in the eye parts 63 of the vertical rod-like elements 6A. In this way, the horizontal rod-like element 6B passing through a hole of the vertical rod-like elements 6A fixates the vertical rod-like elements 6 A in longitudinal direction, i.e. vertical direction, and the second rod-shaped parts 62 of a vertical rod-like element 6A passing through a hole of one or more horizontal rod-like elements 6C fixates the vertical rod-like element 6A in a direction perpendicular to the longitudinal direction, i.e. horizontal direction. In a fourth step, the distal ends of the horizontal rod-like elements 6B, 6C are positioned in the openings 2A of the posts 2. An advantage of the assembling method is that tools, such as screw driver, are not needed to assemble a rigid fence segment 4 from individual rod-like elements. Another advantage is that the assembling method does not damage protective coatings of the rod-like elements. Thus no post-treatment of the fence segment is needed to protect the fence segment against corrosion. Such a post-treatment is necessary when iron parts are welded together and recommended when bolt and nut connections are used to couple the elements. The method of coupling according to the invention does not damage the coatings. Yet another advantage is that the individual rod-like elements of a segment requires less space to store than an assembled fence segment. This has benefits for having fence segments in stock or when transporting a fence to the location of assembly. Yet another advantage is that the fence segment could be easily disassembled without damaging the individual rod-like elements. Yet another advantage is that by having horizontal rod-like elements with N different lengths on stock and vertical rod-like elements with M different lengths on stock, a customer can select from N times M different fence segment sizes. It is practically impossible to have sufficient pre-assembled fence segments with NxM different sizes on stock. Yet another advantage is that the rod-like elements could be manufactured economically by forging processes. Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Yet another advantage of the modular construction is that each element could have its own colour. This enables customers to select different coloured elements to assemble the construction. For example a customer could select two different colours for the vertical rod-like elements and use the different coloured elements alternately in the fence segment. It should be noted that the fence segment could be assembled in other order as described above. For example, one could start with the third step and then the first and second step and finally the fourth step.

A rod-like element with one or more holes could be produced from one piece of metal in the following way. Locally heating a rod, for example by means of induction. Pushing the not heated ends of the rod to each other. The rod will form at the locally heated part a knob or thickening. Subsequently a puncher makes the hole in the knob and reduces the height to obtain the eye-part of the rod-like elements. Depending on the number of holes in a rod-like element these steps are repeated. It should be noted that also cold forging processes could be used to produce the rod-like elements with one or more holes. A forging process improves characteristics of the rod-like elements, such as stiffness, as the rod-like element is of a homogenous material and does not comprise welds. Another advantage is that no process steps such as welding and riveting are necessary to produce the solid rod-like elements. This reduces the production costs of the individual elements. Furthermore, the appearance of a rod-like element or construction without welds is more appealing.

The thus obtained rod-like elements are subsequently subjected to one of the following processes: abrasive blasting, metalizing, priming, anodising, hot dip galvanizing, powder coating, patinating, chroming, polishing and wet painting. The surface properties of the elements are improved by these processes, such as appearance, adhesion, wettability, corrosion resistance, wear resistance, and scratch resistance.

Figure 2 shows schematically a second embodiment of a fencing system 1. The fencing system 1 comprises a plurality of spaced posts 2 arranged in parallel and a plurality of fence segements 4 located between the posts 2. A fence segment 4 is an assembly of solid rod-like elements 6A, 6B, 6D, 6E and 6F. The vertical rod-like elements 6A comprises a structure with one hole 8 as in the first embodiment. The second embodiment differs from the first embodiment in that the outer vertical rod-like 6F of the fence segment 4 comprises two holes 8. Furthermore, there is a horizontal rod-like element 6D which comprises bended distal ends. Furthermore, each distal end have an eye-part with a hole. Horizontal rod-like element 6E comprises a hole for each vertical rod-like element 6A with one hole.

The fence segment in figure 2 is assembled in the following way. In a first step the rod-shape parts 62 of the vertical rod-like elements 6A are inserted through the holes of the horizontal rod-like element 6E. In a second step the lower side eye part 6F1 of vertical rod-like elements 6F are slid over the distal ends of the horizontal rod-like element 6E. Now all vertical rod-like elements 6A and 6F are coupled to the horizontal rod-like element 6E. In a third step the rod-shape part 61 of the vertical rod-like elements 6 A and the rod-shape part 6F2 of the vertical rod-like elements 6F are inserted through the holes of the horizontal rod-like element 6E. In a fourth step, the rod 6B is inserted through subsequently a hole in a first distal end of horizontal rod-like element 6D, a free hole of a first vertical rod-like element 6F, the hole in the vertical rod-like elements 6A, a free hole of a second rod-like element 6F and a hole in a second distal end of horizontal rod-like element 6D. In a fifth step, the distal ends of horizontal rod 6B and horizontal rod-like element 6E are inserted in corresponding openings in the posts 2. In this embodiment the fence segment comprises three horizontal rod-like elements 6B, 6D and 6E, of which only the distal ends of elements 6B and 6E are coupled with the posts 2. Another advantage is that when the fence segment is assembled the distance between the horizontal rod-like elements 6B and 6E is fixed by the vertical rod-like elements 6F. This facilitates the coupling of the fence segment to the posts.

Figure 3 shows schematically a gate having the modular construction of the invention. A gate panel 7 comprises vertical rod-like elements 7A, 7B and 7C, horizontal rod-like elements 7E and 7G and slanted rod-like elements 7D and 7F. Furthermore, a nut 9 is used to prevent that horizontal rod-like element 7G inclines due to its own weight or other vertical forces acting on the horizontal rod-like element 7G. The posts 2 are in this embodiment provided with hinge members 2B. A hinge member 2B comprises a hole for passing vertical rod-like element 7C. Vertical rod-like element 7C is provided at one distal end with a knob or rim and forms the hinge pen or pivot member of the hinge. The vertical rod-like elements 7A and 7B comprises one eye part provided with a hole. The outer vertical rod-like element 7B forming the free end of the gate panel 7 comprises two rims 7B1 and 7B2. Rim 7B2 located at the upper part of the element 7B is configured to support slanted rod-like element 7D. The rim 7B2 prevents that rod-like element 7D will move down and deform the regular structure of the gate panel 7. The slanted rod-like part 7F forms together with horizontal rod-like element 7E and corresponding rod-shape part of vertical rod-like element 7B a triangle. The triangular construction ensures that the structure is stable and will not deform, i.e. incline, due to its own weight.

A gate panel in figure 3 is assembled in the following way. In a first step, the rod-shape part of horizontal element 7E is inserted in the holes of vertical rod-like elements 7 A and 7B. In a second step, the lower side rod-shape parts of the vertical rod- like elements 7 A are inserted in the corresponding holes of slanted rod-like element 7F and the lower side rod-shape part comprising rim 7B 1 is inserted in the hole at a distal end of slanted rod-like element 7F. The eye part forming said hole will be positioned against the rim 7B 1. In a third step, the lower side rod-shape parts of the vertical rod-like elements 7A and 7B are inserted in the corresponding holes of horizontal rod-like element 7G. The eye- part at a distal end of the horizontal rod-like element 7G forming the hole for passing the rod-shape part of vertical rod-like element 7B will be positioned against the eye-part at the distal end of slanted rod-like element 7F. A nut 9 is screwed on a threaded distal end of vertical rod-like element 7B to secure the distal end of rod-like element 7G.

In a fourth step, the upper side rod-shape parts of vertical elements 7 A and

7B are inserted in corresponding holes of the slanted rod-like element 7D. The eye-part at a distal end of the slanted rod-like element 7D forming the hole for passing the upper side rod-shape part of vertical rod-like element 7B will be positioned against the rim 7B2. In a fifth step, vertical rod-like element 7C is inserted in the free holes of the horizontal rod-like element 7E and 7G and the slanted rod-like elements 7D and 7F. In the way described above a gate panel is assembled from solid rod-like elements wherein the elements are coupled with each other to form a demountable modular construction without damaging the protective coatings of the elements.

It should be noted that rod-like element 7D forming the upper rail of the gate panel could also be in the form of a horizontal rod-like element. For example a rodlike element similar to rod-like element 7G. In that case, the rim 7B2 should be positioned lower on the rod-shape part of rod-like element 7B or the vertical rod-like elements 7C, 7A and 7B could have all the same length. Furthermore, it could be possible to apply more than one horizontal rod-like element 7E. In that case, the vertical rod-like elements 7A and 7B should be provided with additional holes and corresponding eye parts.

Figure 4 shows schematically an embodiment of a coupling between two horizontal rod-like elements 9A, 9B of adjacent fence segments in an opening through a post 2. The distal end of the horizontal rod-like elements comprises a coupling structure configured to couple the elements in longitudinal direction such that when the distal ends are positioned in the opening of the post cannot be decoupled. In the embodiment the distal ends comprise an L-shape structure which interlocks. In another embodiment, the distal ends have a semi-circular cross section. The part with semi-circular cross section comprises a hole. When the semi-circular parts are aligned, a pin could be inserted in holes of the aligned semi-circular parts to form a rigid joint between the two horizontal rod-like elements. These two embodiments does not require tools to couple the elements

It should be noted that in the embodiments shown the rod-shaped parts of the horizontal and vertical rod-like elements have essentially the same cross section. It might be clear to the skilled person, that the cross section may differ and that the size of the holes through which a rod-shaped part is inserted when assembled should be adapted accordingly. Furthermore, it should be noted that the rod-like parts of the elements which would not pass a hole during assembly of the construction may be provided with ornaments. The ornaments may be forged from the rod-like parts. This enables one to personalize the fencing system further and to improve the "wrought iron" look of the fencing system.

The modular construction components may be formed of wrought iron or other wrought metals, cast metal, plastic, polyvinyl chloride, or other materials used to construct conventional fencing, railing, or security bar systems. Metals that could be used are: iron, aluminium, low carbon iron, etc.. It should be noted that the concept of the modular construction could also be used to design and assemble articles of furniture such chairs tables and cases, home accessories, utensils, art objects, etc..

The components of this invention may be manufactured with a broad range of dimensions. In the embodiments described above, the rod shape parts of the rod-like elements have a circular cross-section area. It might be clear that the concept of the invention could also be used with rod-like elements having a squared, rectangular, oval or any other suitable cross-sectional area. The openings in the rod-like elements have a corresponding cross-sectional area. Furthermore, parts of the rod-like elements which do not pass an opening of another rod-like element may be provided with decorations. Figure 5 shows some exemplary embodiments of decorated rod-like elements.

Those skilled in the art will appreciate that the fencing, railing, and security systems may be provided with plurality of pickets/balusters and arranged in a

predetermined pattern, as desired, throughout the required length of the system. The modular construction of each of the systems utilizing the separate pickets/balusters with their respective ornaments provides for constructing systems having various ornamental patterns, which systems may be erected at the site of installation. The ability to demount the construction into reusable element allows for changing or replacing individual pickets/balusters or railings as desired to repair damaged components or alter the design of the system, for example. Many building codes and the requirements of other regulatory bodies are such that the spacing between the pickets/balusters of a fence or railing system must be dimensioned in a way that will not allow an object of a certain dimension to pass through the space between the pickets/balusters. In an embodiment , the formed holes in the horizontal rod-like elements are proportioned such that, the vertical rod-like elements installed adjacent to each other will provide a barrier to the passage of such an object.

Those skilled in the art will appreciate from the foregoing description that a fence, gate, railing, and security system has been provided which may be easily prefabricated of a minimum number of parts that may be arranged to provide a functional and aesthetically pleasing fencing, railing, or security system.

The measures described hereinbefore for embodying the invention can obviously be carried out separately or in parallel or in a different combination or if appropriate be supplemented with further measures; it will in this case be desirable for the implementation to depend on the field of application of the construction. The invention is not limited to the illustrated embodiments. Changes can be made without departing from the idea of the invention.