Abstract:
A post for a fit together panel comprising at least one said post and at least one slat, the post comprising a base member and a cover member, the cover member comprising a pair of sidewalls and an interconnecting end wall, the interconnecting end wall containing a plurality of openings through which the end of a slat can pass, the sidewalls adapted for extension over the channel member, the base member comprising a base wall and opposed sidewalls, at least one sidewall comprising a clamping leg adapted for clamping engagement against the end of a said slat passing through a said opening in the cover member, and snap fitting means on the channel member and/or the cover member to enable the channel member and the cover member to be snap fitted together.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is the U.S. national phase of international application PCT/AU2016/000038 filed Feb. 13, 2016 which designated the U.S., and claims the priority of Australian patent application No. 201 5900469 filed Feb. 13, 2015, the entire contents of both of which are hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention is directed extruded aluminum members which are comprised of parts that snap fit together without requiring any screws or rivets. Such members can be used in the construction of assemblies such as post and rail fences, fence panels and balustrades and the like to improve ease of manufacture and installation. 
       BACKGROUND OF THE INVENTION 
       [0003]    Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge. 
         [0004]    Aluminum panels comprising spaced apart post members and an array of spaced apart parallel slat members which are snap fitted together without separate fasteners are quite common and find popularity due to their aesthetic appeal, clean lines, and resistance to weathering and corrosion. Popular uses for such panels include fence panels and screens. 
         [0005]    Australian patent application 2006230672 illustrates a known type of snap together aluminum panel. This panel comprises unitary post members into which slots are cut and edges of slat members pass into the slots. The slats are held in the posts by clamping legs/fins. The post and clamping legs are formed as a single piece typically by extrusion. 
         [0006]    This type of panel assembly suffers from a number of disadvantages. One disadvantage is in the increase cost of manufacture of the post containing the cutouts. The cutouts are formed using a computer controlled cutting machine such as a CNC router. This is a complex and relatively expensive manner in which to provide cutouts. 
         [0007]    Another disadvantage is that the clamping legs/fins can lose their memory over time. The reason for this is that the “hinge” part of the legs comprises the area where the legs extend from an inner wall of the post, and this area (the hinge area) is relatively small and therefore more likely susceptible to fatigue over time. Should this occur, the slats can move or slip or begin to rattle and it may be necessary to replace the entire post. 
         [0008]    Another disadvantage with this type of panel is that it is quite difficult to fit the panel into a desired position. For example, panels may be required to be located between brick or block uprights. In that case the panels need to be fastened to the uprights using masonry anchors or something similar. The design of the panel is such that an internal masonry anchor cannot be used as there is no access to the internal back wall of the panel post. Thus, external brackets may need to be used which can be unsightly. Alternatively, a masonry anchor can be drilled entirely through the post which leaves a visible anchor point which is also unsightly. 
         [0009]    Another disadvantage is that if there is any damage to a particular slat, it becomes necessary to remove the entire post from the brick or block uprights (for example). Refitting of a new post can be time-consuming and may require drilling of new openings in the uprights. 
         [0010]    There is a need for improved snap-fit members which are composed of at least two parts that can be fastened together readily for use in the construction of assemblies such as fences, fence panels, balustrades and the like and which can overcome at least some of the above-mentioned disadvantages or which can provide a commercial choice in the marketplace. 
       SUMMARY OF THE INVENTION 
       [0011]    According to a first aspect of the present invention there is provided a post comprising: 
         [0012]    a base member and a cover member having corresponding snap fit formations by which the base member and the cover member are fastened to each other, 
         [0013]    the cover member including an end wall with first and second buttressing walls projecting therefrom, 
         [0014]    the base member comprising a base wall with first and second clamping legs extending therefrom for clamping a third member therebetween, the clamping legs converging outwardly and inwardly from the base wall to present a minimum space therebetween; 
         [0015]    at least one opening formed through the base wall or the end wall for passage of a third member therethrough; 
         [0016]    wherein the third member is oversized relative to the minimum space between the first and second clamping legs whereby forcing the third member through the minimum space urges portions of the clamping legs against walls of the cover member to thereby assist in retaining the cover member fast with the base member. 
         [0017]    In a first embodiment of the invention the buttressing walls comprise sidewalls that extend over opposed sides of the base member. In this embodiment the at least one opening for passage of the slat is formed through the cover member. In this first embodiment the snap fit formations comprise inwardly projecting lips formed along the opposed sidewalls and corresponding rebates formed along outer edges of the base wall. 
         [0018]    In a second embodiment of the invention the base wall further includes first and second sidewalls extending from opposed sides of the base walls with the first and second clamping legs being located between the first and second sidewalls. 
         [0019]    Preferably, in the second embodiment remote ends of the first and second sidewalls are snap fitted to opposed sides of the cover. 
         [0020]    It is preferred that in the second embodiment the buttressing walls and the clamping legs have portions that snap-fit together. For example, the clamping legs may be formed with outwardly disposed first grooves that receive corresponding inwardly projecting first lips of the buttressing walls. 
         [0021]    Preferably the first and second clamping legs terminate in respective tapering portions to assist in guiding the third member there between in use. It is also preferable that the first and second clamping legs be formed with second outwardly disposed grooves that engage with corresponding inwardly projecting second lips of the buttressing walls during clamping of the third member. 
         [0022]    In a third embodiment of the present invention first and second lateral wings extend from distal ends of the first and second sidewalls wherein outer edges of the lateral wings are formed with snap fit formations for receiving a balustrade or other cover. The snap fit formations may include a slot having a side formed as an undercut adjacent a tapering ridge whereby the tapering ridge assists in installing an edge of a balustrade into the slot. 
         [0023]    A post arrangement according to an embodiment of the invention, such as that illustrated in  FIGS. 1 and 2  provides several advantages. Firstly, fitment of the panel to a surround is straightforward in that the base member can be easily screwed or otherwise fastened to the surround prior to attachment of the cover member. Secondly, if a slat is damaged and needs to be replaced, the slat and the cover member can be removed while keeping the base member fixed to the surround. That is, it is no longer necessary to remove the entire post to replace a slat. Thirdly, the openings in the cover member (through which the slats pass) no longer need to be routed or otherwise cut through the cover member using expensive machinery. Because the cover member can be substantially U-shaped or C shaped, a simple punch die can be used to form the openings as both sides of the interconnecting wall are now available for the punching operation. Fourthly, by having the clamping legs forming part of (and typically essentially the entire) side wall of the base member, the “hinge area” is much more robust and there is much less likelihood of fatigue and loss of memory. 
         [0024]    Another advantage of the post according to the present invention is that the base member profile can remain the same for slats of different sizes as all that is required is to provide a different cover member with larger or smaller openings (depending on the size of the slats) and which can be snap fitted to the base member. 
         [0025]    Another advantage is that should there be damage to a clamping leg on the base member; the base member can be replaced without requiring replacement of the entire post. 
         [0026]    In another form, the invention resides in a panel comprising at least one post as described above and at least one slat. 
         [0027]    Throughout the specification, the term “panel” will be used to include but not limited to fencing, gates, awnings, window screens, other types of screens, and fixed louvres. 
         [0028]    The term “post” is meant to be interpreted broadly and to include any type of elongate member to which slats or other members can be fitted. The post may be positioned substantially vertically in use, substantially horizontally in use, or possibly at some other angle. The post may be an end post or an intermediate post. 
         [0029]    The post will typically be formed of aluminum and typically from extruded aluminum as this is a common process. However, there may be circumstances where the post is made from materials other than aluminum such as plastics, or from metals other than aluminum, or from laminate materials and the like. If the post is formed from aluminum, the aluminum may be treated for corrosion resistance and the treatment may include anodizing, powder coating, painting and the like. 
         [0030]    The length of the post can vary, typically, depending on the size of the panel to be formed. It is envisaged that the usual length of the post will be between 40 cm (for instance a screen for a small toilet window) up to 2 or 3 m for a larger fence screen. The post may comprise a single post member or may comprise a number of post members connected together by any suitable means. For instance, the post members may be connected using an internal sleeve type fixing, or an external socket type arrangement or using fasteners or welding and the like. If post members are to be connected together, it is highly preferred that this is done in an aesthetically pleasing manner. 
         [0031]    The post will typically be formed from two parts being the base member and the cover member and that can be snap fitted together. 
         [0032]    The base member may be of any suitable length and width and have any suitable thickness depending on the size and shape of the panel to be formed and whether the panel will subject to high wind loading, twisting or other types of forces on the panel. It is envisaged that the base member will have a width and a depth of between 10 mm up to 200 mm. Similarly, it is envisaged that the wall thickness of the base member (depending on material) will be between 1-10 mm. 
         [0033]    The base member will typically be substantially U-shaped comprising a base wall and a pair of upstanding sidewalls. However, there may be circumstances where the channel member may have a curved base wall. There may be circumstances where the base wall may have other configurations, inter alia, for aesthetic reasons, for functional reasons (for instance the post may be used as balustrading) or for fitment reasons (for instance the support may include a recess or rebate in which the base wall fits). 
         [0034]    The sidewalls preferably have a width which approximates the width of the sidewalls of the cover member such that when the base member is attached to the cover member, the sidewalls extend substantially through the cover member towards the base wall of the cover member. This can improve the clamping action to the slats since the side walls of the cover member may act as buttresses or buttress walls and assist in holding the clamping legs of the base member firmly against the slat. 
         [0035]    The clamping leg may comprise a turned in portion of each side wall. It is preferred that substantially the entire side wall assists in the clamping action against the slat and this will be described in greater detail below. There may be circumstances where each side wall contains more than one turned in portion and may be circumstances where only one side wall contains a turned in portion. 
         [0036]    The end wall of the cover member is formed with a plurality of openings through which the end of slats can pass. Because the cover member can comprise a simple U-shaped type profile, it is possible to form the openings using a simple punch die which greatly improves manufacturing speed and reduces manufacturing cost. The number of openings will depend on the number of slats that are to be accommodated. The shape of the openings will depend on the shape of the slats that are to be accommodated. It is envisaged that the openings will be substantially identical or, for decorative or strength purposes, some openings may be larger or smaller than others to provide a panel having larger and smaller slats. 
         [0037]    Some form of snap fitting means is provided on the base member and/or the cover member to enable these parts to be snap fitted together. In one form, the snap fitting means may comprise small turned in lips on the cover member which engage into small rebates or recesses on the base member. Alternatively, the base member may be formed with small turned in lips and the cover member may be formed with small rebates or recesses. 
         [0038]    The slats will typically comprise extruded aluminum members. Such members are well-known. These members are usually substantially hollow. It is however possible for the members to be filled with foam or other material to improve strength properties, insulation properties, sound deadening properties and the like. The slats may also comprise materials other than aluminum. For instance, the slats may be formed from solid or hollow plastics. It is envisaged that the slats may also comprise wood or wood laminate slats. The slats may comprise a number of smaller parts attached together to form the slat. The slat may be formed from laminated material or other built-up materials. It is envisaged that the slats may also be formed from a grid like or mesh like material to provide security and ventilation. The slats may be formed from substantially clear material. It is also envisaged that the slats may have end brackets or end pieces adapted to pass into the openings on the post. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0039]    Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: 
           [0040]      FIG. 1 . Illustrates an exploded view of a panel containing slats and a post according to an embodiment of the invention. 
           [0041]      FIG. 2 . Illustrates a section view of a post according to the embodiment of the invention and an attached slat. 
           [0042]      FIG. 3 . Is a top view of a fence comprising a slat and posts according to a further embodiment of the present invention. 
           [0043]      FIG. 4  Is an exploded isometric view of the fence of  FIG. 3 . 
           [0044]      FIG. 5  Is an exploded isometric view of a fence according to a further embodiment of the present invention. 
           [0045]      FIG. 6  Is an isometric view of a portion of a post of the fence of  FIG. 5  according an embodiment of the present invention. 
           [0046]      FIG. 7  Is an end view of the post of  FIG. 6  illustrating the engagement of the two portions of the post. 
           [0047]      FIG. 8  Is an end view of a narrower version of the post of  FIG. 7  showing the two parts prior to their engagement together. 
           [0048]      FIG. 9  Is an end view of the post of  FIG. 8  subsequent to the engagement of the two parts of the post. 
           [0049]      FIG. 10  Is an isometric, exploded view of a post and rail fence according to a further embodiment of the present invention. 
           [0050]      FIG. 11  Is a top plan view of the post of  FIG. 10 . 
           [0051]      FIG. 12  depicts a balustrade assembly according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0052]    Referring now to  FIGS. 1 and 2 , these illustrate an embodiment of the invention which comprises a specially designed two-part post which overcomes the number of disadvantages with existing fit together panels. The various posts that will be described according to embodiments of the invention make use of “snap fit” joints. A snap fit or “snap lock” or sometimes as it is called a “press fit” joint is a joint which is self-locking and which requires no additional fasteners such as screws or rivets to hold the joint together. The mating parts of a snap-fit joint exert a cam action on each other, flexing until one part slips past a raised lip on the other part. Once past this lip, the flexed parts snap back to their normal shape and the lip prevents them from separating. Once snap fitted together the joint cannot usually be unintentionally dissembled. 
         [0053]    The post  15  comprises a base member  17  and a cover member  16 . In the embodiment, each of these is formed from extruded aluminum. Cover member  16  is substantially C shaped and comprises a base wall  18  and a pair of sidewalls  19  this being best illustrated in  FIG. 2 . The outer edge of each side wall  19  contains a small turned in lip  20  which forms part of the snap fitting means and which will be described in greater detail below. 
         [0054]    Base wall  18  (see  FIG. 3 ) is formed with a number of punched out openings  21  to accommodate edges of slats  22 . 
         [0055]    Base member  17  is similar to cover member  16  in that it is also substantially U-shaped or C shaped and comprises a bottom wall  24  (see  FIG. 4 ) and opposed sidewalls  25 . Base member  17  is sized to fit within cover member  16 , or put differently, cover member  16  can snap fit over the sidewalls  25  of base member  17 . The peripheral edge of bottom wall  24  contains a small rebate  26  which forms the other parts of the snap fitting means such that the cover member  16  can be snapped over base member  17  by the turned in lips  20  on cover member  16  engaging against the rebate  26  on the peripheral edge on bottom wall  24  of base member  17 . It can be seen that cover member  16  can substantially conceal base member  17  to provide an aesthetically pleasing effect. 
         [0056]    The sidewalls  25  of each base member  17  are shaped to converge towards an apex  27  and thence to diverge outwardly and away from each other. The apex  27  comprises a turned in portion which forms a clamping leg on each side wall  25 . The opposed turned in portions function to clamp a slat therebetween. The sidewalls  25  diverge outwardly from the turned in portion  27  to the outermost edge  28  of each side wall. The diverging portions of the sidewalls  25  facilitate entry of a slat  22 . 
         [0057]    A slat  22  can be pushed through one of the openings  21  in cover member  16 . As the slat passes through the opening  21  will be guided by the diverging portion to push against the turned in portion  27  and to push these portions outwardly as the thickness of the slat “T” is greater than the distance “X” between the turned in portions. This causes the slat to be securely clamped between the sidewalls  25  which comprise clamping legs. 
         [0058]    The entire side wall  25  can form the clamping leg with the turned in portion forming the contact area and the remainder of the side wall providing the required bias or clamping force. As the side wall is turned in from the bottom wall  24 , this provides a good reliable and long-lasting “memory” to each clamping leg. 
         [0059]    The slat is usually pushed through the opening  21  such that the edge of the slat sits against or closely spaced from the bottom wall  24  such that each turned in portion  27  can properly clamp against a respective side wall of slat  22  and at a position spaced some distance from the edge of the slat. 
         [0060]    A panel can be easily snap fitted together by providing a pair of posts  15  and inserting the slats into the openings on each post  15  with the slats being clamped in place between an adjacent pair of clamping legs  27 . The base member  17  can be screwed or otherwise attached to a supporting post (if required) and the cover member  16  can then be snapped fitted to the base member to provide an aesthetically pleasing finish and completely concealing all the fixing screws to the supporting post. A damaged slat  22  can be removed by uncapping cover member  16  and it is not necessary to remove base member  17 . Different types of cover member  16  can be attached to a common base member  17  which can reduce assembly cost. The openings  21  in cover member  16  can be quickly and inexpensively formed using a punch process. The large clamping legs (suitably comprising each entire side wall of base member  17 ) provide a good clamping force and will function reliably over a long period. 
         [0061]    Referring now to  FIGS. 3 and 4  there are presented top plan and isometric exploded views of a fence  30  according to a further embodiment of the present invention. As may be seen in  FIG. 3 , the post  32  that is used in this embodiment includes a cover  34  that has a cover member  18  and side members  19  as for the embodiment of  FIG. 2 . However the post  32  has a wing  36  that extends laterally from one of the side walls  19  and which is used to fasten the post  32  to a support structure  38  by means of fastener  40 . The post  32  also includes internal wings  42  which are integrally formed on the interior of the sidewalls  19  and which assist the clamping legs  25  to clamp the 3rd member, in the form of slat  22 , therebetween. 
         [0062]      FIGS. 5 and 6  respectively depict a further fence panel assembly  46  and a further post  44  that is used in that fence panel assembly, according to another embodiment of the present invention. 
         [0063]      FIG. 7  is an end view of the post  44  of  FIG. 6 . It can be seen from  FIG. 7  that the post  44  comprises a base  48  that is snap fitted to cover member  50  by snap fit joints  52   a,  . . . ,  52   d.    
         [0064]    The base  48  includes a base wall  54  from which first and second clamping legs  58   a,    58   b  extend. It further includes first and second sidewalls  60   a,    60   b  which extend from opposed sides of the base wall  54  with the first and second clamping legs  58   a,    58   b  being located between the first and second sidewalls  60   a,    60   b.    
         [0065]    It will be observed that remote ends of the first and second sidewalls  60   a,    60   b  are snap fitted to opposed sides of the cover  50  by snap fit joints  52   a,    52   d.    
         [0066]    The cover  50  includes an end wall  62  from which buttressing walls  64   a  and  64   b  project. The buttressing walls  64   a,    64   b  and the clamping legs  58   a  and  58   b  are joined by snap fit joints  52   b  and  52   c.  The snap fit joints  52   b  and  52   c  are due to the clamping legs  58   a,    58   b  being formed with outwardly disposed first grooves  66   a,    66   b,  that receive corresponding inwardly projecting first lips  68   a,    68   b  of the buttressing walls  64   a,    64   b.    
         [0067]    The first and second clamping legs  58   a,    58   b  terminate remotely in respective tapered heads  70   a,    70   b  to assist in guiding a third member to be clamped there between in use. The third member, e.g a slat  22 , enters through an opening  72  (visible in  FIG. 6 ) formed through the cover  50 . The first and second clamping legs  58   a  and  58   b  are also formed with second outwardly disposed grooves  74   a,    74   b  that engage with corresponding inwardly projecting second lips  76   a,    76   b  of the buttressing walls  64   a,    64   b  during clamping of the third member. 
         [0068]    As the third member, e.g. slat  22 , is inserted through opening  72  its end proceeds between tapered heads  70   a  and  70   b  thereby abutting the heads and causing the heads to swing outwardly until they are stopped by the abutment of the second lips  76   a  and  76   b  with the second grooves  74   a,    74   b.  It will therefore be understood that the normal, unclamping, distance between the tapered heads is a little less than the width of the slat that is to be clamped therebetween. 
         [0069]      FIGS. 8 and 9  show an exploded and assembled post  78  in use clamping a third member in the form of a post  22 . Post  78  is entirely similar to post  48  of  FIG. 7  save that it is a little narrower. 
         [0070]      FIG. 10  depicts a fence assembly  80  according to a further embodiment of the present invention. The fence assembly  80  makes use of a post  82  according to a further embodiment of the invention which is illustrated in cross section in  FIG. 11  receiving an end of a 3rd member in the form of slat  22 . It will be observed that the base member  84  is formed with a base wall  88  from which sidewalls  86  extend both forwardly, portions  86   a,  and rearwardly, portions  86   b.  In this embodiment a second cover member  88  spans between the rearward portions  86   b  of the sidewall  86  and is fitted thereto by snap-joints  90 . Fasteners such as screw  92  may be provided to secure for example a lockbox in the fence. In that case the second cover member  88  covers fastener  92 . A first cover member  94  with buttressing walls  96  is also provided. The buttressing walls  96  have lips  98  that engage the outside of tapered heads  100  of clamping legs  102 . 
         [0071]    Referring now to  FIG. 12 , there is illustrated a balustrade assembly  104  according to a further embodiment of the present invention. Balustrade assembly  104  makes use of a horizontally disposed post  106  according to a further embodiment of the present invention. The post  106  includes a base member  108  and a cover member  110 . It will be observed that first and second lateral wings  112   a,    112   b  extend from distal ends of the first and second sidewalls  114   a,    114   b  of base member  108 . Outer edges of the lateral wings are formed with snap fit formations  116   a,    116   b  for receiving an edge of a balustrade  118  or other cover. The snap fit formations  116   a,    116   b  include a slot  120   a,    120   b  formed as an undercut adjacent tapering ridges  122   a,    122   b  which assist in installing edges of the balustrade  118  into the slot. The base member  108  locates over the cover member  110 . 
         [0072]    The base member  108  is formed with clamping legs  132   a,    132   b  which extend from base wall  133  and which clamp a member  130  therebetween in use. Buttressing walls  128   a,    128   b  extend from the interior of the end wall  126  of the cover member  110  past and adjacent to the clamping legs  132   a,    132   b.  The buttressing walls  128   a,    128   b  are formed with remote, inwardly projecting lips  134   a,    134   b  which engage with corresponding grooves  136   a,    136   b  formed along the outsides of the clamping legs. Accordingly, as the member  130  is inserted through an opening in cover member  110  it passes between the clamping legs  132   a  and  132   b  and pushes them outwardly so that the grooves  136   a,    136   b  engage the lips  134   a  and  1   34   b  thereby assisting in fastening the base member  108  to the cover member  110  and firmly clamping the member  130 . The lateral wings  112   a,    112   b  are fastened to a structure such as a railing assembly  138 , of which member  130  is a constituent by means of screws or other fasteners  140   a,    140   b,  which extend through lateral wings  112   a,    112   b.    
         [0073]    The above description identifies at least one specific, substantial and credible use for the invention. For example, preferred embodiments of the invention provide aluminum extrusion posts which are readily attached to each other and which are capable of clamping members such as fence slats. 
         [0074]    In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art. 
         [0075]    Throughout the specification and claims (if present), unless the context requires otherwise, the term “substantially” or “about” will be understood to not be limited to the value for the range qualified by the terms. 
         [0076]    Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention. 
         [0077]    Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. 
         [0078]    Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.