RACKABLE PANEL ASSEMBLY AND METHODS OF ASSEMBLY THEREOF

Abstract

A rackable panel assembly is provided. In one form, the assembly includes a plurality of vertical members each having a pair of opposed ends and at least one sidewall extending longitudinally therebetween and having a rail engagement opening defined therein; and at least one rail having a pair of opposed ends and at least sidewall extending longitudinally therebetween, said at least one sidewall defining sets of opposed openings spaced along a longitudinal length of the at least one rail, each set of opposed openings adapted to receive a vertical member of said plurality of vertical members therethrough and at least partially cover the rail engagement opening of said vertical member. The assembly further includes at least one coupling member adapted to be at least partially received in each said vertical member for pivotally coupling the vertical member to the at least one rail, said coupling member having at least one protruding portion and a biasing member for biasing the at least one protruding portion outwardly from the rail engagement opening in a direction perpendicular to the length of the at least one rail to pivotally couple the vertical member to the at least one rail.

Claims

1. A rackable panel assembly comprising: a plurality of vertical members each having a pair of opposed ends and at least one sidewall extending longitudinally therebetween and having a rail engagement opening defined therein; at least one rail having a pair of opposed ends and at least one sidewall extending longitudinally therebetween, said at least one sidewall defining sets of opposed openings spaced along a longitudinal length of the at least one rail, each set of opposed openings adapted to receive a vertical member of said plurality of vertical members therethrough and at least partially overlap or cover the rail engagement opening of said vertical member; and at least one coupling member adapted to be at least partially received in each said vertical member for pivotally coupling the vertical member to the at least one rail, said coupling member having at least one protrusion and a biasing member for biasing the at least one protrusion outwardly from the rail engagement opening in a direction perpendicular to the length of the at least one rail to pivotally couple the vertical member to the at least one rail, wherein at least one opening of each set of opposed openings is elongate so that said vertical member received therethrough is pivotable relative to the at least one rail.

2. The assembly of claim 1, wherein the vertical members are pivotable relative to the at least one rail so that the rail can be racked to extend substantially parallel to a slope or gradient of an underlying support surface and the vertical members remain substantially vertical.

3. The assembly of claim 1, wherein the rail engagement opening of each vertical member is adapted to be at least partially covered by the rail when the vertical member is coupled to the rail.

4. The assembly of claim 1, wherein the at least one coupling is configured to pivotally couple each said vertical member to the at least one rail.

5. The assembly of claim 1, wherein the at least one protrusion of the at least one coupling member includes an upper wall and an opposed lower wall interconnected by a pair of opposed end walls and a pair of opposed sidewalls.

6. The assembly of claim 5, wherein upper wall includes a concave curve extending longitudinally between the opposed end walls.

7. The assembly of claim 6, wherein the upper wall has a substantially V-shaped profile when viewed along a direction perpendicular to one of the opposed sidewalls.

8. The assembly of claim 5, wherein the opposed end walls of the protrusion are configured to at least partially abut against an inner surface of an upper wall and opposed lower wall of the rail to at least partially prevent axial movement of the vertical member relative to the rail when pivotally coupled together.

9. The assembly of claim 8, wherein the end walls of the protrusion include bevelled or rounded upper portions to at least partially facilitate the rail in sliding over the rail engagement opening of the vertical member and the protrusion of the coupling member at least partially protruding therethrough.

10. The assembly of claim 5, wherein the biasing member of the at least one coupling member includes at least one leg extending away from the at least one protrusion and adapted to abut against an inner surface of the vertical member and bias the at least one protrusion outwardly from the rail engagement opening.

11. The assembly of claim 10, wherein the at least one leg is substantially arcuate in shape curving outwardly and away from the lower wall of the protrusion.

12. The assembly of claim 5, wherein the biasing member includes a pair of arcuately shaped opposed legs curving outwards and away from a location mid-way along the lower wall of the at least one protrusion.

13. The assembly of claim 12, wherein the pair of legs are interconnected by a flexion point adapted to bias the legs outwards and away from one another.

14. The assembly of claim 13, wherein in use the legs of the at least one coupling member are flexed at least partially towards one another and towards the at least one protrusion when being inserted into the vertical member and wherein potential energy stored in flexing of the legs and the flexion point together exert a biasing force for biasing the at least one protrusion outwardly from the rail engagement opening.

15. The assembly of claim 1, wherein the at least one coupling member forms part of a cap for an end of each of said plurality of vertical members for being received in the at least one opening of the at least one rail.

16. The assembly of claim 15, wherein the at least one coupling member includes a pair of protrusion adapted to each respectively protrude from rail engagement openings defined in opposed outwardly facing sidewalls at or near the end of the vertical member, the protrusions and the cap being interconnected by a pair of arcuately shaped legs adapted to function as biasing members for biasing the protrusions outwardly from each respective rail engagement opening.

17. The assembly of claim 15, wherein the at least one coupling member prevents axial movement of each of the plurality of vertical members relative to the at least one rail.

18. A method of assembling a rackable panel, said method comprising: providing a rackable panel assembly in accordance with claim 1; inserting at least one coupling member into each vertical member so that the at least one protruding member is aligned relative to the rail engagement opening; and mounting the vertical members to the at least one rail by individually inserting each vertical member through the opening or openings defined in the rail until the rail covers the rail engagement opening and the at least one protrusion protrudes at least partially outwards from the rail engagement opening in a direction perpendicular to a length of the at least one rail to pivotally couple the vertical member to the at least one rail.

19. The method of claim 18, wherein the at least one coupling member is inserted via an end of the vertical member.

20. The method of claim 18, wherein the at least one coupling member is inserted via the rail engagement opening.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0137] 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:

[0138] FIGS. 1A to 1F show upper perspective views of rackable fence panel assemblies according to embodiments of the present invention, each assembly including a plurality of pickets pivotally coupled to two or more rails;

[0139] FIG. 2 is a sectional end view of a picket pivotally coupled to a rail with a coupling member according to an embodiment of the present invention, and when looking down the end of the rail;

[0140] FIG. 3 is an upper perspective view of the picket pivotally coupled to the rail as shown in FIG. 2;

[0141] FIG. 4 is a front view of the picket pivotally coupled to the rail as shown in FIGS. 2 and 3;

[0142] FIG. 5 is another sectional end view of the picket pivotally coupled to the rail as shown in FIGS. 2 to 4 when looking down the end of the picket;

[0143] FIG. 6 is a perspective view of a coupling member being fitted to a picket;

[0144] FIG. 7 is an upper perspective view of another coupling member according to an embodiment of the present invention;

[0145] FIG. 8 is a sectional end view of a picket pivotally coupled to a rail with the coupling member as shown in FIG. 7;

[0146] FIG. 9 is an upper perspective view of the picket pivotally coupled to the rail as shown in FIG. 8;

[0147] FIG. 10 is an upper perspective view of a picket pivotally coupled to a rail in accordance with an embodiment of the present invention; and

[0148] FIG. 11 is a sectional end view of the picket pivotally coupled to the rail as shown in FIG. 10.

DETAILED DESCRIPTION

[0149] FIGS. 1A to 1F and 2 to 11 show a rackable fence panel assembly (100) and parts thereof according to various embodiments of the present invention.

[0150] Referring to FIGS. 1A to 1F, each of the embodiments of rackable fence assemblies (100) shown comprises a plurality of pickets (110; i.e., vertical members) and two or more rails (120) pivotally coupled together. The pickets (110) and rails (120) are pivotally coupled together such that the rails (120) are able to extend substantially parallel with a slope or gradient of an underlying support surface between adjacently positioned fence posts (not shown), while the pickets (110) remain generally upright.

[0151] Each of the plurality of pickets (110) includes a pair of opposed ends (112) and four walls extending longitudinally therebetween. The four walls include a pair opposed sidewalls (114) and a pair of opposed outwardly facing walls (116).

[0152] Each rail (120) has a pair of opposed ends (122) and four walls extending longitudinally therebetween. The four walls include an upper wall (124), an opposed lower wall (126) and opposed sidewalls (128). The opposed ends (122) are pivotally connectable to adjacently positioned fence posts (not shown) so that the rails (120) can be angled relative to the fence post to extend substantially parallel with the slope or gradient of an underlying support surface.

[0153] Each rail (120) further includes openings or sets of opposed openings (130) defined in the upper and/or lower walls (124, 126) and spaced along a longitudinal length of the rail (120). Each opening (130) or set of openings (130) is adapted to receive a picket (110) therein or therethrough.

[0154] Each picket (110) is pivotally coupled to a rail (120) with a coupling member (150; not visible) that enables the rails (120) to pivot relative to a horizontal plane between 0° and about ±35° while the pickets (110) remain generally vertical. The coupling member (150; not visible) will be described in detail with reference to FIGS. 2 to 11 later.

[0155] The pickets (110) and rails (120) are formed from metal and are of tubular construction.

[0156] Referring to FIG. 1A, in this embodiment the pickets (110) extend through both rails (120) such that the ends (112) of the pickets (110) protrude past the rails (120) and define an upper and lower end of the assembly (100).

[0157] The rails (120) includes sets of opposed openings (130) spaced along the length of each rail (120) for receiving a picket (110) therethrough. The openings (130) are formed in the upper and lower walls (124, 126) of each rail (120).

[0158] The openings (130) defined in the lower wall (126) of each rail (120) are elongate so that pickets (110) received therethrough are able to be pivoted relative to the rails (120). The openings (130) are elongate in a dimension extending substantially parallel with a longitudinal axis of the rail (120).

[0159] As shown, the upper ends (112) of the pickets (110) are crimped and trimmed to be pointed.

[0160] FIG. 1B shows another embodiment of the assembly (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIG. 1A will be referenced with the same reference numerals.

[0161] In this embodiment, the assembly (100) again comprises a plurality of pickets (110) pivotally coupled to two rails (120), including a lower rail (120A) defining a lower end of the assembly (100) and a rail (120) extending substantially parallel to the lower rail (120A) near an upper end (112) of the pickets (110).

[0162] The lower rail (120A) comprising openings (130) defined only in the upper wall (124) for receiving the ends (112) of the pickets (110) therethrough. The ends (112) do not extend through the lower rail (120A). The openings (130) defined in the upper wall (124) of the lower rail (120A) are elongate so that the pickets (110) received therein are able to be pivoted relative to the rails (120).

[0163] FIG. 1C shows another embodiment of the assembly (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIGS. 1A and 1B will be referenced with the same reference numerals.

[0164] In this embodiment, the assembly (100) comprises a plurality of pickets (110) pivotally coupled to three rails (120), including a lower rail (120A) defining a lower end of the assembly (100) and a pair of rails (120) extending parallel to one another and the lower rail (120A) near an upper end (112) of the pickets (110).

[0165] FIG. 1D shows another embodiment of the assembly (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIGS. 1A to 1C will be referenced with the same reference numerals.

[0166] In this embodiment, the assembly (100) again comprises a plurality of pickets (110) pivotally coupled to two rails (120), including a lower rail (120A) defining a lower end of the assembly (100) and an upper rail (120B) defining an upper end of the assembly (100).

[0167] The upper rail (120B), like the lower rail (120A), comprising openings (130) defined only in the lower wall (126) for receiving the ends (112) of the pickets (110) therethrough. The ends (112) do not extend through the upper rail (120B). The openings (130) defined in the lower wall (126) of the upper rail (120B) are elongate so that the pickets (110) received therein are able to be pivoted relative to the rails (120A, 120B).

[0168] FIG. 1E shows another embodiment of the assembly (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIGS. 1A to 1D will be referenced with the same reference numerals.

[0169] In this embodiment, the assembly (100) again comprises a plurality of pickets (110) pivotally coupled to four rails (120), including a lower rail (120A) defining a lower end of the assembly (100), an upper rail (120B) defining an upper end of the assembly (100) and a pair of rails (120) extending parallel to the lower and upper rails (120A, 120B).

[0170] FIG. 1F shows another embodiment of the assembly (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIGS. 1A to 1E will be referenced with the same reference numerals.

[0171] In this embodiment, the assembly (100) again comprises a plurality of pickets (110) pivotally coupled to three rails (120), including a lower rail (120A) defining a lower end of the assembly (100), an upper rail (120B) defining an upper end of the assembly (100) and a single rail (120) extending parallel to the upper rail (120B).

[0172] FIGS. 2 to 6 show an embodiment of the coupling member (150) for pivotally coupling a picket (110) to a rail (120) in which the pickets (110) extend through the rail (120), e.g., as shown in FIG. 1A.

[0173] Referring to FIGS. 2 and 3, the coupling member (150) includes at least one protrusion (160) and a biasing member in the form of a pair of legs (170) extending away from the protrusion (160) for biasing the protrusion (160) at least partially outwards from a rail engagement opening (210) defined in one of the outwardly facing walls (116) of each picket (110) for pivotally coupling the picket (110) to the rail (120). The protrusion (160) and legs (170) are of unitary construction.

[0174] As shown, the rail engagement opening (210) is configured to be covered by the rail (120) when the picket (110) is pivotally coupled to the rail (120).

[0175] The rail engagement opening (210) is an elongate opening extending longitudinally in a direction at least partially along a length of the picket (110).

[0176] Referring briefly to FIG. 6, the coupling member (150) is sized and shaped to be at least partially received in the picket (110) via the rail engagement opening (210). In use, the legs (170) are inserted into the rail engagement opening (210) and the coupling member (150) is then aligned such that the protrusion (160) at least partially protrudes outwardly from the rail engagement opening (210).

[0177] Referring back to FIGS. 2 and 3, the protrusion (160) in use protrudes outwardly from the rail engagement opening (210) in a direction perpendicular to a length of the rail (120) towards an inner surface of one of the pair of opposed sidewalls (128) of the rail (120).

[0178] The protrusion (160) has an elongate shape sized and shaped to correspond to the shape and size of the rail engagement opening (210) and at least partially protrude through the rail engagement opening (210).

[0179] The protrusion (160) includes an outer wall (162, i.e., an upper wall) and an opposed inner wall (166, i.e., a lower wall) interconnected by a pair of opposed end walls (165) and a pair of opposed sidewalls (166) extending longitudinally therebetween.

[0180] The protrusion (160) includes bevelled edges (168) between the outer wall (162) and the end walls (165).

[0181] The outer wall (162) is characterised by a concave surface extending longitudinally between the opposed end walls (165). As shown in FIG. 2, the outer wall (162) has a substantially V-shaped profile when viewed along a direction perpendicular to one of the opposed sidewalls (166).

[0182] In use, the opposed end walls (165) of the protrusion (160) at least partially abut against an inner surface of the upper and opposed lower walls (124, 126) of the rail (120) to at prevent axial movement of the picket (110) relative to the rail (120) when pivotally coupled together with the coupling member (150).

[0183] When coupling a picket (110) and rail (120) together, the bevelled edges (168) at least partially facilitate the rail (120) in sliding over the rail engagement opening (210) of the picket (110) and the protrusion (160) of the coupling member (150) at least partially protruding therethrough.

[0184] Specifically, a lip (132) of a leading opening (130) of the set of opposed openings (130) of the rail (120) slides or rides over the bevelled edge (168) and causes the coupling member (150) to temporarily depress against a biasing force of the biasing member. Once the lip (132) has passed over the protrusion (160), the protrusion (160) is again biased outwardly of the rail engagement opening (210) towards an inner surface of a sidewall (128) of the rail (120) to pivotally couple the picket (110) and the rail (120) together.

[0185] Advantageously, the coupling member (150) provides tactile and/or audible feedback to an installer when coupling a picket (110) and rail (120) together. Specifically, feedback is provided as the lip (132) of the leading opening (130) of the set of opposed openings (130) of the rail (120) slides or rides over the concave-shaped outer wall (162) of the protrusion (160). The feedback is characterised by an initial bias as the lip (132) slides down a declining surface of the outer wall (162) into a trough of the concave-shaped outer wall (162) and then a subsequent resistance as the lip (132) slides up an inclining surface of the outer wall (162) and over the bevelled edge (168) between the outer wall (162) and the adjacent end wall (165).

[0186] As indicated, the coupling member (150) includes a biasing member in the form of a pair of legs (170) extending away from the protrusion (160) for biasing the protrusion (160) at least partially outwards from the rail engagement opening (210).

[0187] The pair of legs (170) are substantially arcuate in shape and curve outwards and away from mid-way along the inner wall (164) of the protrusion (160). Each leg (170) includes a foot (172) operatively associated with an outer end of the leg (170). The foot (172) is adapted to abut against an inner surface of the outwardly facing wall (116) of the picket (110) opposite the rail engagement opening (210).

[0188] The pair of legs (170) and the inner wall (164) of the protrusion (160) are interconnected by a flexion point (180) adapted to bias the legs (170) outwards and away from one another.

[0189] Advantageously, the fitting of the coupling member (150) at least partially into the picket (110) flexes the legs (170) at least partially towards one another and at least partially towards the protrusion (160) storing potential energy in the flexed legs (170). Together, the flexed legs (170) and the flexion point (180) together exert a biasing force for biasing the protrusion (160) outwardly from the rail engagement opening (210).

[0190] Referring to FIGS. 4 and 5, at least one foot (172A) of one of the legs (170) further functions as a positioning member for positioning the protrusion (160) of the coupling member (150) relative to the picket (110) and the rail engagement opening (210).

[0191] As shown, the foot (172A) extends longitudinally between a pair of opposed ends (174) and is sized and shaped to centre the protrusion (160) relative to the rail engagement opening (210). Specifically, the foot (172A) extends transversely across the outer end of the leg (170) with each end (174) extending towards a respective sidewall (114) of the picket (110).

[0192] FIGS. 7 to 9 show an embodiment of the coupling member (150) for pivotally coupling a picket (110; shown only in FIGS. 8 and 9) to a rail (120; shown only in FIGS. 8 and 9) in which the end (112; shown only in FIGS. 8 and 9) of the picket (110; shown only in FIGS. 8 and 9) is received in the rail (120; shown only in FIGS. 8 and 9) and not through the rail (120; shown only in FIGS. 8 and 9), such as, e.g., with the lower rail (120A) and the upper rail (120B) as shown in FIGS. 1B to 1F. For convenience, features that are similar or correspond to features of the embodiment shown in FIGS. 2 to 6 will be referenced with the same reference numerals.

[0193] Referring to FIG. 7, in this embodiment the coupling member (150) forms part of a cap (710) for the end (112) of a picket (110).

[0194] The coupling member (150) includes the cap (710), a pair of protrusions (160) and a pair of arcuately shaped legs (170), each adapted to function as a biasing member and interconnect the cap (710) and a respective protrusion (160). The cap (710), protrusions (160) and legs (170) are of unitary construction.

[0195] Referring to FIGS. 8 and 9, the coupling member (150) is adapted to be fitted to a picket (110) via its end (112). The protrusions (160) are adapted to be biased at least partially outwards of opposed rail engagement openings (210) defined in the opposed outwardly facing walls (116) near the end (112) of the picket (110).

[0196] As shown, the rail engagement openings (210) are configured to be covered by the rail (120) when the picket (110) is pivotally coupled to the rail (120).

[0197] The end wall (165) of the protrusion (160) and the cap (710) at least partially abut against the inner surfaces of the upper and lower walls (124, 126) of the rail (120) to at least partially prevent axial movement of the picket (110) relative to the rail (120) when pivotally coupled together with the coupling member (150).

[0198] In use, the fitting of the cap (710) and coupling member (150) includes flexing of the protrusions (160) and legs (170) at least partially towards each other as the cap (710) is fitted at least partially into the end (112) the picket (110) thereby storing potential energy in the flexed legs (170). The stored potential energy is exerted as a biasing force for biasing the protrusions (160) outwardly from the respective rail engagement openings (210).

[0199] Best shown in FIG. 9, the cap (710) includes partially rounded and deformable outer wall (712) to at least partially facilitate pivoting of the picket (110) and rail (120) relative to one another.

[0200] FIGS. 10 and 11 show a closing member (900) configured to be slidingly received in the rail (120) to at least partially cover any gap defined between an opening (130) and the picket (110) received therethrough.

[0201] The closing member (900) is formed from plastic or metal material or materials.

[0202] The closing member (900) is elongate and configured to at least partially extend along a length of the rail (120). Specifically, along a length of either the lower or upper wall (124, 126) of the rail (120), whichever has the elongate openings (130; visible only in FIG. 10) defined therein.

[0203] The closing member (900) includes a base wall (910) having a front edge (912; visible only in FIG. 11), an opposed rear edge (914; not shown) and pair of opposed side edges (916; visible only in FIG. 11) extending longitudinally therebetween. The base wall (910) includes a pair of opposed surfaces extending substantially parallel to one another.

[0204] The closing member (900) includes a plurality of openings (920; visible only in FIG. 10) defined along a length of the closing member (900) in a spaced arrangement. The openings (920; visible only in FIG. 10) correspond to and at least partially align with the elongate openings (130; visible only in FIG. 10) defined in either the upper or lower walls (124, 126) of the rail (120).

[0205] In use, the pickets (110) are at least partially received through the elongate opening (130) in the rail (120) and the openings (920) in the closing member (900). The closing member (900) is then be slid relative to the rail (120) to offset the openings (920, 130; visible only in FIG. 10) and at least partially close any gap defined between an edge of the elongate opening (130; visible only in FIG. 10) and the picket (110) received therethrough.

[0206] As shown, the base wall (910) further includes a pair of opposed sidewalls (930) orthogonally extending from the respective side edges (916) and extending longitudinally between the front edge (912) and the opposed rear edge (914; not shown). The sidewalls (930) advantageously assist in aligning, and/or maintaining, the base wall (910) of the closing member (900) relative to the upper or lower wall (124, 126) of the rail (120).

[0207] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0208] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0209] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical 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 (if any) appropriately interpreted by those skilled in the art.