AU2004233549A1

AU2004233549A1 - A Fence Panel and Method of Construction

Info

Publication number: AU2004233549A1
Application number: AU2004233549A
Authority: AU
Inventors: Milan Barba
Original assignee: POLY PRODUCTS AUST Pty Ltd
Current assignee: POLY PRODUCTS AUST Pty Ltd
Priority date: 2004-12-01
Filing date: 2004-12-01
Publication date: 2006-06-15

Description

0 A FENCE PANEL AND METHOD OF CONSTRUCTION o Field of the Invention.

The present invention relates to fence panels and in particular to a fence o panel and methods for manufacturing a prefabricated fence panel.

Background Art.

A variety of fence panels and methods of construction of fences and fence panels are available at the present time. A good introductory summary of the en basic types of fences and their associated problems is given in United States Patent No. 6,772,998, and is repeated below.

"The majority of house holders and professional fencing contractors are aware of the difficulties and time consuming process of constructing fences. A product that is quick and easy to construct and that is relatively inexpensive would be desirable to such people.

Fences are usually used in an urban environment round the perimeter of a property, as dividers between the front and back yards, and as swimming pool fencing. Gates are typically installed in the front of the property A very popular fence type is a paling fence. The material typically used for this type of fence is either a fencing grade rough sawn hardwood or treated pine. If a presentable and an easily painted finish is required it is desirable to arris all edges of these timbers. A number of specialized tools are necessary to achieve this result. Even with these tools this exercise is a time consuming and laborious job.

Generally fences are painted to improve both aesthetics and durability of the timbers. Usually a minimum of two coats of acrylic paint or an oil based stain is required to provide an acceptable finish. A third coat can be applied for a better finish and protection. Repainting is generally required every six or seven years. Painting again is a laborious and expensive process. If a tradesperson is instructed to paint the fence, the cost of painting often exceeds the cost of the fence.

A problem with using timber for fencing is its lack of durability and stability. Over a short period of time it may warp and split with resultant poor aesthetics. Timber is also susceptible to wet rot and termite damage. Also timber, particularly hardwood is becoming scarce and a socially unacceptable commodity." Fence panels are also manufactured from a variety of materials such as plastics and other materials. One of the most common materials used in the creation 2

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0of aesthetically attractive residential fencing is wood. While fencing made of newly formed wooden components can be especially attractive, it tends to be expensive to procure, install and maintain, and it tends to degrade over time. Attempts to overcome o the problems associated with wood have included making fencing out of metal, such as steel or aluminum, which can be both expensive and heavy when compared to the O fence of the present invention. Like wood, steel needs to be maintained extensively nwhen compared to the instant invention, in order to prevent it from degrading over e time. Other attempts to overcome the problems associated with fencing of the prior art have included forming fencing of extruded plastic. Unfortunately, while such attempts O 10 may have produced an aesthetically pleasing fence, they have failed to produce a fence having the enduring structural qualities of the instant invention.

Fibre reinforced fences are also use and are advertised as being aesthetically pleasing, and also strong and durable relative to both its structural integrity and its surface colour.

A primary purpose of the instant invention, therefore, is to provide a fence that has all the advantages of prior art and which is relatively simple to manufacture easy to assemble once transported on site.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

Summary of the Invention.

The present invention is directed to a fence panel and method of construction, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

In one form, the invention resides in a fence panel including a first sheet member with at least one substantially planar surface, a second sheet member with at least one substantially planar surface and at least one ground engaging leg member wherein the at least one ground engaging leg member is secured between the sheet members with the substantially planar surfaces of the respective sheet members outermost.

In a second form, the invention resides in a method for manufacturing a fence panel including the steps of providing a first sheet member with at least one 3

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0substantially planar surface, locating at least one ground engaging leg member relative to a surface the sheet member opposed to the substantially planar surface, providing a second sheet member with at least one substantially planar surface, securing the second sheet member relative to the first sheet member such that the at least one ground engaging leg member is secured between the first and second sheet members O with the substantially planar surfaces of the respective sheet members outer most.

It The fence panel according to the invention will preferably be manufactured in standard dimensions and one example of these dimensions is S5000mm in length by 2000mm in height. Other dimensions may be used. The various members will typically be secured relative to one another using a strong adhesive or similar.

The fence panel according to the invention will suitably be adapted to be fixed relative to a ground surface during construction of a fence. There will typically be more than one ground bearing leg member and a lower portion of each of these leg members will generally be embedded into the ground.

Each sheet member may preferably be a single layer to which other layers can be applied. Typically, a finished sheet member may have a layered construction with four layers. The first layer may be an enhanced expanded polystyrene insulation board impregnated with an insect repellent compound and fire retardant. This layer may form the base to which the other layers are applied. The second surface of the polystyrene insulation layer is preferably etched and primed ready to accept a reinforced render layer to cover the attachment means. The polystyrene layer is suitably located internally to the fence panel.

The first layer is generally between Icm and 20cm in thickness. The first layer is suitably located opposite the substantially planar surface of the first and second sheet members.

All remaining layers are preferably located adjacent the outer surface of the panel. The second layer is suitably a polymer modified cement render material, reinforced with alkali resistant fibreglass 160g mesh. The third layer is suitably finished render. This render material is preferably a polymer modified cement render, creating an excellent adhesion and strength. The outer layer is typically an acrylic membrane. This could be a 100% acrylic tinted texture finish allowing the outside of the panel to be coloured or textured. Any of the layers may be painted to finish the O 4

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I panel's appearance. The render layer is generally approximately between 2mm and in thickness.

There are two sheet members which are aligned with one another o provided in each finished fence panel of the invention. In order to secure the leg members between the sheet members, a further wafer member may be provided between the upper portions of the sheet members. The wafer member will typically be an enhanced expanded polystyrene insulation board impregnated with an insect repellent compound and fire retardant The wafer member will generally be approximately 400 mm in height, extend along the length of the fence panel and be attached to both sheet members. The wafer member preferably tapers from a thickness of 50 mm at the top to 70mm at approximately the middle of the wafer member to 50mm at the bottom.

A side wafer member may also be provided on each end of the fence panel. Each side wafer member may be approximately 1600mm in height and approximately 100mm wide. Other infill members may be provided to be "sandwiched" between the first and second sheet members.

Each fence panel preferably has a plurality of ground engaging leg members secured between the first and second sheet members.

Typically, the leg members will be spaced over the length of the sheet member by distances calculated relative to the thickness of the sheet members. For example, for a panel 5000 mm in length and having sheet members which are in thickness, the spacing may be approximately 100mm from either end of the fence panel and 2400mm between the centres of the end leg members and a centrally located leg member. As the thickness of the sheet members increases, the centres of the leg members can be spaced further apart, and as the thickness of the sheet members decreases, the centres of the leg members can be more closely spaced.

The leg members are preferably oriented perpendicular to the length of the panel. The leg members will typically be approximately 2200mm in length.

According to a particularly preferred embodiment, each leg member will be manufactured of 70mm x 70mm metal such as hardened or semi-hardened steel. The leg members may be manufactured of alternative materials such as plastic or similar depending upon preference. There will typically be approximately 600mm of each leg member extending below the sheet members to allow placement in the ground.

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There may be a planar plate member attached to the upper extremity of the leg members prior to locating the leg members within the fence panel to support the fence panel. By doing so, the weight of the panel can be spread over the planar o member instead of being imposed at point sources at the upper extremity of each leg member. A further planar plate member may be provided at a level approximately at Sthe bottom of the sheet members to further support the weight of the panel.

I More than one fence panel according to the invention will generally be n used in construction of a fence and once fitted in place, the only further work required may be sealing of the edges of the fence panels to each other or to the surrounding surfaces if required.

When panels according to the invention are used, a decrease in the amount of time spent in the construction may be realised as the finished fence panels may be transported on site and simply secured in the ground. No further sealing or finishing of the fence is typically required.

Brief Description of the Drawings.

An embodiment of the invention will be described with reference to the following drawings, in which: Figure 1 is a side elevation view of a panel according to a preferred embodiment of the invention, with representative dimensions.

Figure 2 is an elevation view of a first side of a fence panel according to the present invention with representative dimensions.

Figure 3 is a sectional elevation view of the panel illustrated in Figure 2.

Detailed Description of the Preferred Embodiment.

According to a preferred aspect of the present invention, a building panel 10 and system is provided.

As illustrated in Figures 1 and 3 in particular, the fence panel 10 of the preferred embodiment includes a first sheet member 11 with an outer substantially planar surface, a second sheet member 12 with an outer substantially planar surface and three ground engaging leg members 13. The ground engaging leg members 13 are secured between the sheet members 11, 12 with the substantially planar surfaces of the respective sheet members outermost.

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The fence panel 10 according to the invention is manufactured in standard dimensions and one example of these dimensions is 5000mm in length by 2000mm in height.

Each finished sheet member 11, 12 has a layered construction with four layers. The first layer may is an enhanced expanded polystyrene insulation board 14 Oimpregnated with an insect repellent compound and fire retardant. This layer is the if base to which the other layers are applied. The first layer 14 is generally between Icm en and 20cm in thickness.

All remaining layers are preferably located adjacent the outer surface of 0 O 10 the panel 10. The second layer is suitably a polymer modified cement render material, reinforced with alkali resistant fibreglass 160g mesh. The third layer 14 is a finished render layer. This render material is preferably a polymer modified cement render, creating an excellent adhesion and strength. The outer layer is typically an acrylic membrane. This could be a 100% acrylic tinted texture finish allowing the outside of the panel to be coloured or textured. Any of the layers can be painted to finish the panel's appearance. The render layer 15 is approximately between 2mm and 5cm in thickness.

There are two sheet members 11, 12 which are aligned with one another provided in each finished fence panel 10 of the invention. In order to secure the leg members 13 between the sheet members 11, 12 a wafer member 16 is provided between the upper portions of the sheet members 11, 12. The wafer member 16 is an enhanced expanded polystyrene insulation board. The wafer member 16 is approximately 400 mm in height, extends along the length of the fence panel 10 and is attached to both sheet members 11, 12. The wafer member 16 tapers from a thickness of 50 mm at the top to 70mm at approximately the middle of the wafer member to at the bottom.

A side wafer member 17 is also be provided on each end of the fence panel 10. Each side wafer member 17 is approximately 1600mm in height and approximately 100mm wide.

Typically, the leg members 13 are spaced over the length of the fence panel by distances calculated relative to the thickness of the sheet members. For example, for a panel 5000 mm in length and having sheet members which are in thickness, the spacing may be approximately 100mm from either end of the fence panel and 2400mm between the centres of the end leg members 13 and a centrally located leg member 13 as illustrated in Figure 3.

The leg members 13 are oriented perpendicular to the length of the o panel. The leg members are approximately 2200mm in length. According to a particularly preferred embodiment, each leg member will be manufactured of 70mm x 070mm metal such as hardened or semi-hardened steel. There is a length of f approximately 600mm of each leg member 13 extending below the sheet members 11, n 12 to allow placement in the ground.

There is a planar top plate member 18 attached to the upper extremity O 10 of the leg members 13 prior to locating the leg members 13 within the fence panel to support the fence panel 10. A further planar bottom plate member 19 is provided at the bottom of the sheet members 11, 12 to further support the weight of the panel.

In use, the fence panels 10 are manufactured by laying a first sheet member 11 on the substantially planar surface. The leg members and associated top and bottom plates are then located on the sheet member. Infill members are then fastened to the sheet member around the leg members including the wafer member 16 and side wafer members 17 to the first sheet member 11. The adhesive is then applied to exposed surfaces of the wafer members 18, 19. The second sheet member 12 is then aligned and secured using the adhesive. This forms a substantially solid fence panel having three layers, the first, the infill and the second layers. The panel 10 can then be transported once the adhesive is cured and the only construction required on site is the securing of the leg members 13 in the ground.

In the present specification and claims, 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.

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.

In compliance with the statute, the invention has been described in 8 0 0 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 Ssince the means herein described comprises preferred forms of putting the invention o 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, Cci c

Claims

1. A fence panel including a first sheet member with at least one substantially planar surface, a second sheet member with at least one substantially planar osurface and at least one ground engaging leg member wherein the at least one ground engaging leg member is secured between the sheet members with the substantially planar surfaces of the respective sheet members outermost. n

2. A fence panel according to claim 1 wherein each sheet member has a layered n construction.

3. A fence panel according to claim 1 or claim 2 wherein each sheet member o 10 includes an expanded polystyrene layer.

4. A fence panel according to any one of the preceding claims wherein one surface of each sheet member is etched and primed to accept a render layer.

A fence panel according to any one of the preceding claims wherein each sheet member is a single layer to which other layers can be applied.

6. A fence panel according to any one of claims 4 to 6 wherein applied layers are located adjacent an outer surface of the fence panel.

7. A fence panel according to claim 7 wherein a second layer of polymer modified cement render material, reinforced with fibreglass mesh is applied.

8. A fence panel according to claim 8 wherein a third layer of finished render is applied.

9. A fence panel according to claim 9 wherein the third layer is a polymer modified cement render material.

A fence panel according to either claim 9 or 10 wherein an outer layer of acrylic membrane is applied.

11. A fence panel according to any one of the preceding claims further including at least one infill wafer member provided between the first and second members to form a substantially solid fence panel.

12. A fence panel according to claim 11 wherein the wafer member is an enhanced expanded polystyrene insulation board.

13. A fence panel according to claim 12 wherein the wafer member tapers from a thickness of 50 mm at the top to 70mm at approximately the middle of the wafer member to 50mm at the bottom.

14. A fence panel according to any one of the preceding claims further including a O O 0side wafer member provided on each end of the fence panel.

A fence panel according to any one of the preceding claims wherein a plurality of leg members are provided and a planar plate member is attached to an upper oextremity of the leg members prior to locating the leg members within the fence panel to support the fence panel.

16. A fence panel according to any one of claims 1 to 165 wherein a plurality of leg members are provided and a planar plate member is provided at a bottom n of the sheet members to support the weight of the panel and close the bottom of the fence panel.

17. A method for manufacturing a fence panel including the steps of providing a first sheet member with at least one substantially planar surface, locating at least one ground engaging leg member relative to a surface the sheet member opposed to the substantially planar surface, providing a second sheet member with at least one substantially planar surface, securing the second sheet member relative to the first sheet member such that the at least one ground engaging leg member is secured between the first and second sheet members with the substantially planar surfaces of the respective sheet members outer most.

18. A method according to claim 17 wherein the panel is manufactured with the at least one leg member attached thereto and the layer of material is applied to finish the panel, prior to transport to a building site, once on site, fixing the at least one leg member into the ground. Dated this 1 s T day of December 2004 Poly Products Aust Pty Ltd By its Patent Attorneys CULLEN CO