BARRIER SYSTEM

Abstract

A barrier system including two or more panel elements positioned adjacent to each other to at least partially define one or more gaps therebetween, and one or more intermediate elements at least partially positioned between the panel elements respectively, to at least partially occupy the gap(s).

Description

FIELD OF THE INVENTION

This invention is related to a barrier system having a number of panel elements and intermediate elements positioned therebetween respectively.

BACKGROUND OF THE INVENTION

In certain structures (e.g., fences), wooden panel elements typically are positioned substantially abutting each other edge-to-edge, in an attempt to form a barrier that provides privacy. For instance, in a typical board fence, boards that are nominally 1 inch by 6 inches (i.e., nominally 2.54 cm×15.24 cm) are positioned to abut each other edge-to-edge. As is well known in the art, the boards are secured to a structure that supports the boards. However, the boards frequently shrink and, to some extent, warp over time, because the wood dries out (i.e., loses moisture) as it ages.

The result is that one or more gaps typically are formed between the boards. As a result, the barrier provides privacy only to a limited extent.

SUMMARY OF INVENTION

For the foregoing reasons, there is a need for a barrier system that overcomes or mitigates one or more of the deficiencies of the prior art.

In its broad aspect, the invention provides a barrier system including two or more panel elements positioned adjacent to each other to at least partially define one or more gaps therebetween, and one or more intermediate elements at least partially positioned between the panel elements, to at least partially occupy the gap(s).

In one of its aspects, the invention additionally provides a barrier system including a structure subassembly, and two or more panel elements positioned adjacent to each other to at least partially define one or more gaps therebetween, the panel elements being secured to the structure subassembly. The barrier system includes one or more intermediate elements at least partially positioned between the panel elements, to at least partially occupy the gap(s), and one or more utility elements secured to the structure subassembly for at least partially supporting the panel elements.

In another aspect, the invention provides a barrier system including two or more panel elements positioned adjacent to each other to at least partially define one or more gaps therebetween and a structure subassembly for supporting the panel elements. Also, the barrier system includes a number of fasteners for securing the panel elements to the structure subassembly and one or more gap elements at least partially positioned between the panel elements, the gap element(s) including one or more gap web portions extending between a first side thereof and an opposed second side thereof, and a first flange connected to the web portions at the first side thereof and positioned substantially transverse to the web portion(s), the first flange being positioned for at least partial engagement with the panel elements, to at least partially locate the web portion(s) in said at least one gap, the gap element(s) being secured to the structure subassembly.

In yet another of its aspects the invention provides an intermediate element for positioning at least partially between at least two panel elements, the intermediate element including one or more web portions extending between a first side thereof and an opposed second side thereof, a first flange connected to the web portion at the first side thereof, a second flange connected to the web portion at the second side thereof, the web portion being at least partially locatable between the panel elements, and each of the first and second flanges being formed to at least partially engage the panel elements when the web portion is at least partially located between the panel elements, to maintain the web portion at least partially between the panel elements.

In another aspect, the invention provides a panel assembly having a number of rails, the rails being positioned substantially parallel to each other, and a number of panel elements secured to the rails, the panel elements being positioned substantially orthogonal to the rails and located substantially edge-to-edge serially, to define gaps therebetween. The panel assembly also includes a number of intermediate elements, each intermediate element being positioned at least partially between a selected pair of the panel elements. In addition, the panel assembly includes one or more panel supports, for supporting the rails.

In yet another of its aspects, the invention provides a kit of parts for a barrier system. The kit includes a structure subassembly for assembly into a structure, having one or more posts and one or more rails securable to the post, to provide the structure. The kit also includes a number of panel elements securable to the structure, and a number of intermediate elements positionable between the panel elements respectively, the intermediate elements being adapted to cover gaps between the panel elements when the panel elements are secured to the structure. In addition, the kit includes a number of fasteners, for securing the rails to the posts, and for securing the panel elements to the rails.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood with reference to the drawings in which:

FIG. 1 is a side view of an embodiment of a barrier system of the invention, with certain elements omitted for clarity of illustration;

FIG. 2 is a side view of a portion of the barrier system of FIG. 1, drawn at a larger scale;

FIG. 3A is a top view of the portion of the barrier system of FIG. 2;

FIG. 3B is a top view of a portion of the barrier system of FIG. 3A, drawn at a larger scale;

FIG. 4 is an isometric view of an embodiment of an intermediate element of the invention included in the barrier system of FIGS. 1-3B, drawn at a smaller scale;

FIG. 5 is an end view of the intermediate element of FIG. 4, drawn at a larger scale;

FIG. 6 is a side view of another embodiment of the barrier system of the invention with certain elements omitted for clarity of illustration, drawn at a smaller scale;

FIG. 7 is a side view of a portion of the barrier system of FIG. 6, drawn at a larger scale;

FIG. 8 is a cross-section of the portion of the barrier system of FIG. 7, drawn at a larger scale;

FIG. 9 is a bottom view of the portion of the barrier system shown in FIG. 7, drawn at a smaller scale;

FIG. 10 is an end view of an embodiment of a utility element of the invention, drawn at a larger scale;

FIG. 11 is a flow chart schematically illustrating an embodiment of a method of the invention;

FIG. 12 is a flow chart schematically illustrating another alternative embodiment of a method of the invention;

FIG. 13A is a cross-section of a portion of another embodiment of the barrier system of the invention;

FIG. 13B is a flow chart schematically illustrating another alternative embodiment of a method of the invention;

FIG. 14A is a side view of a portion of another embodiment of the barrier system of the invention, drawn at a smaller scale;

FIG. 14B is a top view of an alternative embodiment of the barrier system of the invention, drawn at a larger scale;

FIG. 15 is a top view of another alternative embodiment of the barrier system of the invention, drawn at a smaller scale;

FIG. 16A is a top view of another alternative embodiment of the barrier system of the invention, drawn at a larger scale;

FIG. 16B is a top view of a portion of the barrier system of FIG. 16A, drawn at a larger scale;

FIG. 17A is a top view of another alternative embodiment of the barrier system of the invention, drawn at a smaller scale;

FIG. 17B is a top view of a portion of the barrier system of FIG. 17A, drawn at a larger scale;

FIG. 18 is a top view of an embodiment of a panel assembly of the invention, drawn at a smaller scale;

FIG. 19A is a side view of another alternative embodiment of the barrier system of the invention; and

FIG. 19B is an end view of the barrier system of FIG. 19A.

DETAILED DESCRIPTION

In the attached drawings, like reference numerals designate corresponding elements throughout. Reference is first made to FIGS. 1-5 to describe an embodiment of a barrier system of the invention referred to generally by the reference numeral 20. In one embodiment, the barrier system 20 preferably includes two or more panel elements 22 positioned adjacent to each other to at least partially define one or more gaps 24 therebetween (FIG. 3B). It is also preferred that the barrier system 20 includes one or more intermediate elements 26 at least partially positionable between the panel elements 22, to at least partially occupy the gap(s) 24.

As can be seen, for instance, in FIG. 1, the barrier system 20 may include a fence, and the panel elements 22 may be boards in the fence. Those skilled in the art will appreciate that the barrier system 20 may be used as other types of barriers, e.g., a deck railing, or a deck floor. For convenience, the barrier system illustrated in the attached drawings is a fence.

It will be understood that certain features are exaggerated in certain drawings, for clarity of illustration. For instance, in FIG. 3B, the gap 24 shown between two panel elements identified as 22A and 22B for convenience is shown as being relatively large. It will be appreciated by those skilled in the art that, when the barrier system 20 is first constructed, the web portion of the intermediate element may be substantially engaged with the panel elements it is positioned between (i.e., subject to irregularities in the panel elements), and the gaps between the web portion and the panel elements it is positioned between develop and widen over time, as the panel elements lose moisture. Accordingly, the gaps 24 are primarily the result of the panel elements “drying out” (i.e., losing water content) as they age.

An exemplary barrier system 20 is illustrated in FIG. 1. (It will be understood that certain elements are omitted from FIG. 1 for clarity of illustration, as will be described.) Preferably, the barrier system 20 includes a structure subassembly 28 (FIG. 1) for supporting the panel elements 22 and a number of fasteners 29 (FIG. 2), for securing the panel elements 22 to the structure subassembly 28. For instance, the structure subassembly 28 shown in FIG. 1 includes a post 30 and three rails, i.e., top, middle, and bottom rails 32, 34, 36 respectively. (It will be understood that the fasteners 29 are shown securing only one panel element 22, and are otherwise omitted from FIG. 1 for clarity of illustration.) Those skilled in the art would appreciate that, in practice, the locations of the posts, and the number of rails and their locations, can vary significantly, depending on the height of the fence and its design. Accordingly, the structure subassembly 28 illustrated in FIG. 1 is exemplary only.

As will be described, it is preferred that a top surface 38 of the top rail 32 is located substantially flush (i.e., even) with top ends 40 of the panel elements 22, and a bottom surface 42 of the bottom rail 36 is located substantially flush with bottom ends 44 of the panel elements 22. In one embodiment, each of the panel elements 22 preferably is secured to the rails 32, 34, 36 by suitable fasteners 29, e.g., nails (FIG. 2). As will be described, each of the intermediate elements 26 preferably is positioned on a lengthwise side 48 of the panel element 22 before the panel element 22 is secured to the rails 32, 34, 36.

In one embodiment, the intermediate element 26 preferably includes one or more web portions 50 extending between a first side 52 thereof and an opposed second side 54 thereof. Preferably, the intermediate element 26 also includes a first flange 56 connected to the web portion 50 at the first side 52 thereof, and a second flange 58 connected to the web portion 50 at the second side 54 thereof (FIG. 3B). As can be seen in FIGS. 3A, 3B, and 5, it is also preferred that the first and second flanges 56, 58 are positioned substantially transverse to the web portion 50, for at least partial engagement of the first and second flanges 56, 58 with the panel elements 22, to at least partially locate the web portion 50 in the gap(s) 24. Preferably, each of the first and second flanges 56, 58 is formed to at least partially engage the panel elements 22 in a friction fit, to maintain the web portion 50 at least partially in the gap(s) 24.

For clarity of illustration, the two panel elements partially shown in FIG. 3B are identified as 22A and 22B. As can be seen in FIGS. 3B and 5, the first flange 56 preferably includes first and second inner surfaces 60, 62 formed to at least partially engage the respective exterior surfaces 64, 66 of the panel elements 22A, 22B when the web portion 50 is at least partially positioned in the gap(s) 24. Similarly, the second flange 58 preferably includes first and second inner surfaces 68, 70 formed to at least partially engage the respective exterior surfaces 72, 74 of the panel elements 22A, 22B when the web portion 28 is at least partially positioned in the gap(s) 24.

As can be seen in FIG. 5, in one embodiment, each of the first and second flanges 56, 58 includes two flange parts respectively. For convenience, the two flange parts of the first flange 56 are identified in FIG. 5 by reference numerals 57A and 57B, and the two flange parts of the second flange 58 are identified by reference numerals 59A and 59B. Each of the flange parts 57A, 57B, 59A, 59B extends from the web portion 50 to an outer edge of each flange part respectively. The outer edges of the flange parts 57A, 57B are identified in FIG. 5 by reference numerals 76A, 76B respectively. The outer edges of the flange parts 59A, 59B are identified by reference numerals 78A, 78B respectively. Preferably, each of the outer edges is spaced apart from the web portion 50 by a predetermined distance “D”. It is also preferred that each flange part is positioned to define an acute angle (designated a in FIG. 5) between each flange part and the web portion 50 respectively.

Preferably, and as can be seen in FIG. 5, each of the flange parts 57A, 57B, 59A, 59B includes the inner surface 60, 62, 68, 70 respectively, each of which inner surface is at least partially facing toward a selected other one of the flange parts. For instance, and as can be seen in FIG. 5, the inner surfaces 60, 68 are positioned to at least partially face each other. Similarly, the inner surfaces 62, 70 are positioned to at least partially face each other.

In one embodiment, the first and second flanges 56, 58 preferably are at least partially formed to taper inwardly relative to the web portion 50, for at least partial engagement of the first and second flanges 56, 58 with the panel elements 22A, 22B (FIG. 3B). As can be seen in FIG. 3B, in one embodiment, the first and second flanges 56, 58 preferably are formed so that the first and second inner surfaces 60, 62 and the respective exterior surfaces 64, 66 define acute angles therebetween, when the web portion 50 is at least partially positioned in the gap(s) 24. For instance, as can be seen in FIG. 3B, the inner surface 60 and the exterior surface 64 define an angle θ which, in the example illustrated in FIG. 3B, is approximately 3.5°. Similarly, the first and second inner surfaces 68, 70 and the respective exterior surfaces 72, 74 define acute angles therebetween, when the web portion 50 is at least partially positioned in the gap(s) 24. Because of this, only engagement portions of the inner surfaces 60, 62, 68, 70 engage the exterior surfaces of the panel elements. For clarity of illustration, the engagement portions are identified in FIG. 5 by reference numerals 80, 82, 84, and 86. As can be seen in FIG. 3B, each of the engagement portions 80, 82, 84, and 86 occupies a relatively small proportion of the inner surfaces 60, 62, 68, 70. Because of the manner in which the barrier system 20 preferably is assembled (as will be discussed), it is preferred that each of the intermediate elements 26 engages the panel element 22 along one of its lengthwise sides in a friction fit, so that the intermediate element 26 is relatively easily secured to the panel element 22. As will be described, this configuration is preferred because the intermediate element 26 can be manufactured relatively inexpensively with a relatively consistent profile that will consistently slide into position on the panel element 22.

As can be seen in FIG. 5, the first inner surfaces 60, 68 of the first and second flanges 56, 58 respectively at least partially define a first slot 88 therebetween. Similarly, the second inner surfaces 62, 70 of the first and second flanges 56, 58 respectively at least partially define a second slot 90 therebetween.

The intermediate element 26 may be made of any suitable material, preferably a material that is relatively flexible. Those skilled in the art would be aware of suitable materials. It is preferred that the intermediate element 26 is made of any suitable plastic. For instance, it is believed that the following are suitable materials: polycarbonate, polystyrene, ABS (Acrylonitrite Butadiene Styrene), rigid polyvinyl chloride, and nylon. Also, the intermediate element may be made (in whole or in part) of polytetrafluoroethylene (PTFE). Rubber may also be a suitable material.

Depending on the material, the intermediate element 26 may be provided in a variety of colors. Also, the intermediate element may be clear, or translucent, and colored or colorless. The translucent intermediate element has the advantages that it allows some light through, but provides privacy.

A method of securing the panel elements 22 to the structure subassembly 28 of the invention will now be described. Referring to FIG. 1, it will be understood that the panel element 22 (or another element) positioned immediately adjacent to the post 30 is omitted for clarity of illustration. Preferably, a first panel element 22-1 (FIGS. 1, 2, 3A), with a first intermediate element 26-1 secured to a trailing lengthwise side 48A-1 of the panel element 22-1 (FIG. 1), is secured to the structure subassembly 28 (i.e., to the rails 32, 34, 36) by suitable fasteners 29. The trailing lengthwise side 48A-1 is positioned in the first slot 88-1 of the first intermediate element 26-1 in a friction fit.

Next, a trailing lengthwise side 48A-2 of a second panel element 22-2 is positioned in a first slot (not shown in FIG. 3A) of a second intermediate element 26-2 (FIG. 1). A leading lengthwise side 48B-2 of the second panel element 22-2 is inserted transversely (i.e., substantially in the direction indicated by arrow “A” in FIGS. 1-3A) into the second slot 90-1 of the intermediate element 26-1 (FIG. 3A). Once the leading lengthwise side 48B-2 is positioned in the second slot 90-1, the panel element 22-2 is then secured to the rails 32, 34, 36, using any suitable fasteners, e.g., nails.

A third panel element 22-3 is next put into position. First, a trailing lengthwise side 48A-3 is inserted into a first slot (not shown) of a third intermediate element 26-3. Next, a leading lengthwise side 48B-3 of the panel element 22-3 is inserted transversely into a second slot 90-2 of the intermediate element 26-2. The third panel element 22-3 is then secured to the rails 32, 34, 36, using suitable fasteners 29.

As can be seen in FIG. 1, the process preferably is repeated as needed to complete the barrier system 20 along its length. As noted above, those skilled in the art would appreciate that the manner in which the rails and the posts are positioned relative to each other can vary significantly. In the structure subassembly 28 illustrated in FIG. 1, for example, the post 30 extends outwardly relative to the rails 32, 34, 36. In this situation, the barrier system may include additional elements positioned between the post and the panel elements 22 in order to cover or obstruct any gaps and to provide a generally satisfactory appearance overall, as will be described. Such elements are omitted from FIG. 1 for clarity of illustration.

In use, after the panel elements 22 are secured to the structure subassembly 28, the intermediate elements 26 are in position on the panel elements 22, so that the web portions 50 thereof are at least partially located in the gap(s) 24. This prevents observation through the gaps 24, to provide privacy.

As described above, after a fence or similar wooden structure is built, the wooden elements tend to lose moisture. The panel elements shrink as they lose moisture over time, and this leads to gaps opening up between adjacent panel elements. As noted above, in this situation, the prior art fence or other barrier may not provide the desired degree of privacy, as the gaps permit observation therethrough. However, as can be seen in FIG. 1, once the panel elements 22 are assembled with the intermediate elements 26 therebetween, at least part of the intermediate element 26 obstructs the user's view through the gap(s). Accordingly, the barrier system 20, if used as a fence, provides and maintains privacy by filling the gap(s) 24 between the panel elements.

From the foregoing, it can be seen that the intermediate element 26 preferably is formed so that the engagement portions engage the respective exterior surfaces of the panel elements 22A, 22B to a limited extent only. Accordingly, it is preferred that the intermediate element 26 is formed to fit onto panel elements having predetermined dimensions, and are securely held against the panel elements because the intermediate elements fit onto the panel elements in a friction fit. Preferably, the intermediate element 26 is formed so that it is relatively easily slid into position substantially lengthwise onto the panel element 22. However, it is also preferred that, once the intermediate element 26 is in position on the panel element 22, the intermediate element 26 is securely engaged with the panel element 22, so that it remains in position thereon.

In summary, an embodiment of a method 103 of forming the barrier system 20 of the invention preferably includes providing the structure subassembly 28 (step 105, FIG. 11) and providing the panel elements 22 positionable adjacent to each other to at least partially define the gaps 24 therebetween, each of the panel elements having first and second lengthwise sides (step 107). In addition, intermediate elements 26 are provided (step 109). The trailing portion of a first one of two panel elements is positioned in the first slot 88, to engage the first inner surfaces 60, 68 with the first panel element 22 along the first lengthwise side thereof (step 111). The first panel element is secured to the structure subassembly 28 (step 113). Next, the leading portion of the second panel element is positioned in the second slot 90, to engage the second panel element with the second inner surfaces 62, 70 of the intermediate element 28 along the second lengthwise side 48 thereof (step 115). Finally, the second one of the panel elements 22 is secured to the structure subassembly 28 (step 117). It will be understood that the method is repeated for as many panel elements 22 as are needed for a particular barrier system.

Those skilled in the art would appreciate that alternatives to certain of the sequences of steps of the method 103 as described above and as illustrated in FIG. 11 are possible. For example, either or both of step 107 and step 109 may precede step 105.

An alternative embodiment of the barrier system 220 of the invention is illustrated in FIGS. 6-10. In one embodiment, the barrier system 220 preferably includes the structure subassembly 28 and the panel elements 22 positioned adjacent to each other to at least partially define the gap(s) 24 therebetween. Preferably, the panel elements 22 are secured to the structure subassembly 28. The barrier system 220 preferably also includes intermediate elements 26 at least partially positioned between the panel elements 22 respectively, to at least partially occupy the gap(s) 24 therebetween. It is also preferred that the barrier system 220 includes one or more utility elements 292 secured to the structure subassembly 28 for at least partially supporting the panel elements 22, as will be described.

As can be seen in FIG. 10, in one embodiment, the utility element 292 includes a utility web portion 294 and a utility flange 296 positioned substantially transversely to the utility web portion 294. Preferably, the utility flange 296 includes two flange parts 298, 202. Each flange part preferably extends from the utility web portion 294 to outer edges 204, 206 of each of the flange parts 298, 202 respectively. Each of the outer edges is spaced apart from the utility web portion 294 by a predetermined distance “D₁”. Each flange part preferably is positioned to define an acute angle α₁ between each flange part 298, 202 and the utility web portion 294 respectively.

As can be seen in FIGS. 8 and 9, in one embodiment, the utility element 292 preferably is secured to the bottom rail 36 by a number of suitable fasteners 229, e.g., nails. Preferably, the utility web portion 294 is nailed to the bottom rail 36 so that an inner surface 208 (FIG. 10) of the flange part 298 is at least partially engaged with the bottom surface 42 of the bottom rail 36. From FIG. 8, it can be seen that the flange part 298 serves to position the utility element 292 properly relative to the rail 36 as the utility element 292 is secured to the rail 36.

As can be seen in FIG. 8, after the utility web portion 294 is secured to the rail 36, the inner surface 210 of the flange part 202 is exposed. After the utility element 292 is secured to the rail 36, the bottom end 44 of panel element 22 is positioned on the inner surface 210 of the flange part 202. Preferably, the bottom end 44 is positioned in this way as the panel element 22 is being positioned relative to other panel elements 22, as described above. From the foregoing, those skilled in the art would appreciate that the flange part 202 locates and supports the panel element 22 before it is secured to the structure subassembly 28, and also serves to locate and support it thereafter, to a lesser extent.

As shown in FIG. 10, the flange parts 298, 202 preferably are tapered, i.e., they each define the acute angle α₁ between them and the utility web portion 294 respectively. However, it will be understood that this is optional. When the utility element 292 is formed with the flange parts tapered, the utility element 292 preferably is formed of material that is relatively flexible (e.g., a suitable plastic) so that, when the utility element is in position (i.e., secured to the rail 36) as shown in FIGS. 8 and 9, the flange parts may be pressed downwardly so that the acute angle between the flange parts and the web portion respectively is somewhat decreased. When secured to the structure subassembly, the utility element is subject to tension, so it is self-loading.

As noted above, the utility element 292 at least partially locates and supports the panel elements 22 during installation of the panel elements 22, and also after installation, i.e., after the panel elements are secured to the structure subassembly 28 by fasteners (e.g., nails) 29. However, as noted above, it has been found that, after the panel elements 22 have been installed for a period of time, the panel elements lose moisture, causing them to shrink, and sometimes to warp. Due to these changes in the shapes of the panel elements over time, the intermediate element 26 tends to become less securely attached to the panel elements over time, at least in part. In particular, it has been found that, during hot weather, the thermal expansion of the intermediate element can cause the intermediate element to become only loosely attached to the panel elements which it is located between. In these circumstances, the utility element supports the intermediate elements as well as the panel elements.

An embodiment of the barrier system 220 is illustrated in FIG. 15. As can be seen in FIG. 15, in one embodiment, the structure subassembly 28 includes posts 30 supporting the rails that are on one side of the rails. (In FIG. 15, only the top rail 32 is shown.) Those skilled in the art would appreciate that the arrangement of the structure subassembly 28 shown in FIG. 15 permits the panel elements 22, the intermediate elements 26, and the utility elements (not shown in FIG. 15) to be assembled and secured to the rails relatively quickly.

Those skilled in the art would appreciate that the barrier system of the invention preferably is also provided in the form of a kit of parts, i.e., to be assembled into the barrier system. From the foregoing, it can be seen that the kit preferably includes the structure subassembly for assembly into a structure. The structure subassembly preferably includes one or more posts and one or more rails securable to the posts, to provide the structure. The kit preferably also includes a number of panel elements that are securable to the erected structure subassembly, and a number of intermediate elements which are positionable between the panel elements respectively, as described above. In particular, and as described above, the intermediate elements are adapted to cover gaps between the panel elements when the panel elements are secured to the structure subassembly. It is also preferred that the kit includes a number of fasteners, for securing the rails to the posts, and for securing the panel elements to the rails.

In another embodiment, the kit preferably also includes one or more utility elements, for at least partially supporting the panel elements. The utility elements preferably are also securable to the structure subassembly, as described above. As described above, the utility element preferably also supports intermediate elements.

Those skilled in the art would also appreciate that the utility element 292 may be provided in various forms. One such alternative form of the utility element 292 is disclosed in FIGS. 19A and 19B. As can be seen in FIG. 19A, the barrier system 220 includes panel elements 22 with the intermediate elements 26 positioned therebetween. The panel elements and the intermediate elements are supported by the utility element 292, which is shown in FIGS. 19A and 19B in the form of another board, or a series of boards positioned end-to-end. The utility element 292 is secured to the bottom rail 36 by fasteners 29. In the barrier system 220 illustrated in FIGS. 19A and 19B, the structure subassembly 28 includes only the top rail 32 and the bottom rail 36.

An embodiment of a method 303 of forming the barrier system 220 of the invention includes providing the structure subassembly 28 (step 305, FIG. 12), and providing the panel elements 22 positionable adjacent to each other to at least partially define the gaps therebetween (step 307). The intermediate elements 26 are also provided (step 309). In addition, the utility elements 292 are provided (step 319). Next, each utility element 292 is secured to the structure subassembly 28, to position the utility flange part 202 for at least partially supporting the panel elements 22 (step 321). The bottom end 44 of the first panel element 22 is at least partially engaged with the utility flange part 202, so that the first panel element is at least partially supported thereby (step 323). The trailing portion of a first panel element is positioned in the first slot, to engage the first inner surfaces with the first panel element along the first lengthwise side thereof (step 311). Next, the first panel element 22 is secured to the structure subassembly 28 (step 313). The leading portion of a second panel element 22 is positioned in the second slot (step 315). Next, the bottom end 44 of the second panel element 22 is at least partially engaged with the utility flange part 202 (step 325). Finally, the second panel element 22 is secured to the structure subassembly 28 (step 327). It will be understood that the method is repeated for as many panel elements 22 as are needed for a particular barrier system.

Those skilled in the art would appreciate that alternatives to certain of the sequences of steps of the method 303 as described above and as illustrated in FIG. 12 are possible. For example, any one or all of steps 307, 309, and 319 may precede step 305. Also, step 323 may be performed before or after step 311, and step 325 may be performed before or after step 313.

As noted above, the structure subassembly 28 may have various designs. For instance, in one design, the posts 30 are positioned to protrude beyond front surfaces of the rails. In one embodiment, the barrier system 220 of the invention preferably includes an end element 216 secured to a selected one of the posts 30. Preferably, the end element 216 defines an end element slot 218 in which a lengthwise side of a selected one of the panel elements is at least partially receivable. It is preferred that the end element 216 is secured to the post 30 by the fastener 29, e.g., a nail. The end element 216 at least partially occupies any gaps between the post and the panel element nearest to the post.

It would be appreciated by those skilled in the art that, when the panel elements are installed, certain arrangements are required to be made at one end of the barrier system. For example, referring to FIG. 16A, it is assumed for the purposes hereof that installation begins at the end of the barrier system 220 identified as “X” in FIG. 16A, at which a post identified for convenience as 30X is located. As can be seen in FIG. 16A, an end element 216X preferably is secured (e.g., nailed) to the post 30X. Those skilled in the art would appreciate that, after the end element 216X is secured to the post, a first panel element 22X is slidable into the slot 218 of the end element 216X. Subsequently other panel elements are installed working toward the other end (“Y”) of the barrier system, with the intermediate elements 26 positioned therebetween. However, those skilled in the art would appreciate that, in order to install a final panel element 22Y after panel elements up to and including panel element 22N are installed, an end element 216Y first is secured to the post 30Y. An intermediate element 26N is attached to the panel element 22N before the panel element 22N is installed. Those skilled in the art would appreciate that the final panel element 22Y preferably is positioned in the slots of the end element 216Y and the intermediate element 26N respectively by positioning lengthwise sides of the panel element 22Y in such slots, and then lowering the panel element 22Y into position, i.e., with its bottom end supported by the utility element. Once the panel element 22Y is in position therebetween, it is secured to the structure subassembly 28 by fasteners (not shown in FIGS. 16A, 16B).

The invention also provides a pre-assembled panel assembly 412, illustrated in FIG. 18. Those skilled in the art would appreciate that, where one or more of the pre-assembled panel assemblies 412 are used, the barrier system may be formed more quickly. In one embodiment, the panel assembly 412 of the invention includes a number of the rails, positioned substantially parallel to each other. The panel assembly 412 preferably also includes a number of panel elements 22 secured to the rails. The panel elements 22 preferably are secured to the rails using any suitable fasteners 29, e.g., nails, as described above. (Only the top rail 36 is shown in FIG. 18.) It is also preferred that the panel elements 22 are positioned substantially orthogonal to the rails and located substantially edge-to-edge serially, to define gaps therebetween. Preferably, the panel assembly also includes a number of intermediate elements 26, each intermediate element 26 being positioned at least partially between a selected pair of the panel elements 22. As described above, each intermediate element includes a web portion 50 and first and second flanges 56, 58 transversely connected to the web portion. The web portion 50 is at least partially locatable between the panel elements 22 in the selected pair. In the same manner as described above, each of the first and second flanges is formed to at least partially engage the panel elements when the web portion is at least partially located between the panel elements, to maintain the web portion at least partially therebetween. It is also preferred that the panel assembly 412 includes one or more panel supports 495, for supporting the rails.

It will be understood that the panel assembly 412 preferably also includes one or more utility elements secured to the structure subassembly, for at least partially supporting the panel elements.

Those skilled in the art would appreciate that, in use, the pre-assembled panel assembly 412 preferably is secured to posts (not shown in FIG. 18), to support the panel assembly 412. The panel assembly 412 preferably is secured to the posts using any suitable fasteners, in any suitable manner, as would be known to those skilled in the art.

In one embodiment, a pre-assembled panel assembly 412′ (FIGS. 17A, 17B) of the invention includes one or more end elements 416 positioned at least partially between the panel support 495 and the panel element nearest to the panel support 495. It will be understood that the end element 416 optionally may be included in the pre-assembled panel assembly.

An embodiment of a barrier system 420 including the pre-assembled panel assembly 412′ is illustrated in FIGS. 17A and 17B. In this embodiment, the panel assembly 412′ includes the end element 416 secured to the panel support 495. It is preferred that the panel support 495 is positioned adjacent to the post 30, and secured thereto. It is also preferred that the end element 416 defines an end element slot 418 in which a lengthwise side of a selected one of the panel elements is at least partially receivable.

Those skilled in the art would appreciate that the end element 416 provides a means for filling the gap between a panel support 495 and the panel element nearest thereto that can be used in any design where the post extends or protrudes beyond a plane substantially defined by the front surfaces of the rails.

In another embodiment, the barrier system 520 includes one or more gap elements 514 at least partially positioned between two panel elements 22. As can be seen in FIG. 13A, in one embodiment, the gap element 514 preferably includes one or more gap web portions 550 extending between a first side 552 thereof and an opposed second side 554 thereof. The gap element 514 preferably also includes a first flange 556 connected to the gap web portion 550 at the first side 552 thereof and positioned substantially transverse to the gap web portion, the first flange 556 being positioned for at least partial engagement with the two panel elements 22, to at least partially locate the gap web portion 550 in the gap 24. As can be seen in FIG. 13A, it is preferred that the gap element 514 is secured to the structure subassembly 28.

As can be seen in FIG. 13A, in one embodiment, the gap element 514 can be in a form substantially the same as the utility element 292.

As can be seen in FIG. 13A, the gap element 514 preferably is used in retrofit situations. In another method 603 of the invention of forming the barrier system, the method includes providing the structure subassembly 28 (step 605, FIG. 13B), and providing two or more panel elements 22 secured to the structure subassembly 28 and positioned adjacent to each other to at least partially define one or more gaps 24 therebetween (step 631). Also, the gap elements 514 are provided, the gap elements 514 being at least partially positionable between the panel elements 22 to at least partially occupy the gaps 24 therebetween (step 633). The gap web portion 550 preferably is at least partially inserted in the gap(s) 24, to engage the first flange 556 with the two panel elements 22 (step 635). Finally, the gap element 514 is secured to the structure subassembly 28 (step 637).

As described above, the structure subassembly 28 may be provided according to different designs. A barrier system 720 is disclosed in FIGS. 14A and 14B in which the post 30 protrudes outwardly, past the rails. As can be seen in FIGS. 14A and 14B, the barrier system 720 preferably includes an end element 716 positioned between the post 30 and an end panel element, designated 22E in FIGS. 14A and 14B. Those skilled in the art would appreciate that the end element 716 is used where the space between the post 30 and the end panel element 22E is not sufficiently large to accommodate another panel element. In this situation, the end element 716 preferably is positioned in the space between the post and the end panel element 22E, and secured to the structure assembly 28. The gap element 514 preferably is then positioned to cover the gap(s) defined between the end element 716 and the end panel element 22E, and secured to the structure subassembly.

Any element in a claim that does not explicitly state “means for” performing a specific function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112, para. 6.

The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

1. A barrier system comprising:

at least two panel elements positioned adjacent to each other to at least partially define at least one gap therebetween; and

at least one intermediate element at least partially positioned between said at least two panel elements, to at least partially occupy said at least one gap.

2. A barrier system according to claim 1 in which said at least one intermediate element comprises:

at least one web portion extending between a first side thereof and an opposed second side thereof;

a first flange connected to said at least one web portion at the first side thereof;

a second flange connected to said at least one web portion at the second side thereof; and

the first and second flanges being positioned substantially transverse to said at least one web portion for at least partial engagement of the first and second flanges with said at least two panel elements, to at least partially locate said at least one web portion in said at least one gap.

3. A barrier system according to claim 2 in which each of said first and second flanges is formed to at least partially engage said at least two panel elements in a friction fit, to maintain said at least one web portion at least partially in said at least one gap.

4. A barrier system according to claim 2 in which:

each of the first and second flanges comprises two flange parts respectively, and each said flange part extends from said at least one web portion to an outer edge of each said flange part respectively, the outer edge being spaced apart from said at least one web portion by a predetermined distance; and

each said flange part is positioned to define an acute angle between each said flange part and said at least one web portion respectively.

5. A barrier system according to claim 3 in which each said flange part comprises an inner surface at least partially facing toward a selected other one of said flange parts.

6. A barrier system according to claim 2 in which the first and second flanges are at least partially formed to taper inwardly relative to said at least one web portion, for at least partial engagement of the first and second flanges with said at least two panel elements.

7. A barrier system according to claim 2 additionally comprising:

a structure subassembly for supporting said at least two panel elements; and

a plurality of fasteners, for securing said at least two panel elements to the structure subassembly.

8. A barrier system comprising:

a structure subassembly;

at least two panel elements positioned adjacent to each other to at least partially define at least one gap therebetween, said at least two panel elements being secured to the structure subassembly;

at least one intermediate element at least partially positioned between said at least two panel elements, to at least partially occupy said at least one gap; and

at least one utility element secured to the structure subassembly for at least partially supporting said at least two panel elements.

9. A barrier system according to claim 8 in which said at least one utility element comprises:

a utility web portion;

a utility flange positioned substantially transversely to the utility web potion.

10. A barrier system according to claim 9 in which:

the utility flange comprises two flange parts, each said flange part extending from the utility web portion to outer edges of each said flange part respectively, the outer edge being spaced apart from the utility web portion by a predetermined distance; and

each said flange part is positioned to define an acute angle between each said flange part and the utility web portion respectively.

11. A barrier system according to claim 8 in which:

the structure subassembly comprises at least one post;

the barrier system additionally comprises: an end element positioned adjacent to the post, to define at least one second gap between the end element and a selected one of said at least two panel elements; a gap element comprising: a gap web portion extending between a first side thereof and an opposed second side thereof; a flange connected to the gap web portion at the first side thereof, the flange being positioned substantially transverse to the gap web portion, for at least partial engagement of the flange with the end element and the selected one of said at least two panel elements, to at least partially locate the gap web portion in said at least one second gap;

the gap web portion being at least partially positioned in said at least one second gap; and

the gap element being secured to the structure subassembly.

12. A barrier system according to claim 8 additionally comprising an end element secured to a selected one of the posts, the end element defining an end element slot in which a lengthwise side of a selected one of the panel elements is at least partially receivable.

13. A barrier system comprising:

at least two panel elements positioned adjacent to each other to at least partially define at least one gap therebetween;

a structure subassembly for supporting said at least two panel elements;

a plurality of fasteners for securing said at least two panel elements to the structure subassembly;

at least one gap element at least partially positioned between said at least two panel elements, said at least one gap element comprising: at least one gap web portion extending between a first side thereof and an opposed second side thereof; a first flange connected to said at least one web portion at the first side thereof and positioned substantially transverse to said at least one web portion, the first flange being positioned for at least partial engagement with said at least two panel elements, to at least partially locate said at least one web portion in said at least one gap; and

said at least one gap element being secured to the structure subassembly.

14. An intermediate element for positioning at least partially between at least two panel elements, the intermediate element comprising:

at least one web portion extending between a first side thereof and an opposed second side thereof;

a first flange connected to said at least one web portion at the first side thereof;

a second flange connected to said at least one web portion at the second side thereof;

said at least one web portion being at least partially locatable between said at least two panel elements;

each of the first and second flanges being formed to at least partially engage said at least two panel elements when said at least one web portion is at least partially located between said at least two panel elements, to maintain said at least one web portion at least partially between said at least two panel elements.

15. A panel assembly comprising:

a plurality of rails, the rails being positioned substantially parallel to each other;

a plurality of panel elements secured to the rails, the panel elements being positioned substantially orthogonal to the rails and located substantially edge-to-edge serially, to define gaps therebetween;

a plurality of intermediate elements, each said intermediate element being positioned at least partially between a selected pair of the panel elements, each said intermediate element comprising: at least one web portion extending between a first side thereof and an opposed second side thereof; a first flange connected to said at least one web portion at the first side thereof; a second flange connected to said at least one web portion at the second side thereof; said at least one web portion being at least partially locatable between the panel elements in the selected pair; each of the first and second flanges being formed to at least partially engage said at least two panel elements when said at least one web portion is at least partially located between the panel elements, to maintain said at least one web portion at least partially between the panel elements; and

at least one panel support, for supporting the rails.

16. A barrier system comprising:

at least one post;

the panel assembly according to claim 15; and

said at least one panel support being secured to said at least one post.

17. A panel assembly according to claim 16 additionally comprising at least one utility element secured to the structure subassembly for at least partially supporting the panel elements.

18. A kit of parts for a barrier system, the kit comprising:

a structure subassembly for assembly into a structure, comprising: at least one post; at least one rail securable to the post, to provide the structure;

a plurality of panel elements securable to the structure;

a plurality of intermediate elements positionable between the panel elements respectively, the intermediate elements being adapted to cover gaps between the panel elements when the panel elements are secured to the structure; and

a plurality of fasteners, for securing the rails to the posts, and for securing the panel elements to the rails.

19. A kit of parts according to claim 18 additionally comprising at least one utility element for at least partially supporting the panel elements, said at least one utility element being securable to the structure subassembly.