IMPROVED SYSTEM AND METHOD FOR SECURING ELEMENTS TO A SURFACE

Abstract

A system and a method are provided for securing an element (50) to a support surface (70). The system comprises at least one rail member (10), a mounting part (20) and the element. The rail member comprises a lower face (11) at least partially contacting the support surface, opposed to an upper face (12) and connected thereto by opposed lateral walls (14, 15) thereby to define a box section. Each lateral wall projects above the upper surface and an edge portion thereof forms an inward flange to define a substantially C-profiled rail with the upper surface. The mounting part (20) comprises a base plate, is substantially rectangular, made at least partially of a resilient material and dimensioned complementarily with the rail member, such that a width of the base plate corresponds at least to a distance intermediate the opposed lateral walls and a thickness of the base plate corresponds at least to a distance intermediate the upper face of the rail member and an underside of the flange, the at least partial resiliency of the base plate causing the mounting part to compress for sliding between the opposed rails and to decompress for achieving an interference fit. The base plate of the mounting part (20) comprises a topside (22) bearing at least a pair of upward feet (26A, 26B), each foot being configured on a same face with at least one tenon projecting orthogonally thereto. The or each element (50) has a lower face configured with at least two recesses (56A, 56B), each recess comprising a groove dimensioned for engagement with the or each tenon of a respective foot in use.

Description

FIELD OF INVENTION

The invention belongs to the field of surface cladding. More particularly, the present invention relates to a system and a method for securing one or more elements to a support surface.

BACKGROUND TO INVENTION

Internal and external aspects of buildings are commonly clad with facings, typically elements such as boards, panels or strips made from wood, glass or composite materials, to enhance the aesthetic appearance of a surface and/or its usability.

For instance, curtain walling involves cladding a vertical wall within or outside a building, often made from concrete poured into formwork, with infill panels of opaque glass that are secured to an aluminium framework anchored into the wall. Similarly, decking involves cladding a horizontal surface in or adjacent a house with wooden strips fastened to an underlying wooden framework resting upon an insulating membrane.

Many systems already exist to facilitate surface cladding like curtain walling or decking, including systems of interlocking components designed for rapid assembly, which improve upon the traditional and long-lived tongue and groove techniques. EP 2729638 B1 of the applicant discloses such a system and an associated method of assembly. However, such systems still exhibit numerous disadvantages associated with sub-optimal ventilation, speed of assembly and adjustment of components during same

For example, a joist or rail component of an underlying framework made from a solid bloc of material, typically wood, is heavy to handle and so frequently of a modest height, more so the case if the framework should be useable with both a vertical surface cladding system and a decking system. This configuration maintains the lower face of the assembled system relatively close to the surface underlying the framework, and therefore maintains a correspondingly low volume of air circulating under that surface, which inhibits ventilation underneath the assembled system.

Furthermore, the adjustment of a mounting part interfacing a joist or rail framework component with a cladding or decking element, is severely inhibited during assembly when the locking mechanism between that framework component and the mounting part is unidirectional, such as the ratchet mechanism described in EP 2729638 B1. In that disclosure, if a system fitter slides the mounting part along the framework component past a desired location on the ratchet mechanism, wherein a reversing movement becomes required, the ratchet configuration prevents this adjustment and the mounting part needs to be slid along the entire framework component and off it, then re-engaged therewith anew.

This problem is compounded when several mounting parts need to be engaged in a sequence along a same framework component, and the fine reversing adjustment becomes required with one of the later mounting parts in the sequence, such that all mounting parts already in place need to be slid off the element then re-engaged.

Accordingly there is a requirement for an improved system addressing at least some of the problems observed in prior art systems described and referenced above.

SUMMARY OF INVENTION

Aspects of the invention are set out in the accompanying claims, aimed at various embodiments of a system and a method for securing an element to a support surface.

A first embodiment of the system comprises at least one rail member, at least one mounting part and at least the element to be secured.

The or each rail member comprises a lower face opposed to an upper face and connected thereto by opposed lateral walls so as to define a box section. At least a portion of the lower face contacts the support surface in use. Each lateral wall projects above the upper surface and an edge portion of each lateral wall is configured as a flange to define a substantially C-profiled rail with the upper surface.

The or each mounting part is substantially rectangular, having at least a longitudinal portion made of a resilient material. The mounting part comprises a base plate having a underside and a topside, wherein the topside comprises at least a pair of feet. Each foot extends substantially orthogonally to the topside and is located proximate a respective end thereof. Each foot is configured on a same face with at least one tenon projecting orthogonally thereto.

The or each element has a lower face configured with at least two recesses, each recess comprising a groove dimensioned for engagement with the or each tenon of a respective foot in use.

The rail member and the mounting part are dimensioned complementarily, such that a width of the base plate corresponds at least to a distance intermediate the opposed lateral walls and a thickness of the base plate corresponds at least to a distance intermediate the upper face of the rail member and an underside of the flange, the at least partial resiliency of the base plate causing the mounting part to compress for sliding between the opposed rails and to decompress for achieving an interference fit.

The mounting part and the grooved recess are configured complementarily, such that the element is secured to the mounting part by engaging each foot in a respective recess without the or each tenon penetrating the respective groove in a first movement, then displacing the element to engage the or each tenon in the respective groove in a second movement orthogonal to the first.

In another embodiment of the system, the topside of each flange may be covered with an elastomeric joint, in use sandwiched between the rail member and elements secured thereto. The joint may be produced by extrusion of an ethylene-propylene-diene monomer (‘EPDM’) compound, known to have outstanding durability and insulating properties, and advantageously providing this embodiment of the system with both an antiskid surface atop each rail member during the securing of elements thereto, and enhanced weather and noise insulation.

In a further embodiment, the system may further comprise an elongate and substantially rigid cross-member having opposed ends, each lateral wall of the rail member preferably comprising engagement means, wherein each end of the cross-member and each engagement means is configured complementarily for the cross-member end to securely and releasably engage a respective engagement means. This configuration advantageously simplifies the assembly of a framework including a plurality of rail members, with uniform spacing provided between the rails by the cross-members which enhance the transversal rigidity of the framework.

An embodiment of the engagement means may be a substantially L-profiled rail on the face opposed to the box section, with the web portion of the L-shaped rail distal the lateral wall and the flange portion intermediate the web and the lateral wall, each end of the cross-member being slotted at a distance corresponding substantially to the flange portion for securely and releasably engaging the web portion. This complementary configuration of the engagement means and the cross-member ends allows a system fitter to engage one with the other mechanically through gravity alone, without any complementary fastening required.

In yet another embodiment, preferably intended for decking applications, the system may further comprise a foot member configured as the support surface contacted by the portion of the rail member lower face. This configuration advantageously permits the system to be assembled atop a ground surface that need not be waterproofed with a web, a screen or the like. Considering the ease of assembly of rail members, mounting parts and cladding or decking elements without fasteners, common to all embodiments described herein, this configuration is particularly suited for temporary or semi-temporary decking ad hoc applications, e.g. for punctual events.

In a variant of this further embodiment, a topside of the foot member may comprise anchoring means configured complementarily with the at least portion of the rail member lower face to achieve a snap-fit therewith. This further embodiment inherits the advantages described immediately above, and enhances the structural rigidity of the framework of rail members, particularly when combined with rigid cross-members intermediate the rails.

In embodiments of the system, the rail member and/or the cross-member may be produced by extrusion of an aluminium alloy or composite material.

In embodiments of the system, the or each element is substantially rectangular and comprises a tongue at a first end and, at a second end opposite the first, a groove suitable for receiving the tongue of an adjacent element. This configuration enhances the longitudinal rigidity of the system when elements are secured end to end.

In embodiments of the system, the mounting part is moulded or printed in a single piece from an elastomeric material. Additive manufacturing technologies are considered particularly apt for producing the mounting part from a set of instructions encoding the design of an embodiment thereof.

A first embodiment of the method for fastening an element to a support surface, based on embodiments of the system as defined hereinbefore, comprises the steps of fastening at least a first rail member to the support surface; securing at least a first mounting part to the or each rail member, by exerting a compressing force upon the first or each mounting part by presenting then pushing same between the opposed rails, sliding the or each compressed mounting part atop the upper face between the opposed rails, and releasing the compressing force upon the or each compressed mounting part to cause an interference fit with the opposed rails; and fastening the element on the or each mounting part, by engaging each foot of the mounting part into a respective recess in the lower face of the element, in a first movement, and displacing the element towards the tenons to push each tenon into a respective groove, in a second movement orthogonal to the first.

Another embodiment of the method may comprise the further steps of securing a plurality of mounting parts to each rail member of a plurality thereof; and fastening each element on the plurality of mounting parts by engaging each foot of the plurality of mounting parts that is aligned with the element, into a respective recess in the lower face of the element, in a first movement; and displacing the element towards the tenons of the plurality of mounting parts that is aligned with the element, to push each tenon into a respective groove, in a second movement orthogonal to the first.

Another embodiment of the method may comprise the further steps of providing each rail member with engagement means; locating at least a second rail member atop the support surface, adjacent the first rail member so that respective engagement means of the first and second rails are opposed to each other; providing at least one cross-member, opposed ends of which are configured complementarily with the engagement means, for each end to securely and releasably engage a respective engagement means; and engaging opposed ends of the or each cross-member with respective engagement means of adjacent rail members.

In a variant of this embodiment, wherein each engagement means is a rail extending from a lateral wall of the rail member and comprising a web, and wherein the cross-member is substantially U-shaped and is configured complementarily with the engagement means by partially slotting adjacent each end of the cross-member, the step of engaging may further comprise translating each slot above a respective web and lowering the cross-member relative to the adjacent rail members.

In another embodiment of the method, the step of fastening the or each rail member to the support surface may comprise the further steps of providing a plurality of foot members by way of support surface, each foot member having a top surface configured with anchoring means, wherein the anchoring means is configured complementarily with the lower face of the rail member to provide a snap fit therebetween; and securing the lower face of the or each rail to one or more foot members with the anchoring means.

In another aspect, the present invention provides a data structure, or a set of instructions, encoding or recording a design for any one or more embodiment(s) of a mounting part as disclosed herein, at least readable by an additive manufacturing apparatus or system for manufacturing the mounting part therewith.

Other aspects of the invention are set out in the accompanying claims.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:—

FIG. 1 is an end view of a first embodiment of a rail member.

FIG. 2 is a perspective view of a first embodiment of a mounting part.

FIG. 3A is a top view of the mounting part of FIG. 2.

FIG. 3B is a top view of an alternative embodiment of the mounting part.

FIG. 4 is a side view of the mounting part of FIG. 2.

FIG. 5 is an end view of a first embodiment of an element to be secured.

FIG. 6 is a perspective and cut-away view of the element of FIG. 5.

FIG. 7 shows a first embodiment of the system of the invention, wherein the element of FIGS. 5 and 6 is secured to the rail member of FIG. 1 by the mounting part of FIGS. 2 to 4.

FIG. 8 is an end view of a second embodiment of a rail member

FIG. 9 is a side view of a cross-member releasably securable to the rail member of FIG. 8.

FIG. 10 is an end view of the cross-member of FIG. 9.

FIG. 11 shows a second embodiment of the system of the invention, wherein the element of FIGS. 5 and 6 is secured to the rail member of FIG. 8 by the mounting part of FIGS. 2 to 4 and the cross-member of FIGS. 9 and 10 is releasably secured to the rail member of FIG. 8.

FIG. 12 is an end view of a third embodiment of a rail member.

FIG. 13 is a perspective view of an end of the rail member of FIG. 13.

FIG. 14A is a perspective view of an end of a joint member secured to the rail member of FIGS. 12 and 13 in use.

FIG. 14B is an end view of the joint member of FIG. 14A.

FIG. 15 shows a third embodiment of the system of the invention, wherein the element of FIGS. 5 and 6 is secured to the rail member of FIGS. 12 and 13 configured with joint members of FIGS. 14A, 14B by the mounting part of FIGS. 2 to 4.

FIG. 16 is a perspective view of a foot member useable as a support surface for a rail member.

FIG. 17 is a side view of anchoring means located atop and centrally of the foot member of FIG. 16.

FIG. 18 shows a fourth embodiment of the system of the invention, consisting of the system of FIG. 15 with the rail member secured to the floor member of FIG. 16 by the anchoring means of FIG. 17.

FIG. 19 is a perspective view of the system of FIG. 18 including a plurality of foot members, a plurality of rail members, and a plurality of elements secured thereto by mounting parts.

DETAILED DESCRIPTION OF DRAWINGS

There will now be described by way of example specific modes contemplated by the inventor. In the following description and accompanying figures, numerous specific details are set forth in order to provide a thorough understanding, wherein like reference numerals designate like features. It will be readily apparent to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail, to avoid obscuring the description unnecessarily.

With reference to FIGS. 1 to 7 initially, core components of a first embodiment of the system according to the invention are shown, which include a rail member 10, a mounting part 20 and an element to be secured 50.

In this embodiment, the rail member 10 is an elongate profile extruded from aluminium with four main outer faces defining a box section, and an internal configuration of parallel spars enhancing structural strength. Viewed in section, a lower face 11 is substantially parallel and opposed to an upper face 12, which comprises co-planar edge sections 12A that are substantially parallel and opposed to the lower face 11, disposed on either side of an inverted V section 12B, the apex of which is centred substantially about the main axis of the member 10. Parallel spars 13A, 13B extend between the lower face 11 and the upper face 12, orthogonally to the lower face 11, equidistantly from the apex of the inverted V section 12B and intermediate same and the edge sections 12A.

The lower and upper faces 11, 12 are connected to each other by substantially parallel and opposed lateral walls 14, 15 that are substantially orthogonal to the lower and upper faces 11, 12 and separated by a distance D. At least a portion 16 of the lower face 11 contacts the support surface 70 in use. In the embodiment shown, the portion 16 is implemented as a pair of foot sections 16A, 16B. Viewed in section, each foot section comprises an outer side defined by a lower portion 14A, 15A of a respective lateral wall 14, 15, an inner side defined by a portion 11A of the lower face 11 orthogonal to the main plane 11B thereof, and an edge section 11C parallel to the main plane 11B but vertically offset by the inner side 11A intermediate the inner and outer sides.

Each lateral wall 14, 15 projects above the upper face 12 and a longitudinal edge portion 17 thereof forms a right angle relative to the lateral wall, oriented inwardly of the rail member, thereby forming a flange 17 partially overlying, and substantially parallel to, a respective co-planar edge section 12A and separated therefrom by a distance d.

Viewed in section, a substantially C-profiled rail is thus defined on each longitudinal edge of the upper face 12 by the flange 17, the portion of the lateral wall 14, 15 projecting above the co-planar edge section 12A intermediate the flange 17 and the upper surface 12, and the co-planar edge section 12A, wherein one rail is oriented in opposition to the other and each rail has a height d and is separated from the other rail by a gauge D.

The mounting part 20 is a substantially rectangular part which, depending on the embodiment, may be extruded as a single piece from a partially resilient material, preferably an elastomer, which is shown in FIGS. 2 to 4, but may alternatively be manufactured and assembled in a variety of materials and techniques so that longitudinal edge portions of the mounting part 20, or a central longitudinal portion thereof, are made from that resilient material, in all cases to confer the requisite degree of partial resilience to the mounting part that is required by the inventive principle disclosed herein.

The mounting part 20 comprises a base plate having an underside 21, a topside 22 and opposed ends 23A, 23B. A width W of the base plate 20 between the underside 2 and the topside 22 corresponds at least to the distance D intermediate the opposed lateral walls 14, 15. A thickness T of the base plate 20 corresponds at least to the distance d intermediate the upper face 11 of the rail member 10 and an underside of the flange 17. The base plate is thus dimensioned to slot in and engage respective C-profiled rails of a rail member 10 in use, wherein the at least partial resiliency of the mounting part allows a transversal compression for fitting and sliding between the opposed rails, and a decompression for achieving an interference fit with the opposed rails, thereby remaining secured in position.

A first end 23A of the base plate 20 is configured with a tongue portion 24 and the second end 23B is configured with a groove portion 25. The tongue and groove portions 24, 25 are respectively dimensioned to complement each other, so that the respective tongue portion 24 of a longitudinally adjacent mounting part can be lodged in the groove portion 25, and reciprocally.

The topside 22 comprises a pair of feet 26A, 26B, with each foot located proximate a respective end 23A, 23B, and a stop 27 located adjacent the end 23B configured with the groove portion 25. Each foot 26A, 26B and the stop 27 extends upwardly from the topside 22 and orthogonally thereto. Each foot 26A, 26B and the stop 27 extends transversally across a substantial portion of the topside 22, equidistantly relative to a main axis of the mounting part and short of opposed longitudinal edge portions of the topside surface 22.

A continuous width 28 of each longitudinal edge portion of the topside surface 22 is dimensioned to correspond substantially to the width of the flange 17 overlying the upper surface 12 of the rail member 10. This configuration advantageously causes opposed lateral faces of the feet 26A, 26B and of the stop 27 to correspond substantially to respective edges of opposed flanges 17, thus to help guide the mounting part 20 longitudinally between the C-profiled rails of the rail member 10 when the mounting part is transversally compressed, then to provide additional and respective points of interference fit when the mounting part is decompressed.

Each foot 26A, 26B is configured on a same face 29 orthogonal to the main axis of the mounting part 20, with two tenons 30 projecting orthogonally to the face 29 and oriented towards the mounting part end 23A configured with the tongue 24. Each pair of tenons 30 is arranged symmetrically relative to a median portion of the face 29. Each tenon 30 is substantially square in top section, and of identical dimensions to, and co-planar with, the other tenons of the mounting part 20.

Accordingly, tenons 30 of a same pair are transversally aligned with one another, relative to the base plate 20, and tenons 30 of respective pairs are longitudinally aligned with one another, symmetrically relative to a main axis of the base plate 20 and separated by a dimension corresponding substantially to the dimension between the respective faces 29 of the feet 26A, 26B.

The element 50 is an elongate substantially rectangular part which, depending on the embodiment, may be milled from a wood blank and routed in the configuration described hereafter, or extruded as a single piece profile from a variety of materials, typically a polymer compound with properties selected for enhanced wear and environmental resistance.

The element 50 comprises a lower face 51, an upper face 52 and opposed ends 53A, 53B. A first end 53A of the element 50 is configured with a tongue portion 54 and the second end 53B is configured with a groove portion 55. The tongue and groove portions 54, 55 extend across the width of the element 50 and are respectively dimensioned to complement each other, so that the respective tongue portion 54 of a longitudinally adjacent element can be lodged in the groove portion 55, and reciprocally.

The lower face 51 of the element 50 is configured with two rectilinear recesses or trenches 56A, 56B, which are parallel with one another, extend over the entire length of the element 50, and have a depth shorter than the level of the tongue 54 and groove 55. The two recesses 56A, 56B are located equidistantly of a main axis of the element 50 and are separated by a dimension corresponding substantially to the dimension between both feet 26A, 26B of a base plate upper surface 22.

A first lateral wall 57A of each recess 56A, 56B comprises a rectilinear groove 57B, which extends over the entire length of the element 50 and is shaped and dimensioned for engagement with the pair of aligned tenons 30 of a respective foot 26A, 26B, i.e. has a height and transversal depth corresponding closely to the height and length of a tenon 30.

In the embodiment shown, each recess 56A, 56B further comprises a second rectilinear groove 58B in the lateral wall 58A of the recess opposed to the first 57A. The second rectilinear groove 58B again extends over the entire length of the element 50, has a height corresponding to the height of the first groove 57B, but has a shorter transversal depth.

In use, at its simplest, an element 50 is fastened to the support surface 70 as follows. A first rail member 10 is located on, and preferably fastened to, the support surface. The support surface may optionally be prepared for long-term covering by the system with a weatherproofing technique involving a web, a screen or the like.

A first mounting part 20 is next compressed transversally and slid into position between the opposed C-profiled rails atop the rail member 20. The mounting part 20 is initially presented in a longitudinal orientation, e.g. with the tongued end 23A leading, between the substantially C-profiled rails atop the upper face of 12 the rail member, i.e. with lateral edges of the underside 21 of the base plate abutting the co-planar edge sections 12A of the upper face 12 and opposed lateral edges 28 of the topside 22 abutting respective lower edges of the flanges 17. The mounting part is then compressed as it is pushed, then slid longitudinally along the rail member 10, between the opposed C-profiled rails atop the upper face 12. Once located into a requisite element-securing position along the rail member 10, the transversal compressing force upon the mounting part 20 is released.

With the width W of the uncompressed base plate 20 corresponding at least to the gauge D of each C-profiled rail, and the thickness, or height, T of the uncompressed base plate 20 corresponding at least to the height d of each C-profiled rail, a longitudinal interference fit is achieved between the base plate 20 and the opposed C-profiled rails, over the entire areas respectively delimited by the continuous width 28 of each longitudinal edge portion of the mounting part 20, along the topside surface 22, the opposed underside surface 21, and lateral edges between both, whereby that the mounting part 20 is secured to the rail member 10. Moreover, with opposed lateral faces of the feet 26A, 26B and of the stop 27 corresponding substantially to respective edges of opposed flanges 17, additional and respective points of interference fit with the opposed flanges 17 are provided at corresponding locations, three on each side of the mounting part 20 above its topside surface 21.

Should the system fitter require minor adjustment of the mounting part 20 in either direction along the rail member 10, whether at the time of securing the mounting part or at a subsequent time when fitting further components of the system, a suitable compressing force can be re-exerted upon the mounting part 20 to push and slide it again, ad hoc, between the opposed C-profiled rails.

The element 50 is next fastened to the uncompressed mounting part 20, by engaging each foot 26A, 26B of the mounting part into a respective recess 56A, 56B in the lower face 51 of the element in a first movement, then displacing the element 50 towards the tenons 30 so as to push each tenon into a respective groove 57A, 57B in a second movement orthogonal to the first.

With reference to FIGS. 8 to 11 now, core components of a second embodiment of the system according to the invention are shown, which include an alternative embodiment of the rail member 110 useable with the mounting part 20 and the element 50, and a cross member 90.

This alternative embodiment of the rail member 110 reprises all features of the first embodiment as described with reference to FIGS. 1 to 7, to which symmetrical engagement means 80 are added on either side of the rail member 110 for releasably securing a respective end of the cross member 90. The rail member 110 is thus again an elongate profile that may be extruded from aluminium with four main outer faces defining a box section, an internal configuration of parallel spars enhancing structural strength, and the engagement means integral with the rail member but external to the box section.

In the embodiment shown, each engagement means 80 comprises a substantially L-profiled rail 80 projecting from outer face of the rail member lateral wall 14, 15 opposed to the box section. The web portion 82 of the L-shaped rail is distal the lateral wall 14, 15 and the flange portion 84 is intermediate the web 82 and the lateral wall 14, 15 thereby defining an open topped channel with a width w. Each flange portion 84 projects from the lower portion 14A, 15A of a respective lateral wall 14, 15, at a same position intermediate the edge section 11C and the main plane 11B of the lower face 11.

The cross-member 90 is an elongate with opposed ends opposed ends 91, 92. The purposes of the cross-member 90 are to mechanically link and uniformly distance adjacent rail members 110 in a system according to the invention, therefore the cross-member 90 is substantially rigid and may for instance be extruded from aluminium like the rail member 110. In the embodiment shown, the cross-member 90 has a substantially U-shaped section made of parallel lateral walls 93A, 93B connected by an intermediate topside 94 orthogonal thereto.

The U-shaped section of the cross-member 90 is slotted (95) transversally, at a distance from each end 93A, 93B corresponding substantially to the width w of the L-shaped rail intermediate the lateral wall 14, 15 and the web 82. The slotting is partial, extending from the edge of each lateral wall 93A, 93B distal the topside 94 on a length corresponding substantially to the height of the web portion 82 of the L-shaped rail. The width of each slot 95 corresponding substantially to the width of the web portion 82 of the L-shaped rail.

With this alternative embodiment, an element 50 is fastened to the support surface 70 substantially as previously described, but the method of assembly further comprises locating two or more rail members 10 adjacent each other atop the support surface 70, so that respective lateral engagement means 80 of adjacent rail members 10 are opposed to each other.

Cross-members 90 are next located intermediate each pair of adjacent rail members, and used to facilitate orientation and distancing of adjacent rail members one relative to the other, advantageously without any tools or measuring apparatus. Each cross-member 90 is then lowered, whereby each of its two slots 95 at its opposed ends engages a respective web portion 82 of the pair of adjacent rail members, each cross-member 90 thus securing and bracing adjacent rail members through a simple, gravity-based mechanical engagement.

With reference to FIGS. 12 to 15 now, core components of a third embodiment of the system according to the invention are shown, which include a further embodiment of the rail member 210 useable with the mounting part 20, the element 50 and the cross member 90 and a pair of elastomeric joints 140. It will be readily understood from the description, that this alternative embodiment of the rail member 210 may also be produced, and used, without the engagement means 80 and the cross-member 90 shown and described with reference to FIGS. 8 to 11.

This alternative embodiment of the rail member 210 reprises all features of the first and second embodiments as described with reference to FIGS. 1 to 11, wherein the topside of each flange 17 atop the rail member is covered with the elastomeric joint 140. The purposes of the elastomeric joint 140 are to facilitate the handling and securing of elements 50 during assembly of the system, and thereafter to provide enhanced soundproofing and weather insulation characteristics to the system. Accordingly the joint 140 may be made of, or extruded from, an elastomeric compound with properties selected for enhanced wear and environmental resistance, for example ethylene-propylene-diene monomer (‘EPDM’).

In this embodiment, the rail member 210 is the same elongate profile that may be extruded from aluminium as shown and described with reference to FIG. 8 to 11, further including joint fitting means 150 integral with the rail member but external to the box section, located adjacent each flange 17 partially overlying a respective co-planar edge section 12A, thus on opposed sides of the upper face 12.

Each joint fitting means 150 is configured for releasably securing an underside portion 142 of a respective joint 140, wherein the joint underside 142 is dimensioned complementarily with the joint fitting means 150 to implement a secure press-fit therein. In the embodiment shown, each joint fitting means 150 comprises a substantially U-profiled rail 150, opposed upper edges of which form a neck 152 delimiting and partially enclosing a lumen 154 oriented orthogonally to the adjacent flange 17, effectively an upturned C-shaped profile. Each U-profiled rail 150 projects from the upper portion of a respective lateral wall 14, 15, at a same position intermediate the upper face 12 of the rail member and the flange 17.

Viewed in section, the joint 140 is shaped substantially as an assymetric T, with the underside 142 forming the vertical bar and a topside 146 forming the horizontal bar. The underside 142 comprises a necked portion 143 extending underneath the topside 146, having a width substantially equal to the width of the rail neck 152. An end of the necked portion 143 distal the topside 146 is integral with a lower portion 144 of the underside 142, which is symmetrically-flared about a longitudinal lumen 145 with walls dimensioned complementarily with the rail lumen 154.

Viewed in section still, the underside 142 is vertically offset relative to a median axis of the topside 146, wherein a wider portion of the topside width extends over the flange 17 on a side of the joint 140 proximate the rail member 210, and a shorter portion of the topside width extends over the portion of the substantially U-profiled rail 150 distal the rail member 210 on the other side of the joint 140.

With this alternative embodiment, an element 50 is fastened to the support surface 70 substantially as previously described, with or without cross-members 90, with the advantage of facilitating the handling of elements 50 atop rail members 10 during assembly, because the increased friction ratio between element undersides 51 and joint topsides 146 above rail member topsides 12 provides an anti-slip effect.

Furthermore, subject to the dimensional tolerances of the components in this embodiment, the second movement engaging mounting part tenons 30 into element grooves 57A, 57B also sandwiches the joint 140 between upper edges of the U-shape rail 150 and the element underside 51. This enhances soundproofing of the system and inhibits ingress of humidity between an element 50 and an underlying rail member 10.

With reference to FIGS. 16 to 19 now, a fourth embodiment of the system according to the invention is described, which is based upon a combination of any of the three embodiments previously described with reference to FIGS. 1 to 15 with one or more feet members 160 by way of the support surface 70. In this embodiment, each foot member 160 is located intermediate the support surface 70 and a rail member 10, 110, 210, and configured as the support surface contacted by the portion 11C of the rail member lower face 11.

An embodiment of a foot member 160 is shown in FIGS. 16 and 17, which comprises a circular base plate 161, a circular top plate 162 having a shorter diameter than the base plate, and a cylinder section 163 extending between, and having a uniform diameter shorter than, the base and top plates 161, 162.

A portion of the top surface of the base plate 161 surrounding the cylinder section 163 of shorter diameter defines a peripheral flange, about which a plurality of through-apertures 164 are provided equidistantly, for facilitating anchoring of the foot member 160 into the underlying surface 70 contacted by the base plate underside. A plurality of reinforcing ribs 165 are provided equidistantly about the entire periphery of the cylinder section 163, wherein each rib extends between the base and top plates 161, 162 and orthogonally thereto along the outer surface of the cylinder section 163.

A central portion 166 of the topside of the top plate 162 is configured with anchoring means 170 configured complementarily with the rail member lower face 11 to implement a secure snap-fit therebetween. In the embodiment shown, the anchoring means 170 comprises two pairs of opposed tenons 172, with one pair orthogonal to the other and both pairs centred about the geometrical centre 168 of the central portion 166, projecting upwardly from a truncated pyramidal base 173 also centred about the geometrical centre 168.

Each tenon 172 is shaped as an inverted V in section and made of three substantially oblong sections. A first section 174 projects upwardly from the truncated pyramidal base 173 and orthogonally thereto. A second section 176 projects orthogonally from an edge of the first section 174 distal the truncated pyramidal base 173 and forms the apex of the tenon 172, having a planar top surface. An edge of the second section 176 distal the first section 174 has a rounded profile tapering into a third section 178 projecting downwardly therefrom. The third section 178 forms an acute angle relative to the first section 174 and an edge 179 of the third section 178 distal the second section is free of any connection or attachment to the topside of the top plate 162. The first and second sections 174, 178 are of substantially equal length, and both are longer than the intermediate apex section 176.

A distance between the outermost edges of respective third sections 178 in a pair of opposed tenons 172 is substantially equal to the distance between opposed portions 11A of the lower face 11 orthogonal to the rail member 10, 110, 210 which form the respective inner sides of the rail member feet 16A, 16B.

A height between the planar top surface of the second apex section 176 of each tenon 172 and the topside of the top plate 162 is substantially equal to the height between the main plane 11B and the edge section 11C of the lower face 11 of the rail member 10, 110, 210, i.e. equal to the vertical offset therebetween constituted by a lateral foot portion 11A.

The free edge 179 of the third section 178 is substantially level with the topside of the truncated pyramidal base 173, so as to define a clipping channel delimited by the free edge 179 at the top, by the topside of the top plate 162 at the bottom and, on one side, by the inclined lateral wall of the truncated pyramidal base 173. The configuration of the anchoring means 170 as orthogonal pairs of opposed tenons 172 thus results in two pairs of opposed clipping channels, with each pair orthogonal to the other.

The inner corner of each foot 16A, 16B of a rail member 10, 110, 210 between the upright portion 11A and the horizontal edge section 11C of the lower face 11 is formed with a longitudinal lip 180 projecting towards the main plane 11B of the lower face 11, which is shaped complementarily with the clipping channel. In the embodiment shown, a top aspect of the lip 180 abuts the free edge 179, a bottom aspect of the lip abuts top plate 162 and, on one side, a lateral aspect of the lip 180 abuts the inclined lateral wall of the truncated pyramidal base 173.

With this alternative embodiment, an element 50 is fastened to the support surface 70 substantially as previously described, but the method of assembly initially comprises locating at least a first foot member 160 on the ground surface 170 (for instance where a rail member 10, 110, 210 is supported at a height from the ground surface 170 by a joist, a ledge or some other structural support at one end), alternatively at least two foot members 160 at or adjacent each end of a rail member 10, 110, 210.

Additional structural rigidity may be conferred to the system by locating several foot members 160 along each rail member 10, 110, 210, as illustrated in FIG. 19. Additional stability may be conferred to the system by securing the foot member 160 to the ground surface 170 by driving a fastener in one or more of the through-apertures 164.

Each rail member 10, 110, 210 is then secured to the one or more foot members 160 underneath it. Each anchoring means 170 is substantially aligned with the rail member feet 16A, 16B, wherein the inclined aspect of the third section 178 of each tenon 172 helps guide and centre the opposed longitudinal lips 180 of the rail member relative to the geometrical centre(s) 168 of the central portion(s) 166.

The rail member 10, 110, 210 is pressed downwards, whereby the opposed longitudinal lips 180 of the rail member press against the respective third section 178 of a pair of opposed tenons 172 orthogonal to the rail member, and gradually deform the opposed tenons 172 inwardly towards the geometrical centre 168.

When the downward pressure upon the opposed longitudinal lips 180 eventually results in their co-location with respective and opposed clipping channels, the deformation force exerted upon the opposed tenons 172 is released, achieving a snap-fit between the foot member 160 and the rail member 10, 110, 210.

The foot member 160 may be injection-moulded or -cast as a single piece from a partially resilient material, preferably an elastomer. Alternatively the foot member 160 may be manufactured and assembled in a variety of materials and techniques, wherein at least the central section 166 of the top surface and the anchoring means 170 thereon are made from that at least partially resilient material, in all cases to confer the requisite degree of partial resilience to the anchoring means 170, e.g. the tenons 172 in the embodiment shown.

Accordingly, the invention disclosed herein provides a structure for the rear section of a vehicle, together with a method of manufacturing a vehicle with same, embodiments of which all generally increase the operational safety of fueling a vehicle from a liquid petroleum gas tank.

In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa. The invention is not limited to the embodiments hereinbefore described but may be varied in both construction and detail.

Claims

1. A system for securing an element to a support surface, comprising

at least one rail member (10) comprising a lower face (11) opposed to an upper face (12) and connected thereto by opposed lateral walls (14, 15) so as to define a box section, wherein at least a portion (16) of the lower face contacts the support surface (70) in use, and wherein each lateral wall projects above the upper surface and an edge portion (17) thereof is configured as a flange to define a substantially C-profiled rail with the upper surface;

at least one substantially rectangular mounting part (20), having at least a longitudinal portion made of a resilient material, the mounting part comprising a base plate having an underside (21) and a topside (22), the topside comprising at least a pair of feet (26A, 26B), wherein each foot extends substantially orthogonally to the topside and is located proximate a respective end (23A, 23B) thereof, and wherein each foot is configured on a same face (29) with at least one tenon (30) projecting orthogonally thereto; and

at least one element (50) having a lower face (51) configured with at least two recesses (56A, 56B), each recess comprising a groove (57B) dimensioned for engagement with the or each tenon of a respective foot in use;

characterised in that

the rail member (10) and the mounting part (20) are dimensioned complementarily, such that a width (W) of the base plate corresponds at least to a distance (D) intermediate the opposed lateral walls and a thickness (T) of the base plate corresponds at least to a distance (d) intermediate the upper face of the rail member and an underside of the flange, the at least partial resiliency of the base plate causing the mounting part to compress for sliding between the opposed rails and to decompress for achieving an interference fit; and

the mounting part (20) and the grooved recess (56A, 56B) are configured complementarily, such that the element (50) is secured to the mounting part by engaging each foot (26A, 26B) in a respective recess without the or each tenon (30) penetrating the respective groove in a first movement, then by displacing the element to engage the or each tenon in the respective groove in a second movement orthogonal to the first.

2. The system according to claim 1, wherein the topside of each flange is covered with an elastomeric joint (140).

3. The system according to claim 1, further comprising an elongate and substantially rigid cross-member (90) having opposed ends (91, 92), wherein each lateral wall of the rail member further comprises engagement means (80), and wherein each end of the cross-member is configured complementarily with the engagement means to securely and releasably engage same.

4. The system according to claim 3, wherein the engagement means (80) comprises a substantially L-profiled rail on a face of the rail member lateral wall opposed to the box section, with a web portion (82) of the L-shaped rail distal the lateral wall and a flange portion (84) intermediate the web and the lateral wall, the cross-member being slotted adjacent each end at a distance corresponding to a dimension (w) of the flange portion, for lodging the web portion.

5. The system according to claim 1, wherein the rail member and/or the cross-member is/are produced by extrusion of an aluminium alloy or a composite material.

6. The system according to claim 1, further comprising a foot member configured as the support surface contacted by the portion of the rail member lower face.

7. The system according to claim 6, wherein a topside of the foot member comprises anchoring means (170) configured complementarily with the lower face portion of the rail member to achieve a snap fit therewith.

8. The system according to claim 1, wherein the or each element is substantially rectangular and comprises a tongue (54) at a first end and, at a second end opposite the first, a groove (55) configured for receiving the tongue of an adjacent element.

9. The system according to claim 1, wherein the mounting part is moulded in a single piece from an elastomeric material.

10. The system according to claim 9, wherein the mounting part is printed with an additive printing device.

11. A method for securing an element to a support surface based on an arrangement as defined in claim 1, the method comprising the steps of:

securing at least a first rail member (10) to the support surface (70);

securing at least one mounting part (20) to the or each rail member, by exerting a compressing force upon the or each mounting part, sliding the or each compressed mounting part atop the upper face (12) and between the opposed rails, and releasing the compressing force upon the or each compressed mounting part to cause an interference fit with the opposed rails; and

securing the element (50) on the or each mounting part, by engaging each foot (26A, 26B) of the mounting part into a respective recess (56A, 56B) in the lower face (51) of the element, in a first movement, and displacing the element towards the tenons (30) to push each tenon into a respective groove (57B), in a second movement orthogonal to the first.

12. The method according to claim 11, further comprising

securing a plurality of mounting parts to each rail member of a plurality thereof; and

securing the or each element on the plurality of mounting parts by engaging each foot of the plurality of mounting parts that is aligned with the element, into a respective recess in the lower face of the element, in a first movement; and displacing the element towards the tenons of the plurality of mounting parts that is aligned with the element, to push each tenon into a respective groove, in a second movement orthogonal to the first.

13. The method according to claim 11, comprising the further steps of

providing each rail member with engagement means (80);

locating at least a second rail member atop the support surface, adjacent the first rail member so that respective engagement means of the first and second rails are opposed to each other;

providing at least one cross-member (90), opposed ends (91, 92) of which are configured complementarily with the engagement means to securely and releasably engage same; and

engaging opposed ends of the or each cross-member with respective engagement means of adjacent rail members.

14. The method according to claim 13,

wherein each engagement means is a rail extending from a lateral wall (14,15) of the rail member and comprising a web portion (82), and

wherein the cross-member is substantially U-shaped and is configured complementarily with the engagement means by partially slotting the cross-member adjacent each end thereof,

the step of engaging further comprising locating the cross-member so that each slot stands above a respective web portion, then lowering the cross-member relative to the adjacent rail members.

15. The method according to claim 11, wherein the step of fastening the or each rail member to the support surface comprises the further steps of

providing a plurality of foot members (160) by way of support surface, each foot member having a top surface (162) configured with anchoring means (170), wherein the anchoring means is configured complementarily with the lower face of the rail member to provide a snap fit therewith; and

fastening the lower face of the or each rail member to one or more foot members with the anchoring means.