Metal gates and fencing and methods of making the same

Abstract

 A method of manufacturing a metal gate or fencing section comprising providing a mold 14a defining a decorative profile and positioning the ends of two steel tubes (4,6) in a predetermined relative to extend into the mold (14a). The mold (14A) is then fitted with molten aluminium or aluminium alloy so that the molten material envelops those parts of the tubes received by the mold and conforms to the decorative profile defined by the mold. When the molten material has solidified it will lock the tubes in their predetermined relative configuration. Thereafter, the solidified material and the tubes can be released from the mold.

Description

[0001] The present invention relates to metal gates and fencing and methods of making the same.

[0002] Heavy metal gates are traditionally used to provide access to property. Like-wise heavy metal fencing or railings are used to surround property. Such gates and fencing have been made out of lengths of steel or cast iron bar welded together to form a matrix. For example, a series of spaced uprights can be welded to upper and lower horizontal bars. To make the gate or fencing more attractive, a series of shaped decorative profiles such as a spear head or a fleur-de-lys are welded at intervals, for example to the upper horizontal bar, each profile being aligned with a corresponding upright.

[0003] The method of constructing such gates or fencing sections is relative slow. Each upright must be cut fairly accurately from a length of stock and welded to both upper and lower horizontals. The profiles must first either be cast or worked to the desired shape and then welded to the upper horizontal bar.

[0004] It is an object of the invention to provide an improved metal gate or fencing section and an improved method of manufacture.

[0005] According to the present invention there is provided an array of tubular members in the form of a gate or fencing section in which adjoining members are coupled together by an aluminium or an aluminium alloy casting and in which selected ones of said castings include a cast decorative profile.

[0006] Advantageously, a casting in the form of a hinge or other fixing is secured to at least one said tubular member.

[0007] Preferably the tubular members are of mild steel and of circular cross-section. Instead, the tubular members are of square-cross section.

[0008] Advantageously, the sole means coupling adjacent tubular members together is the casting.

[0009] The aluminium alloy can comprises an aluminium silicon alloy.

[0010] The present invention further provides a method of manufacturing a metal gate or fencing section comprising providing a mold defining a decorative profile, positioning a first elongate steel tube and a second elongate steel tube in a predetermined relative configuration so that both extend into the mold. Filling the mould with molten aluminium or aluminium alloy so that the molten material envelops those parts of the first and second tube received by the mold and conforms to the decorative profile defined by the mould, allowing the molten material to solidify to lock the first and second tubes in the predetermined relative configuration and releasing the solidified material and the tubes from the mold.

[0011] Advantageously, the tubes are positioned within the mold so that the intermediate portion of the first tube traverses the mold and an end portion of the second tube extends into the mold at right angles to the first tube, but lies spaced from the first tube.

[0012] Preferably, an array of molds is provided to receive an array of tubes and to lock the array of tubes together when the molds are filled with the molten material.

[0013] Preferably, the tubes, when inserted into the mold, are at room temperature so that as the molten material solidifies it forms a shrink fit around the tubes.

[0014] Metal gates, fencing sections and methods of making them, all embodying the invention, will now be described, by way of example, with reference to the accompanying diagrammatic drawings, in which:

Figure 1 is a front elevation of a fragment of a gate or fencing section;

Figure 2 is a front elevation of a mold half for producing an upper joint; and

Figure 3 is a front elevation of a mold half for producing the lower joint.

[0015] Figure 1 shows a fragment of a gate, fencing or railing section. As can be seen, the arrangement comprises upper and lower parallel spaced mild steel tubes 2 and 4. Extending between the upper and lower tubes 2 and 4 are a series of vertical or upright tubes 6 of mild steel (only two shown). The tubes 6 extend parallel to one another and are spaced at regular intervals. The tubes 6 extend at right angles to the tubes 2 and 4 so that their longitudinal axes intersect the longitudinal axes of the tubes 2 and 4.

[0016] The lower end of each tube 6 is coupled to the lower horizontal tube 4, by an casting 8 of aluminium or an aluminium alloy, such as an aluminium silicon alloy (BS 1490 - 1988 - LM6). The upper end of each tube 6 is coupled to the upper horizontal tube by a casting 10 of aluminium or aluminium alloy. The casting 10 also defines a decorative profile 12 in the form of a spear head. The decorative profile may have other shapes such as a fleur-de-lys for example.

[0017] Figure 2 shows one half of a mold 14 for producing the casting 10. As can be seen, the mold 14 defines a transverse channel 18 having an intermediate section of larger diameter and two outer sections of smaller diameter. The smaller diameter sections are just slightly larger than the tube 2 that the mold is arranged to accommodate. The mold also defines a recess 20 of circular cross-section which communicates with the channel 18. The longitudinal axis of the recess 20 extends at right angles to the longitudinal axis of the channel 18. The section of the recess 20 closest to the channel 18 has a larger diameter equal to the larger diameter of the channel 18. The section of the recess 20 remote from the channel 18 has a smaller diameter which is just slightly larger than the outside diameter of the tube 6. The mold 14 has a further recess 16 which communicates with the channel 18 and which defines an ornamental profile.

[0018] A convergent inlet opening 22 extends from the exterior surface of the mold to the junction of the channel 18 with the recess 20 on one side of the longitudinal axis of the recess 20 and a convergent outlet opening 24 extends from the exterior surface of the mold to the junction of the channel 18 with the recess 20 on the other side of the longitudinal axis of the recess.

[0019] In operation, the two hollow tubes 2 and 6 which are at room temperature are placed in the mold 14 in the configuration shown in Figure 2. It will be noted that the length of the tube 6 is not critical and provided the end of the tube is inserted into the recess 20 so that it extends at least half the length of the wider diameter section, it need not abut the tube 2. The other half of the mold which is a mirror image of the first half is then secured to the first half by means not shown. Molten aluminium or aluminium alloy is then forced under gravity into the inlet 22 to fill the cavities within the mold and then to emerge from the outlet 24. Where the molten metal passes into the narrow gaps between the tubes 2 and 6 and the reduced sections of the channel 18 and the reduced section of the recess 20, it quickly cools and effects a seal to prevent escape at these locations. The molten melt is allowed to cool, and to form a shrink fit around the tubes 2 and 6 so locking the tubes very firmly together. The casting is then released from the mold and the solidified metal portions which were formed into the inlet 22 and outlet 24 are snapped off to leave a casting such as is shown in Figure 1. Of course, when filling the mold 14, it is inverted from the position shown in Figure 2 so that when injecting molten metal under gravity , it is forced down the inlet and allowed to rise up out of the outlet. Also, the extent of which the molten metal rises up the inside of the tube 6 will be limited by gravity to the level of the outlet 24.

[0020] The casting shown in Figure 3 is similar to the casting shown in Figure 2 except that there is no cavity for forming an ornamental profile. Parts similar to those in Figure 2 are similarly referenced except with the suffix A.

[0021] It will be appreciated that a casting can be used to lock three or more tubes together. Also, the casting can be used on a single tube to provide a functional item such as a hinge in the case of a gate and a fastening projection in the case of a section of fencing. Instead of hollow tubes, solid tubes can be used.

Claims

1. An array of tubular members in the form of a gate or fencing section in which adjoining members are coupled together by an aluminium or an aluminium alloy casting and in which selected ones of said castings include a cast decorative profile.

2. An array according to Claim 1 including a casting in the form of a hinge or other fixing secured to at least one said tubular member.

3. An array according to Claim 1 or to Claim 2, wherein the tubular members are of mild steel and of circular cross-section.

4. An array according to Claim 1 or to Claim 2 wherein the tubular members are of square-cross section.

5. An array according to any preceding claim, wherein the sole means coupling adjacent tubular members together is the casting.

6. An array according to any preceding claim wherein the aluminium alloy comprises an aluminium silicon alloy.

7. A method of manufacturing a metal gate or fencing section comprising the steps of providing a mold defining a decorative profile, positioning a first elongate steel tube and a second elongate steel tube in a predetermined relative configuration so that both extend into the mold, filling the mould with molten aluminium or aluminium alloy so that the molten material envelops those parts of the first and second tube received by the mold and conforms to the decorative profile defined by the mould, allowing the molten material to solidify to lock the first and second tubes in the predetermined relative configuration and releasing the solidified material and the tubes from the mold.

8. A method according to Claim 7, wherein the tubes are positioned within the mold so that the intermediate portion of the first tube traverses the mold and an end portion of the second tube extends into the mold at right angles to the first tube, but lies spaced from the first tube.

9. A method according to Claim 7 or to Claim 8 including the step of providing an array of molds to receive an array of tubes and to lock the array of tubes together when the molds are filled with the molten material.

10. A method according to any one of Claims 7 to 9, wherein when the tubes are inserted into the mold, they are at room temperature so that as the molten material solidifies it forms a shrink fit around the tubes.

Drawing