ASSEMBLY

FIELD OF THE INVENTION

The invention relates to a structural assembly and/or to components for a structural assembly to be used in constructing barriers such as fences, walls, gates, canopies and the like.

BACKGROUND OF THE INVENTION

In construction, it is often desirable to design structural assemblies that are modular, easy to assemble and disassemble and strong enough to withstand the forces they may be subjected to during application.

In some cases, the structure needs to be moveable and the assembly should include one or more moveable parts.

It is an object of the present invention to provide an alternative structural assembly and/or alternative components for a structural assembly, or to at y7u68least provide the public with a useful choice.

STATEMENTS OF THE INVENTION

In a first aspect the invention may broadly be said to consist of a coupling device for use in a structural assembly comprising at least one substantially hollow elongate shaft member, the coupling device comprising :

a main coupling member having an elongate body with at least one internal channel extending longitudinally therethrough, the channel being open at an end of the body for receiving a corresponding longitudinal inner wall section of a first corresponding structural shaft member during insertion of the coupling member into the hollow shaft, and

a locking mechanism operable to fix the body to the first shaft member in a locked position and allow insertion or removal of the body relative to the shaft in an unlocked position.

Preferably the elongate body of the coupling member has an outer peripheral wall profile substantially corresponding to an inner peripheral wall profile of an open end of the first corresponding structural shaft member for enabling the coupling member to be inserted and accommodated within the open end of the first shaft member in use. Preferably the elongate body is substantially cylindrical. Alternatively the elongate body may comprise any cross-sectional shape such as rectangular or polygonal. Preferably the elongate body of the coupling member comprises one or more longitudinal grooves extending along the outer peripheral wall of the body and configured to slidably receive one or more longitudinal skirts spaced about and extending along the inner periphery of the first corresponding shaft member. More preferably the elongate body of the coupling member comprises one or more pairs of opposed longitudinal grooves for receiving one or more pairs of opposed longitudinal skirts of the first corresponding shaft member.

Preferably each channel forms an opening along a length of the body. In a first configuration, the elongate body comprises one longitudinal channel extending substantially diametrically across the body for receiving a corresponding internal wall extending substantially diametrically across the interior of the first corresponding shaft member. Preferably the elongate body comprises one pair of opposed longitudinal grooves located on a portion of the outer peripheral wall located to one side of the channel. Alternatively the elongate body comprises two pairs of opposed longitudinal grooves located on either side of the channel. The pairs may be spaced by approximately 180 degrees about the periphery of the body or alternatively acutely or orthogonally spaced.

In a second configuration, the elongate body comprises two or more radially spaced longitudinal channels extending through the body for receiving two or more radially spaced internal walls of the corresponding shaft.

Preferably in the second embodiment, the elongate body comprises three radially spaced longitudinal channels. Preferably two radially spaced longitudinal channels are substantially orthogonal or are substantially acutely spaced. Preferably each pair of opposed longitudinal grooves is located on a portion of the outer peripheral wall located between two adjacent channels. Preferably the locking mechanism comprises at least one fastener moveable at an angle relative to a longitudinal axis of the elongate body between a locked position and an unlocked position, wherein in the locked position each fastener engages an associated internal wall of a corresponding shaft being received within a channel of the body to prevent relative movement between the body and corresponding shaft and in the unlocked position each fastener disengages the associated internal wall to allow relative movement between the body and the corresponding shaft. Preferably each fastener is moveable along a transverse axis substantially orthogonal to the longitudinal axis of the elongate body. Preferably each fastener is threadably received within the body for translational movement along the transverse axis. Preferably each fastener is located between each pair of opposed grooves. The locking mechanism preferably comprises one fastener but may alternatively comprise two or more fasteners radially spaced about the periphery of the elongate body.

Preferably the main coupling member further comprises a base section at an end of the elongate body opposing the open end of the at least one internal channel.

In a preferred embodiment the coupling device further comprises a second locking mechanism for locking the base section end of the coupling member to a secondary component of the assembly.

Preferably the base section comprises an open central cavity extending longitudinally through the base section.

Preferably the second locking mechanism comprises:

a locking pin configured to be received within the central cavity at one end and having an opposing end configured to engage against an abutment surface of the secondary component in situ; and

a fastener moveable at an angle relative to a longitudinal axis of the elongate body between a fastened position and an unfastened position, wherein in the fastened position the fastener engages the end of the locking pin received within the central cavity to lock the locking pin in position relative to the body and the surface of the secondary component to thereby lock the coupling device relative to the secondary component and in the unfastened position the fastener disengages the end of the locking pin to enable relative movement between the coupling device and the secondary component. Preferably the fastener is moveable along a transverse axis substantially orthogonal to the longitudinal axis of the elongate body. Preferably the fastener is threadably received within the body for translational movement along the transverse axis.

Preferably the locking pin comprises a tapered groove at the end of the pin received within the cavity and the associated fastener comprises a corresponding tapered end complementary and configured to engage with the tapered groove in the fastened position.

Preferably in the unfastened position the tapered end of the fastener is slightly misaligned or offset relative to the tapered groove such that as the fastener is moved from the unfastened position to the fastened position, a tapered section of the end of the fastener engages and moves along a corresponding tapered section of the corresponding groove to thereby shift the groove into alignment with the fastener end causing the locking pin to shift toward the base section end of the body and force the opposing end of the locking pin into deeper frictional engagement with the corresponding surface of the secondary component.

In a first configuration of this preferred embodiment, the second locking mechanism is configured to lock the base section end of the coupling device to a second structural shaft member. Preferably the coupling device is configured to orthogonally couple the second structural shaft member.

In this configuration, preferably the coupling device further comprises a joining surface at or adjacent the base section. Preferably the joining surface faces away from the elongate body and is aligned with the longitudinal axis of the body. Preferably the joining surface is contoured to correspond to an outer peripheral wall of the second structural shaft member to engage about at least a portion of the periphery of the second structural shaft member. Preferably the joining surface is concave to engage about a corresponding convex section of the second structural shaft member. Preferably the joining surface is configured to engage the second shaft in alignment with a transverse axis substantially orthogonal to a longitudinal axis of the second shaft to thereby enable a substantially orthogonal engagement between the coupling device and the second shaft. Preferably the joining surface is configured to engage about the second shaft at or adjacent an opening along the second shaft.

Preferably the second locking mechanism is configured to enable the joining surface to fix to the second shaft at a plurality of positions along the length of the second shaft in situ. Preferably the locking pin in situ is configured to extend transversely through an adjacent opening of the second shaft and engage an internal wall of the second shaft in situ. Preferably the coupling device further comprises a joining member having the joining surface and being configured to removably couple the main coupling member at the base section. Preferably the joining member comprises a central aperture alignable with the central cavity of the body at the base section for receiving the locking pin therethrough. Alternatively the joining surface is integral with the main coupling member and is part of the base section. Preferably the locking mechanism comprises a coupling block configured to removably fix to the second shaft and to the joining surface to thereby fixedly couple the joining surface to the second shaft. Preferably the coupling block is configured to be fixed to the second shaft in one of a plurality of positions along the length of the shaft. Preferably the coupling block is configured to slidably move along a length of the shaft to locate the block in a desired relative position along the shaft and fix the block in the desired relative position. Preferably the coupling block comprises a pair of opposed tracks configured to slidably receive a pair of opposed skirts extending longitudinally along an opening of the second shaft. Preferably the coupling block comprises a central aperture alignable with the aperture of the joining surface and/or the central cavity for receiving the locking pin therethrough in situ to fix the joining surface to the second shaft.

Alternatively the locking mechanism may comprise an elongate coupling plate configured to removably fix to the second shaft and to the joining surface to thereby fixedly couple the joining surface to the second shaft. The coupling plate may extend along at least a portion of the length of the second shaft and comprises a plurality of longitudinally spaced apertures that are alignable with the aperture of the joining surface to fix the joining surface in one of a plurality of longitudinal positions relative to the second shaft second. The coupling plate may be configured to slidably move along a length of the shaft to locate the plate in a desired relative position along the shaft and fix the block in the desired relative position. The coupling plate may comprise a pair of opposed tracks configured to slidably receive a pair of opposed skirts extending longitudinally along an opening of the second shaft.

In a second configuration of this preferred embodiment the coupling device further comprises a rotatable joint member at or adjacent the base section configured to rotatably couple a corresponding rotatable joint member at or adjacent a base section of a second coupling device and wherein the second locking mechanism is configured to lock the base section of the body to the rotatable joint member. Preferably the rotatable joint member is part of a joint system configured to enable relative rotation between the joint member of the coupling device and the corresponding joint member about one axis, but alternatively about two axes.

In a third configuration of this preferred embodiment the secondary component is a base plate and the locking mechanism is configured to removably couple the base section of the main coupling member to the base plate.

In a fourth configuration of this preferred embodiment the secondary component is a cap element and the locking mechanism is configured to removably couple the base section of the main coupling member to the cap element.

In a second aspect the invention may broadly be said to consist of a structural system for a barrier comprising :

a plurality of substantially hollow longitudinal shaft members, wherein each shaft member comprises:

at least one internal wall extending longitudinal through at least a portion of the interior of the shaft, and

at least one opening along at least a portion of the length of the shaft; and

at least one coupling device, each coupling device having :

a main coupling member having an elongate body with at least one internal channel extending longitudinally therethrough, the channel being open at one end of receiving an interior wall of an end of an associated shaft member, and

a locking mechanism operable to fix the body to the shaft in a locked position and allow insertion or removal of the body relative to the shaft in an unlocked position.

Preferably at least some of the coupling devices further comprise:

a joining surface at one end of the elongate body, the joining surface configured to engage a corresponding outer surface of a second associated shaft member at or adjacent a longitudinal opening of the second associated shaft member; and a second locking mechanism associated with the joining surface for fixing the joining surface in position relative to the second associated shaft member.

Preferably the joining surface is configured to cause the coupling device to substantially orthogonally engage the second associated shaft member to thereby substantially couple the associated shaft member.

In some embodiments the system further comprises one or more base plates each configured to couple a base section of an associated coupling device.

In some embodiments the system further comprises one or more cap elements, each configured to couple a base section of an associated coupling device.

In one embodiment the structural system comprises a plurality of spaced and substantially parallel first shaft members each having a coupling device coupled to a corresponding end thereof, and one or more second shaft members extending substantially orthogonally to the first shaft members and being coupled to the end of the first shaft members via the corresponding coupling devices. Preferably an opposing end of each of the first shaft members comprises a coupling device having a base plate fixed thereto.

In another embodiment the structural system comprises a network of substantially orthogonal shaft members, each coupled substantially orthogonally at one or both ends of the shaft member to another shaft member via an associated coupling device.

Any one or more of the above embodiments or preferred features can be combined with any one or more of the above aspects.

The term "barrier" as used in this specification and claims means any form of physical barrier separating a first region from a second region and includes in its definition structures such as walls, fences, partitions, roofs, ceilings, gates, canopies, handrails, balustrades and the like.

The term "shaft" as used in this specification and claims means an elongate structural member used to form a frame or bracing of a structural system and includes in its definition members such as posts, rails, beams, columns, balusters, extrusions and the like.

The term "comprising" as used in this specification and claims means "consisting at least in part of". When interpreting each statement in this specification and claims that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun. The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which :

Figure 1 shows a first embodiment of a barrier constructed using a structural system of the invention; Figure 2 shows an exploded view of the barrier of figure 1;

Figure 3 shows a close-up view of a junction between a post member and a rail member of the structural system of figure 1 being coupled via a coupling device of the invention;

Figure 4 shows a close-up view of a post member being fixed to a base plate via the coupling device of the invention;

Figure 5 shows a close-up exploded view of an end of a shaft member, a coupling device and a base plate;

Figure 6 shows a close-up exploded view of a pair of shaft member being orthogonally coupled via a coupling device of the invention; Figure 7 shows a perspective view from one end of a first form shaft member having a single longitudinal opening; Figure 8 shows two end perspective view of a first form coupling device corresponding to the first form shaft member;

Figure 9 shows an exploded view of the first form coupling device relative to a second shaft member for orthogonally coupling the second shaft member;

Figure 10 shows a perspective view from one end of a second form shaft member having a pair of longitudinal opening spaced at 90 degrees relative to one another;

Figure 11 shows two end perspective view of a second form coupling device corresponding to the second form shaft member;

Figure 12 shows an exploded view of the second form coupling device relative to a second shaft member for orthogonally coupling the second shaft member; Figure 13 shows a perspective view from one end of a third form shaft member having a pair of longitudinal openings spaced at 180 degrees relative to one another;

Figure 14 shows two end perspective view of a third form coupling device corresponding to the third form shaft member;

Figure 15 shows an exploded view of the third form coupling device relative to a second shaft member for orthogonally coupling the second shaft member; Figure 16 shows a perspective view from one end of a fourth form shaft member having three longitudinal openings circumferentially spaced about the shaft;

Figure 17 shows two end perspective view of a fourth form coupling device corresponding to the fourth form shaft member;

Figure 18 shows an exploded view of the fourth form coupling device relative to a second shaft member for orthogonally coupling the second shaft member; Figure 19 shows a bottom perspective view of a coupling plate of an alternative coupling device embodiment of the invention;

Figure 20 shows a perspective view from one end of the coupling plate of figure 19 partially in situ;

Figure 21 shows a second form barrier built using the structural system of the invention;

Figure 22 shows an embodiment of a structural system of the invention for building a barrier; Figure 23 shows an exploded view of a pair of coupling devices of the invention forming a first form joint;

Figure 24 shows an exploded view of a pair of coupling devices of the invention forming a second form joint;

Figures 25-30 show various embodiments of cap elements configure to couple the coupling device of the invention;

Figure 31 is a close up of two configurations of a locking pin of a locking mechanism of the preferred form coupling device of the invention;

Figure 32 is a simplified cross-sectional schematic of a coupling device of the invention being orthogonally coupled to a shaft member via a preferred form locking mechanism of the invention, with the locking mechanism moving towards the locked position; and

Figure 32 is a simplified cross-sectional schematic of a coupling device of the invention being orthogonally coupled to a shaft member via a preferred form locking mechanism of the invention, with the locking mechanism in the fully locked position. DETAILED DESCRIPTION OF THE INVENTION

Referring to figures 1 to 6, a preferred embodiment of a structural system or assembly for a barrier 100 such as a balcony barrier, a wall, a roof, a canopy, a fence, a partition or the like is shown comprising a plurality of elongate shafts 110, 130 and 210 relatively disposed and connected in a manner to form a frame for the barrier 100. The shafts 110, 130 and 210 in the preferred embodiment are longitudinal, generally hollow, and generally cylindrical extrusions. In alternative embodiments the shafts may have other polygonal cross-sectional shapes. The shafts may be formed from metal, plastics, wood or any other desired structural material relevant to the application.

The shafts may be utilized as post members 110, 210 or rail members 130. In the preferred embodiment the post and rail members are generally of a same or similar nature as will be described. Barrier panels 120 are supported in between pairs of substantially parallel, upright and spaced post members 110. In this embodiment, one end 111, 211 of the post members 110, 210 couples a substantially orthogonal rail member 130 for bracing the post members 110, 210 to help maintain their (preferably uniformly) spaced relationship and for rigidizing the structure 100. A coupling device 150, 250 (see figure 3) is provided between each end 111, 211 of the post member 110, 210 and the rail member 130 for removably connecting the end of the post member to the rail member. The other end 112, 212 of each post 110, 210 comprises a base member 140 for mounting the structure onto a (preferably level) surface. In a preferred embodiment a base plate 140 is provided to each post member 110, 210. Alternatively a single base member 140 may be coupled to more than one post member 110, 210. A coupling device 160, 260 is provided between each post member 110, 210 and the associated base plate 140 for removably connecting the end 112, 212 of the post member 110, 210 to the base plate 140 (see figure 4). The base member 140 may form part of the coupling device 260 in some embodiments.

The various configurations of the shaft members and associated coupling devices that can be utilized to build a structural system such as the one described above will now be described in detail before reverting back to the description of the structural system 100 of the first embodiment.

Referring to figures 7-18 the structural system 100 may utilize any one or more of the following configurations of shaft members and corresponding coupling devices to build the necessary assembly required for the desired application. The general construction of the shaft and corresponding coupling device will be described with reference to the first configuration of figures 7-9.

Each shaft member 110 comprises a hollow interior that is open at either end 111 and 112 of the member 110. In some embodiments the shaft may be open at only one end. The hollow interior may form a single channel running through the longitudinal length of the member 110 or in the preferred embodiment is partitioned into two or more elongate channels 113/114 by one or more inner partition walls or webbing 115 extending radially from a central longitudinal axis toward an inner peripheral wall 116 of the hollow shaft 110. In some embodiments, the shaft 110 comprises at least one channel 113 that is open along at least a portion 113a of the length of the channel for receiving and retaining therein an edge 121 of an associated panel 120 and/or a coupling device 150/160 of the system 100 (herein after referred to as an open channel) - see figures 2 and 3.

Some shaft members 110 may comprise a single open channel 113 for receiving a single panel edge 121 and/or a coupling device 150/160, and some may comprise two or more open channels 113 radially spaced about the periphery of the post member 110 for receiving two or more panel edges and/or coupling devices 150/160. Some shaft members 110 may comprise a channel 114 that is closed along the length of the channel except at one or both ends 111,112 (hereinafter referred to as closed channel). In the preferred embodiment, along the opening of at least one of the open channels 113 of each shaft member 110, is a pair of opposed projections, rails or skirts 117 extending inwardly into the hollow shaft from the inner peripheral wall 116 of the post member 110 and adjacent either edge of the opening 113a of the channel 113. In the preferred embodiment, a pair of opposed skirts 117 are formed along each opening 113a.

One or more shaft members 110 may be associated with a coupling device 150 having a coupling member or spigot 151. The coupling member 151 is receivable within one of the ends 111, 112 of the shaft member 110. The coupling member comprises a substantially elongate body 151 extending from a base section 153 of a substantially larger diameter. The body 151 is configured to be received within the hollow interior of the shaft 110 at the associated end 111/112. The elongate body 151 comprises an outer peripheral wall 152 having a shape and/or profile that is substantially similar and/or complementary to a shape and/or profile of the inner peripheral wall 116 of the associated shaft 110. In the embodiment shown, both the coupling device 150 and the shaft 110 are generally cylindrical with the shaft 110 having an inner diameter at its ends 111 that is substantially the same as the outer diameter of the elongate body 151 to thereby form a close friction fit between the coupling device 150 and the shaft 110. Furthermore, the end 111/112 of the shaft 110 and the elongate body 151 comprise complementary formations for assisting in the frictional engagement of the two parts and for enabling a multichannel post member construction. The base section 153 comprises an outer diameter that is substantially larger than at least an inner diameter of the hollow post member at end 111/112 (but preferably larger than an outer diameter of the post member at end 111/112) to thereby form an abutment surface 153a for the terminal end 111/112 of the post member to rest against and to restrict further insertion of the elongate body into the hollow end 111/112.

The elongate body 151 comprises one or more channels 154 that extend radially from a central longitudinal axis to the outer peripheral wall 152 of the body 151. Each channel 154 is sized and shaped to receive therein a complimentary inner partition wall 115 of the corresponding shaft 110 as the elongate body 151 is inserted into the substantially hollow end 111/112. Each channel 154 is open at the end distal from the base section 153 to receive the inner partition wall 115 of the shaft 110. It will be appreciated that the number and orientation of inner channels 153 corresponds to the number and orientation of the inner partition walls 115. In the embodiment shown, the shaft 110 comprises a single partition wall 115 extending diametrically through the center of the member shaft 110. The corresponding coupling device 150 therefore comprises a complementary single channel 154 extending diametrically through the center of the coupling device. In other configurations, shown in figures 10-17 for example, the shaft may comprise two or three channels separated by two or three angled partition walls and the elongate body of the corresponding coupling device may also comprises two or three similarly angled channels for receiving the inner partition walls there through. Each channel preferably is open along at least one side of the channel (more preferably at each intersection between the channel and the outer peripheral wall 152 of the body 151) to create a longitudinal opening along the outer peripheral wall of the body for sliding the corresponding inner partition wall therethrough.

The pair of elongate skirts 117 of the shaft is configured to be received within a complementary pair of opposed elongate recesses 157 formed in the outer peripheral wall 152 of the elongate body 151 of the corresponding coupling device 150. As above, the number and location of elongate recess pairs 157 formed along the periphery of the elongate body 151 corresponds to the number of open channel 113 having elongate skirt pairs 117 of the corresponding shaft 110. In this embodiment, the shaft 110 having a single open channel 113 comprises a single pair of skirts 117 at either edge of the opening 113a of the channel 113. Similarly, the associated coupling device 150 comprises a single pair of elongate recesses 157 formed longitudinally along the outer wall of the body member 151. During assembly, the elongate skirts 117 are longitudinally aligned with the corresponding pair of elongate recesses 157 and slidably received there through, at the same time as the inner partition walls 115 are slidably received through the aligned inner channels 154 of the corresponding coupling device 150.

The coupling device 150 further comprises a locking mechanism operable between a locked position in which the body 151 can be fixed to the corresponding shaft 110 and an unlocked position in which the body 151 can be moved relative to the shaft to insert or remove the body from the shaft. The locking mechanism comprises a fastener 156 threadably retained and moveable within the body 151 at an angle relative to the longitudinal axis of the body 151. Preferably the fastener 156 is retained and reciprocally movable along an axis substantially orthogonal to the longitudinal axis of the body 151. The fastener 156 may be receivable and moveable within the body 151 via a suitable encapsulated nut (shown exploded out of the body in figures 8 and 9 - this nut may take on any suitable shape or form) or in any other suitable manner. To secure the body 151 in place, the fastener is moved from an unlocked position to a locked positon in which the fastener 156 protrudes from one of the channels 154 and abuts against a corresponding partition wall 115 of the shaft 110. To release the coupling device 150 from connection with the shaft, the fastener is moved into the unlocked position where it disengages the partition wall 115. The fastener 156 may be rotated between the unlocked and locked positions and vice versa, via a suitable tool such as a hex key for example. The locking mechanism may comprise two or more fasteners 156 circumferentially spaced about the body 151 as shown in other configurations, however this is not necessary and any one of the configurations described may contain a single fastener.

The coupling device 150 may further comprise or is associated with a second locking system, assembly or mechanism for coupling the shaft member to any one or more other structural components of the system. The coupling member 151 of the coupling device 150 is configured to longitudinally couple the associated shaft member 110. The second locking mechanism, system or assembly is configured to fix the coupling member 151 to another secondary component of the structural system to thereby join the shaft to that other component. That other component for example may be a base plate, another shaft, a rotatable joint member or a cap element as will be described in further detail below. Referring to figures 31-33 the second locking mechanism is preferably associated with the base 153 of the coupling device to thereby couple the base of the device to the secondary component. In figures 32 and 33 the components and function of the second locking mechanism are illustrated as part of a joining system for perpendicularly coupling a first shaft 110 associated with the coupling device to a second shaft 110a. However, it will be appreciated that the same or a similar locking mechanism can be used to fix the coupling device to another component.

The second locking mechanism may comprise one of two forms of locking pins 145a or 145b. A first locking pin type comprises a threaded end 146b whereas a second locking pin type comprises a non-threaded end 146b. An opposing end of both types of locking pins 145a/b comprises a groove 146a. The groove 146a is tapered for receiving a corresponding tapered end 147a of a fastener 147. Each type of locking pin is suitable for a particular type of joining system, mechanism, assembly and/or secondary component. The groove end 146a is configured to be received within a central cavity 155 extending longitudinally through the base section 153 of the coupling device 150 in situ. The end 146b of the locking pin is configured to protrude from the coupling device 150 to abut and frictionally engage a corresponding surface on the secondary component. In the embodiment shown, the end 146b engages an inner partition wall 115a of the second shaft 110a. The end 146b of the wall may be shaped to complement the surface it engages. The fastener 147 is moveable along a transverse axis that is at an angle, and preferably that is substantially orthogonal, to the longitudinal axis of the body 151 of the device 150. An associated threaded nut 147b may be encapsulated in the body 151 of the coupling device for receiving a threaded length of the fastener 147 and allowing linear movement of the fastener 147 along the associated transverse axis. In this manner, the fastener 147 is moveable between a locked and an unlocked position. In the unlocked position shown in figure 32 the fastener end 147a is separate or distal from the groove 146a of the locking pin 145 and therefore enables movement of the locking pin 145 and coupling device relative to the second component 110a. In the locked position shown in figure 33 the fastener 147 is moved fully home to mate the tapered end 147a with the tapered groove 146a of the locking pin 145 thereby locking the locking pin 145 in position relative to the coupling device 150 and to the second component 110a. In the locked position the outer end of the fastener 147 (opposing the tapered end) lies substantially flush with the outer wall of the coupling member 151.

In the preferred embodiment, the fastener 147, and in particular the tapered end 147a of the fastener, is slightly offset and misaligned by an amount V with the tapered groove 146a of the locking pin 145 when the locking pin 145 is fully inserted inside the cavity 155 of the coupling device 150 and the fastener is in the unlocked position. In particular the fastener is nearer the base section end of the coupling device than the groove 146a in this state. This configuration allows the fastener to achieve a particularly strong frictional coupling between the locking pin 145 and the surface 115a the locking pin is to engage at the opposing end. As the fastener is moved from the unlocked position to the locked position shown in figure 33, the complementary tapered surfaces of the fastener end 147a and the grooved end 146a of the locking pin 145 engage, forcing the grooved end 146a of the locking pin 145 into alignment with the fastener end 147a and thereby shifting the locking pin 145 longitudinally towards the secondary component 110a. This in turn increases the frictional connection between the other end 146b of the locking pin and the corresponding surface 115a of the secondary component 110a. Referring back to figures 7-9 a joining system utilizing the above described second locking mechanism is shown for perpendicularly coupling the associated shaft 110 of the coupling device 150 to a second shaft 110a. It will be appreciated that the second shaft may be any other type of shaft (of figures 10-18 for example) and not necessarily the same as the one coupled to the coupling member 151.

In this embodiment of a supplementary joining system, the coupling device 150 further comprises a mounting member 158 and a coupling block 159 configured to fix the base section 153 of the elongate body 151 to the second shaft 110a. The mounting member 158 is generally cylindrical or alternatively complementary to the cross-sectional shape of the elongate body member 150 and comprises a substantially planar face 158b and an opposed substantially curved, concave face 158a. The concave face 158a comprises a contoured profile that is complementary to a general profile of the outer peripheral wall 118 of the second shaft 110 at or adjacent one of the openings 113a. In use, the concave face 158a is coupled against the second shaft 110a. The concave face 158a preferably extends over and beyond the entire width of the opening 113a. The mounting member 158 further comprises a central aperture 158c extending longitudinally through the mounting member 158. The aperture 158c is configured to align with a central cavity 155 of the base section 153 of the body 151. The central cavity 155 is configured to receive a grooved end 146a of the locking pin 145 of the second locking mechanism described above. An intermediate portion of the locking pin 145 extends through the aperture 158c of the mounting member 158 in situ (as shown in figures 32 and 33). A washer plate 158d may also be provided to rest in between the surfaces 158b and 153b of the mounting member 158 and base member 153 respectively to distribute load in the assembled state as is well known in the art. It will be appreciated that in an alternative embodiment the mounting member 158 may be permanently coupled or integral with the body member 151. For example, the base section 153 may comprise an exposed concave face 158a complementary to the outer periphery 118 of the second shaft 110a .

The coupling block 159 comprises a pair of opposed recesses 159a and 159b on either side for engaging a corresponding pair of skirts 117 along a longitudinal opening 113a of an open channel 113 of the second shaft 110a . One end 159c of the coupling block comprises a substantially convex surface complementary to the generally concave inner peripheral wall 116 of the corresponding second shaft 110a. During assembly, the coupling block 159 is inserted though one of the open ends 111/112 of the shaft 110a at the opening 113a of the open channel 113, by sliding the recesses 159a, b over the skirts 117. The block 159 can then be slidably moved into a desired position along the longitudinal length of the second shaft 110a corresponding to the relative mounting position desired for the first shaft 110. A central aperture 159d is provided through the block 159 for aligning with the central apertures 158c and cavity 155 and for receiving an opposing threaded end 146b of the corresponding locking pin 145 therethrough. The central block preferably comprises an internal thread for threadbaly engaging an external thread 146b at an end of the locking pin 145. In situ, the threaded end 146b of the locking pin 145 is configured to abut and frictionally engage an inner partition wall 115a of the second shaft 110a .

To assemble and connect the coupling device 150 to the second shaft 110a, the coupling block 159 is first slidably moved into the desired relative position along the second shaft 110. The mounting member 158 is then placed with the concave face 158a over the opening 113a of the channel 113 of the second shaft 110a and aligned with the block member 159. The washer is aligned over the surface 158b of the mounting member 158 and then the locking pin 145 is inserted through the washer and threaded into the aperture 159d of the block 159 until an end 146b of the locking pin 145 engages an internal abutment surface of the second shaft 110a. The internal abutment surface can be for example the inner peripheral wall 116 or an internal partition wall 115 or an intersection between two partitions 115. This secures the washer 158d, the mounting plate 158 and the block 159 in a relative position along the length of the second shaft 110a. The body member 151 is then engaged with the locking pin 145 by inserting the grooved end 146a of the locking pin 145 through the central cavity 155 and engaging the base surface 153b with the washer 158d. The fastener 147 is then moved into the locking position to lock the locking pin 145 in place as described above in relation to the second locking mechanism.

A first shaft 110 is therefore substantially orthogonally coupled to a second shaft 130 by first coupling the first shaft 110 to the main body 151 of the coupling device 150, then fixing the coupling device 150 to the second shaft 110a in the desired relative position as explained above.

Referring to figures 19-20 in some embodiments instead of using a coupling block 159, an elongate coupling plate 459 may be provided having similar recessed edges 459a, b as the block along its length, and a curved convex surface 459c on one side. The plate may extend along a portion or an entire length of a corresponding shaft member for example and may comprise two or more apertures 459d along the length of the plate 459 for predefining relative positions and/or spacing between other shaft members (such as posts 110) to be coupled orthogonally to the associated second shaft 110a (or rail 130). In some embodiments the coupling plate 459 may be used as a blanking plate for closing a corresponding opening 413a of an open channel 413 of the associated shaft 413.

Figures 7-9 show a first configuration of a shaft 110 having a single open channel 113 and a corresponding coupling device 150.

Figures 10-12 show a second configuration of a shaft 210 and an associated coupling device 250 where the shaft comprises two open channels 213 having openings that are radially spaced at approximately 180 degrees relative to one another. An inner partition wall 215 extends diametrically through the interior of the shaft to separate the channels 213. Each opening 213a has a pair elongate skirts 217 extending along the length of the opening. A corresponding coupling device 250 comprises complementary recess pairs 257 radially spaced at approximately 180 degrees relative to one another to accommodate the complementary skirts 217 of the shaft 210, and a corresponding channel 254 for accommodating the internal partition wall 215 therein. The coupling device may further comprise a coupling block 259 and a mounting member 258 to couple the shaft 210 to another shaft member 210a (of any type). The coupling device 250 comprises a fastener 256 encapsulated within the body 251 for fixedly connecting the coupling device body 251 to the associated shaft 210 as previously described for the first locking mechanism associated with the previous embodiment. A second locking mechanism containing a locking pin 245 and a fastener at the base 253 (not shown), and an associated joining system 258/259 may be provided for coupling the device 250 to a second component, such as shaft 210a as shown in figure 12. Figures 13-15 show a third configuration of a shaft member 310 and an associated coupling device 350 where the shaft member comprises two open channels 313 having opening that are radially spaced at approximately 90 degrees or less (acutely) relative to one another. An inner partition wall 315 extends diametrically through the interior of the shaft to separate the channels 313. Each opening 313a has a pair elongate skirts 317 extending along the length of the opening. A corresponding coupling device 350 comprises complementary recess pairs 357 radially spaced at approximately 90 degrees relative to one another to accommodate the complementary skirts 317 of the shaft member 310, and a corresponding channel 354 for accommodating the internal partition wall 315 therein. The coupling device may further comprise a coupling block 359 and a mounting member 358 to couple the shaft 310 to another shaft member 310a (of any type). The coupling device 350 comprises a fastener 356 for fixedly connecting the coupling device body 451 to the associated shaft 310 as previously described for other embodiments. A second locking mechanism containing a locking pin 345 and a fastener at the base 353 (not shown), and an associated joining system 358/359 may be provided for coupling the device 350 to a second component, such as shaft 310a as shown in figure 15.

Figures 16-18 show a third configuration of a shaft member 410 and an associated coupling device 450. The shaft 410 comprises three parallel internal channels 413 that are open at either end and along the length of the channel 413a. Each channel 413 comprises a pair of elongate opposed skirts 417 along either edge of the opening 413a. The openings 413a of the channels are radially spaced about the periphery of the shaft 410. The openings 413a may be evenly or uniformly spaced or radially spaced in accordance with any desired relative radial positions. Three internal wall partitions 415 extend radially from the center of the hollow shaft 410 to the inner periphery 316, to separate the three channels 413. The relative angles of the wall partitions 416 determine the relative size and location of the three open channels 413. In the embodiment shown, one of the channel openings 413 opposes a substantially acute pair of adjacent partition walls 415, and the other two channel openings 413 oppose a substantially obtuse pair of adjacent partition walls 415. This results in two substantially larger (having a higher volume) channels and one substantially smaller channel. In alternative embodiments the partition walls 415 may be equilaterally spaces and angled at approximately 60° relative to one another.

A coupling device 450 associated with the shaft 410 comprises three internal and radially extending longitudinal channels 454 similarly disposed relative to one another as the partition walls 415 of the corresponding shaft 410. The coupling device further comprises three pairs of opposed elongate recesses 457 that are complementary to the three pairs of skirts 417 of the corresponding shaft 410. The coupling device may further comprise a coupling block 459 and a mounting member 458 to couple one shaft 410 to another shaft member 410a (of any type). The coupling device 450 comprises a fastener 456 for fixedly connecting the coupling device body 451 to the associated shaft 410 as previously described for other embodiments. A second locking mechanism containing a locking pin 445 and a fastener at the base 453 (not shown), and an associated joining system 458/459 may be provided for coupling the device 450 to a second component, such as shaft 410a as shown in figure 18.

Referring now back to figures 1-6, an embodiment of a structural assembly 100 is built using the above described components. In particular the first configuration shaft 110 is used as edge post members 110 and as an orthogonal top rail member 130, and the second configuration shaft 210 is used as intermediate post members 210. The open channels 113 and 213 of the post members support edges 121 of barrier panels 120 in use. Coupling devices 150 and 250 are provided to orthogonally couple the post members 110 and 210 to the rail member 130.

A second coupling device 160, 260 is provided at the other end of each post member 110, 210 to connect the post members to base plates 140. The coupling devices 160, 260 have a coupling member 161, 261 similar in structure to the coupling members 151, 251 and are therefore configured to couple the ends 112, 212 of the associated post member 110, 210 in the same manner. A secondary locking mechanism as described above for joining the coupling devices 150 to second shaft member 110a is provided to couple the member 161, 261 to the associated base plate 140. In this particular configuration the first type of locking pin 145a shown in figure 31 is used to couple member 161, 261 to the base plate 140. Referring to figure 5 in particular, the base section 163 of the coupling device 160 is configured to be fixedly mounted to a corresponding base plate 140. It will be appreciated that any method well known in the art such as using one or more screws or bolts etc. may be used to fixedly mount the base section 163. In the preferred embodiment, the base section comprises a central cavity 165 through surface 163b configured to abut the base plate 140 for receiving a locking pin 145a. The base plate 140 comprises a central aperture 141 configured to align with the central cavity 165 of the base section 163. In this manner, to fix the coupling device to the base plate, the central aperture 141 and cavity 165 are aligned and the locking pinl45a is inserted through the aperture 141 and the cavity 165 until it abuts a terminal end of the cavity 165. A fastener 147 (not shown in figure 5), moveable at an angle relative to the locking pin , is configured to lock and unlock the pin 145. The fastener 147 is preferably substantially orthogonal relative to the longitudinal axis of the coupling device and extends through the peripheral wall to the cavity 165 within which the locking 145a is located in situ. To secure the coupling device 160 to base plate 140 the fastener is moved to the locked position where the tapered end of the fastener engages the grooved end of the locking pin 145a . To release the coupling device 160 from connection with the locking pin 145a, the fastener 147 is moved into the unlocked position where it disengages the locking pin 145a. The locking pin 145a may comprise a tapered, conical, or otherwise shaped end 146b configured to sit flush with a surface of the base plate 140 in situ.

It will be appreciated that the above coupling device and associated base plate joining system may be used with any other shaft member of the invention.

Figure 21 shows another form of barrier 500 formed using the structural elements of the invention. This embodiment is similar to that of figure 1 except a base plate 140 is coupled at either end of each post member 110 using an associated coupling device 160 and the barrier 500 does not comprise intermediate post members. The post members 110 are single open channel members having a panel retained therebetween to form the barrier. For example, this construction could be used to build a fence. Figure 22 shows an embodiment of a frame 600 for a wall, barrier, canopy or other structure formed from the structural elements of the invention described above. In this configuration, the elongate shafts 110/130 are coupled in a networked manner to form the frame 600. In particular, the frame 600 comprises a pair of rails 630 extending along opposing edges of the frame 600 and one or more spaced posts 610 extending substantially orthogonally therebetween. Each rail 630 may be formed from one or more substantially aligned rail members and each post 610 may be formed from one or more substantially aligned post members as described above. Intermediate rails 640 may be spaced between the outer rails 630 and extending substantially orthogonally to the posts 610. The intermediate rails 640 may each comprise a plurality of rail members, for example each extending between a pair of adjacent post members. Coupling devices 650 are provided at the junction of each orthogonal post and rail member to couple the members as described above. The frame 600 is formed as a two dimensional frame using the post and rail members and associated coupling devices. It will be appreciated that in some embodiments the frame may be formed as a three-dimensional frame by coupling the post and rail members at an angle relative to one another along at least two substantially orthogonal planes. The embodiments shown in figures 7-18 further enable the construction of a barrier system having angled panel elements that extend across three dimensions. In this manner, entire enclosures may be formed using the structural elements of the invention. It is envisaged that in some embodiments the coupling devices described may comprise one or more channels through the body for also receiving an end of a panel of an associated barrier system.

Referring to figures 23-24 another joint system 700 of the invention will now be described. The joint system 700 is configured to be fixedly coupled between the base sections 753 of two corresponding coupling devices 750 to moveably couple the coupling devices 750. In this manner associated shafts can be moveably coupled relative to one another to form a moving frame structure. In the preferred configuration the joint system is a knuckle joint system 700. The joint system comprises a first joint head 710 and a second complementary joint head 720 that are configured to rotatably couple one another. A hinging pin 730 is coupled to each of the first and second joint heads 710, 720 about a common axis to form a hinging axis for the heads 710, 720 to rotate about. Each head 710, 720 comprises a base section 711,721 at one end configured to couple a corresponding base section 753 of the associated coupling member 750. One or more alignment pins 712, 722 may be provided to align the base sections together, however it is envisaged that these are not necessary components. A double eye 713 extends from the base 711 of the first joint head 710 and is configured to rotatably couple a single eye 723 of the associated second joint head 720. The double and single eye sections comprise alignable apertures 714, 724 for receiving the hinging pin 730 therethrough. In the preferred configuration the first joint head 710 comprises a central channel 715 having a substantially arcuate outer profile or envelope and formed between two substantially parallel outer discs or eyes 713. The second joint head comprises a single central disc or eye 723 having a corresponding profile and configured to be rotatably received within the channel 715 of the corresponding first joint head 710. Outer walls 726 extend from the base either side of the central disc 723 to form two outer channels 725 complementary to and configured to rotatably receive the outer discs 713 of the corresponding first joint head 710. A second locking mechanism as described above is provided to each of the joint heads 710, 720 for fixing the joint head to the associated coupling device 750.

Referring to figure 24 in some embodiments a washer plate 717, 727 may be provided for coupling between the base section 711, 721 of each joint head 710, 720 and the corresponding base section 753 of the associated coupling device 750.

The preferred joint system 700 enables rotational movement between the joint heads about a single axis of rotation. In alternative embodiments the joint system 700 may enable rotation about two or more substantially orthogonal axes. For example, the joint system may comprise a swivel joint configuration that is similarly coupled to corresponding coupling devices 150 for rotatably coupling two beam members and enabling relative rotation about two or more substantially orthogonal axes.

Referring now to figures 25-29 embodiments of a cap element 800 of the invention are shown. Similar to the previously described base plate 140, the cap element 800 is configured to couple a base section 153 of an associated coupling device 150 to conceal and provide aesthetic appeal to exposed ends or corners of a frame structure constructed using the previously described structural elements. The cap element may be coupled to the base 153 using any desired locking mechanism comprising a locking pin 810, such as described in relation to the base plate 140 and the coupling device 160. A washer element 820 may be provided between the cap element 800 and the base section 153.

The cap element 800 can take on any three-dimensional shape required to provide the desired aesthetic effect. A non-exhaustive example of various shapes is shown in figures 24-29 where each cap element is formed as a frustum having three or more side faces. For example the cap element 800 may have three (figure 26), four (figure 25), five (figure 29), six (figure 24), seven (figure 28) or ten (figure 27) faces. Other shapes are envisages such as bulbous or cylindrical caps. An aperture 805 having an internal thread may be formed through one or more faces of the cap element 800 for receiving and encapsulating a fastener (not shown) of the locking mechanism to fixedly couple the cap 800 to the locking pin 810.

It will be appreciated that the above described components of a structural system or assembly may be formed from any materials required for the particular application. The shaft members are preferably formed from a metallic material, but alternatively may be formed from a rigid plastics material. The coupling devices are preferably formed from a rigid plastics material such as a thermoplastic, but in alternative embodiments may be formed from metal or other suitable rigid materials.

The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention as defined by the accompanying claims.