Abstract:
The invention is directed to a fence post and a modular fencing system and method that utilizes same. The fence post has an elongated body having an outer wall and at least one elongated channel defined by said outer wall. The elongated channel has opposing sides and an open front. A fastener guide is defined in the outer wall along a plane that is generally orthogonal to the opposing sides of the component channel. In a further embodiment the component channel includes a lip protruding inwardly from the opposing sides adjacent to the front portion. In a further embodiment the fencing system includes post reinforcement members and rail reinforcement members. In other embodiments a fencing system is provided which includes posts, rails, pickets, screens and spacers that interconnect with the aid of fasteners to define a fence structure.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention is directed to fencing systems and in particular to modular fencing systems.  
       BACKGROUND OF THE INVENTION  
       [0002]     Modular fencing systems are becoming increasingly popular particularly those having components formed of extruded or molded materials such as polyvinylchloride (PVC) or other plastics or composites. Such materials are durable and resistant to rotting or insects. One problem with current modular fencing systems is the manner in which the fencing components are interconnected. Current systems are not adapted for securely fastening the components together in a simple, accurate and aesthetically pleasing way.  
         [0003]     There is a need to improve upon existing fencing system designs in order to simplify their assembly, to allow a variety of design variations from the same set of components, and improve their overall strength. Furthermore, there is a need to improve the manner of securing components together while maintaining a pleasing aesthetic appearance to the finished product.  
       SUMMARY OF THE INVENTION  
       [0004]     In one aspect the invention provides a fence post comprising (a) an elongated body having an outer wall; (b) at least one elongated component channel defined in said body by said outer wall, said component channel having a pair of opposing sides, a back extending between said opposing sides and an open front defined between said opposing sides; and (c) at least one fastener guide defined in said outer wall along a plane that intersects said opposing sides of said component channel.  
         [0005]     In another aspect the invention provides a modular fencing system comprising (a) a plurality of fence posts, each said fence post comprising (i) an elongated body having an outer wall, (ii) at least one elongated component channel defined in said body by said outer wall, said component channel having a pair of opposing sides, a back extending between said opposing sides and an open front defined between said opposing sides, (iii) at least one fastener guide defined along a plane that is orthogonal to said opposing sides of said component channel; and (b) a plurality of rails for extending between adjacent pairs of said fence posts, said rails having a cross-sectional profile that is sized to fit within said component channels.  
         [0006]     In another aspect the invention provides a modular fencing system comprising (a) a plurality of fence posts, each said fence post comprising (i) an elongated body having an outer wall, (ii) at least one elongated component channel defined in said body by said outer wall, said component channel having a pair of opposing sides, a back extending between said opposing sides and an open front defined between said opposing sides, (iii) a lip protruding inwardly from each of said opposing sides of said component channel adjacent to said front; and (b) a plurality of rails for extending between adjacent pairs of said fence posts, said rails having a cross-sectional profile that is sized to fit within said component channels.  
         [0007]     In another aspect the invention provides a fence post comprising (a) an outer wall defining an elongated body having a hollow interior; (b) at least one elongated component channel defined in said body by said outer wall; and (c) an elongated post reinforcement member disposed within said hollow interior, said post reinforcement member defining an elongated channel for nesting with said component channel of said body.  
         [0008]     In another aspect the invention provides a method for constructing a modular fence system composing the following steps: (a) securing elongate fence posts into a ground surface each of said fence posts have elongate component channels with opposing sides and an open front and at least one fastening guide defined along a plane that is orthogonal to said opposing sides of said component channel; (b) positioning rails laterally between pairs of fence posts with the ends of said rails being disposed in said component channels; (c) drilling access holes through said fence posts and said rails; (d) drilling pilot holes through at least one side of said component channel and at least one wall of said rails disposed in said component channel; and (e) securing said rails to said posts using fasteners extending through said pilot holes in said component channels and said rails.  
         [0009]     The terms “fence” and “fencing system” as used herein are intended to include all forms of barrier systems having a support member and a spacing member including, without limitation, fence systems, railing systems, noise barrier systems, partition wall systems and the like. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a plan view of a modular fencing system (with caps removed) in accordance with the present invention;  
         [0011]      FIG. 2  is an exploded perspective view of a portion of the modular fencing system identified at  2  in  FIG. 1 ;  
         [0012]      FIG. 3  is a perspective view of a portion of the modular fencing system identified at  3  in  FIG. 1 ;  
         [0013]      FIG. 4  is a sectional view of the assembled components for the modular fencing system as shown along lines  4 - 4  of  FIG. 2 ;  
         [0014]      FIG. 5  is a sectional view of the assembled components for the modular fencing system as shown along lines  5 - 5  of  FIG. 2 ;  
         [0015]      FIG. 6  is a sectional view of the assembled components for the modular fencing system as shown along lines  6 - 6  of  FIG. 2 ;  
         [0016]      FIG. 7  is a sectional view of an intermediate post for the modular fencing system of  FIG. 1 ;  
         [0017]      FIG. 8  is a sectional view of a corner post for the modular fencing system of  FIG. 1 .;  
         [0018]      FIG. 9  is a sectional view of an end post for the modular fencing system of  FIG. 1 .  
         [0019]      FIG. 10  is a sectional view of a blank spacer for the modular fencing system of  FIG. 1 ;  
         [0020]      FIG. 11  is a sectional view of a post element for a modular fencing system in accordance with another embodiment of the present invention;  
         [0021]      FIG. 12  is a sectional view of a post comprising two inter-fitted post elements as shown in  FIG. 11 .  
         [0022]      FIG. 13  is an exploded perspective view of a portion of a modular fencing system in accordance with another embodiment of the present invention;  
         [0023]      FIG. 14  is a sectional view of an intermediate post with reinforcement member for the modular fencing system of  FIG. 13 ;  
         [0024]      FIG. 15  is a sectional view of a corner post with reinforcement member for the fencing system of  FIG. 13 ;  
         [0025]      FIG. 16  is a sectional view of an end post with reinforcement member for the fencing system of  FIG. 13 ; and  
         [0026]      FIG. 17  is a front view of a fence section for the modular fencing system of  FIG. 13  with reinforcement members being shown in phantom outline. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     A modular fencing system in accordance with the present invention is shown generally at  20  in the Figures. The system includes a plurality of elongate posts  22  adapted for laterally supporting a plurality of elongate rails  24 . Additional modular fencing components such as screens  26  and pickets  28  are similarly supported between rails  24  and posts  22 .  
         [0028]     Posts  22 , as depicted in the figures, are generally square in cross section however, posts  22  may instead be round, polygonal, or any other suitable cross-sectional shape. The outer surface of posts  22  may be smooth as shown in the figures, or may be textured such as with a wood grain texture or any other desirable texture that can be formed thereon. As shown, the posts  22  are adapted to be secured in the ground within holes (not shown) that are filled with dirt or cement. Alternatively, the posts  22  may include a base (not shown) that may form a free-standing support or that may be secured with fasteners to a floor, a walkway, a deck or a similar surface.  
         [0029]     Referring to FIGS.  1  to  3 , posts include end posts  22   a,  intermediate posts  22   b,  and corner posts  22   c.  Posts  22  have an outer wall  30  that defines a hollow interior  32  and at least one component channel  34  for receiving rails  24  and component spacers  36 . The hollow interior  32  is adapted to optionally receive a reinforcement member  110  to reinforce the post  22 . More details concerning a fencing system utilizing one or more reinforcement members is described below and shown in  FIGS. 13-17 .  
         [0030]     Component channel  34  has a generally rectilinear profile and is preferably rectangular with opposing sides  38  and a back  40 . Channel  34  has an open front  42  in order to receive rails  24  and spacers  36 . A lip  44  protrudes inwardly from sides  38  adjacent to front  42  for frictionally engaging rails  24  and for slidably supporting spacers  36  within channel  34 .  
         [0031]     As shown in FIGS.  4  to  9 , intermediate posts  22   b  have opposing channels  34  defined along a common central axis C to facilitate construction of a straight section of fencing, corner posts  22   c  have channels  34  defined along orthogonal central axes C to facilitate construction of a right-angled corner section of fencing and end posts  22   a  have a single channel  24  to facilitate construction of an end section of fencing. Alternatively, intermediate posts  22   b  or corner posts  22   c  may be adapted to function as end posts  22   a  and, if desired, a blank spacer  46  may be disposed into channel  24  to provide a more pleasing aesthetic appearance (as shown in  FIGS. 1 and 10 ).  
         [0032]     Referring to  FIGS. 2 and 3 , rails  24  include a screen rail  24   a,  an intermediate rail  24   b,  and a picket rail  24   c.  Intermediate rail  24   b  is only required for dual component configurations such as shown in the figures with one set of fencing components disposed at an upper portion of the fence and another set of fencing components disposed at a lower portion of the fence. It will be understood that various configurations are possible utilizing all or some of rails  24 , pickets  28 , and screens  26 .  
         [0033]     Rails  24  preferably have a hollow interior  48  with an outer wall  50  that defines at least one rail channel  52  for slidably receiving fencing components such as pickets  28  or screens  26 . Rails also may be straight, curved or any other desired shape according to the desired aesthetic design. The hollow interior  48  is adapted to receive a reinforcement member  112  to reinforce the rail  24 . More details concerning the reinforcement member for the rail are described below and shown in  FIGS. 13-17 . Screen rail  24   a  includes a screen channel  52   a  for receiving screen  26  and picket rail  24   c  includes a picket channel  52   b  for receiving pickets  28 . Intermediate rail  24   b  includes rail channels  52  defined on opposing surfaces in order to receive screens  26  and/or pickets  28 . In the configuration shown in the figures, intermediate rail  24   b  includes both screen channel  52   a  and picket channel  52   b.  It could instead include two screen channels  52   a  or two picket channels  52   b  if such configurations are desired.  
         [0034]     Screen rail  24   a,  intermediate rail  24   b  and picket rail  24   c  may be interchanged to support alternate configurations of fencing components. For instance, if only a picket fence configuration is desired then two picket rails  24   c  are utilized with picket channel  52   b  of the upper picket rail  24   c  extending downwardly and picket channel  52   b  of the lower picket rail  24   c  extending upwardly. It is intended that a consumer would purchase only those posts  22  and rails  24  required to produce the configuration of fencing product desired.  
         [0035]     Referring to  FIGS. 5 and 6 , spacers  36  are preferably substantially hollow with an outer wall  54  that defines a spacer channel  56  for receiving pickets  28  or screens  26 . Thus, a screen spacer  36   a  may include a screen channel  56   a  for receiving screens  26  and a picket spacer  36   b  may include a picket channel  56   b  for receiving pickets  28 . Spacer channels  56  have a width W that is slightly narrower than the width w of the corresponding screens  26  and pickets  28 . Spacer channels  56  have sides  58  that are sufficiently resilient that the sides  58  will deform to receive and support the corresponding screen  26  or picket  28  under compression.  
         [0036]     Referring to  FIGS. 2 and 3 , caps  60  are provided to fit snugly over the top of posts  22  to cover the hollow opening and provide a pleasing aesthetic appearance to the fence. Caps  60  include an outer wall  62  that is adapted to snugly fit over outer wall  30  at the top of posts  22  without the need for fasteners to secure the cap in place.  
         [0037]     Referring to  FIGS. 7-9 , fastener guides  70  are defined in outer wall  30  of posts along a plane F that is generally orthogonal to sides  38  of channels  34 . Fastener guides  70  are preferably defined as an elongate groove extending along the length of the posts. The guides  70  may have a v-shaped or a u-shaped profile as shown in the figures or it may have a different rounded or rectilinear profile if desired.  
         [0038]     Fastener guides  70  are provided to facilitate alignment of a drill bit (not shown) to drill an access hole  72  in outer wall  30  of posts  22  and a pilot hole  74  in sides  38  of channels  34  and rails  24  for receiving fasteners  76 . Fasteners  76  may be self tapping screw fasteners as shown or may be any other form of suitable fastener such as bolts, nails or the like. Access hole  72  is preferably formed with a diameter D that is slightly larger than the widest diameter of fastener  76 . Pilot hole  74  is preferably formed with a diameter d that is slightly smaller than the narrowest diameter of fastener  76 . Thus, during installation, access holes  72  would first be drilled at desired locations through outer surface  30  of posts  22  and then pilot holes  74  would subsequently be drilled in alignment with access holes  72  through sides of channels  34  and rails  24 . While it is preferable that fasteners  76  are countersunk within posts  22 , it is contemplated that fasteners  76  may instead be secured to posts  22  such that the head of the fastener is engaged against the outer surface of post  22  (thus avoiding the need of forming an access hole  72  for counter-sinking the fasteners  76 ).  
         [0039]     It is contemplated that a single fastener  76  would be extended through both sides  38  of channels  34  and rails  24  (or other fencing components disposed therein). Alternatively, a first fastener  76  may be secured through a single side  38  of channel  34  and rail  24  with a second fastener  76  being secured through the opposing side  38  and rail  24  if desired (this configuration is not shown).  
         [0040]     As shown in  FIG. 4  it is preferable that fasteners are secured at least through rails  24  in order to securely fasten rails  24  and posts  22  together. It is further preferred that a pair of fasteners  76  are used to secure each rail  24 . Provided that rails  24  are firmly secured to posts  22 , it is not necessary, although possible if desired, to secure fasteners  76  through spacers  36 , pickets  28  or screens  26 .  
         [0041]     Once fasteners are secured, plugs  78  may then be inserted into access holes  72  to snugly cover the opening to deter water or other materials from entering the post and to provide a pleasing finished appearance to posts. Should it be necessary to dismantle the fencing components, such as for instance, to replace a broken rail  24  or picket  28 , plugs  78  may be removed and fasteners  76  may be accessed.  
         [0042]     Referring to  FIGS. 11 and 12 , an alternative embodiment of post  22  is depicted with like reference numerals referring to like elements described above. In this embodiment, post  22  comprises a pair of post elements  100  that are identical in profile and that include nesting elements  102  that allow post elements  100  to be secured together either by way of slidable insertion, or by way of snap-fit insertion. Nesting elements  102  include first shoulders  104  that engage second shoulders  106  to facilitate post elements being secured together. First shoulders  104  further include a tapered wall  108  that facilitates a snap fit engagement between corresponding post elements  100 .  
         [0043]     Referring to  FIGS. 13-17 , an alternative embodiment of a fencing system  20  is depicted with like reference numerals referring to like elements as described above. In this embodiment, one or more of the posts  22  are reinforced with post reinforcement members  110  and one or more of the rails  24  are reinforced with rail reinforcement members  112 . For instance, for the section of fencing depicted in  FIG. 13 , screen rail  24   a  and picket rail  24   c  are each reinforced with corresponding rail reinforcement members  112 . A rail reinforcement member  112  may also be disposed within intermediate rail  24   b  if additional reinforcement is desired.  
         [0044]     Referring to  FIGS. 14-16 , post reinforcement member  110  is configured to fit closely with component channels  34 . Accordingly, for an intermediate post  22   b  configuration, post reinforcement member  110  includes opposing side walls  114  spanned by opposing back walls  116 . Side walls  114  and back walls  116  are sized to fit closely with sides  38  and back  40  of component channel  34 . A channel  118  is defined between side walls  114  and back walls  116  to accommodate an additional reinforcing bar (not shown) if desired. Since post reinforcement members  110  are adapted to be embedded in the ground (or secured to a base member) an additional reinforcing bar is not believed to be necessary.  
         [0045]     A similar configuration of post reinforcing member  110  may be used for an end post  22   a  as shown in  FIG. 16 .  
         [0046]     For a corner post  22   a,  as shown in  FIG. 15 , the post reinforcing member  110  comprises back walls  120  that are adapted to be arranged generally parallel to the opposing back walls  40  of the component channels  34 . Post reinforcing member  110  further includes side walls  122  that are disposed at the ends of back walls  120  and that extend perpendicular to the sides  28  of the component channels  34 .  
         [0047]     Similarly, rail reinforcement members  112  are configured to fit closely with the interior surface of rail walls  50 . Preferably, the rail reinforcement members  112  are generally hollow and, in the case where rails  24  are generally rectangular in cross section, will have a corresponding rectangular cross section. The rail reinforcement member  112  used for screen rail  24   a  will have a slightly different configuration then rail reinforcement member  112  used for picket rail  24   c  or intermediate rail  24   b  in view of the size and configuration of rail channels  52 .  
         [0048]     Post reinforcement member  110  and rail reinforcement member  112  are preferably formed from metal (preferably galvanized or coated) where such metal is sufficiently rigid to provide the desired reinforcement along the length of the post or rail. It has been found that a galvanized G90 metal having a thickness of 14 gauge is suitable for most fencing applications. While metal is the preferred material for reinforcement it will be understood that other materials may be utilized including extruded or molded PVC or other plastics or composites having sufficient rigidity.  
         [0049]     Referring to  FIGS. 13-14 , it can be seen how fasteners  76  extend through the walls of reinforcement members  110  and  112  as well as the walls of posts  22  and rails  24 . As described above, access holes  72  and pilot holes  74  are drilled with the aid of fastener guides  70  to facilitate accurate location of fastener  76 . Fasteners are then secured in place and plugs  78  are provided to cover the access holes.  
         [0050]     In use, a fencing system  20  is constructed by first identifying the desired fencing configuration and then selecting the fencing components required to construct the desired configuration. Posts  22 , with post reinforcement members  110  if desired, would be secured into the ground in known manner with end posts  22   a,  intermediate posts  22   b,  and corner posts  22   c  disposed in the appropriate locations with channels  34  located squarely across from channels  34  disposed in adjacent posts  22 . Rails  24 , with rail reinforcement members  112  if desired, would be arranged for placement between posts  22 . Lower rails  24  would be cut if necessary to their desired lengths and disposed between posts  22  in their desired positions. Spacers  36  would be cut if necessary to desired length and disposed in component channels  34 . Intermediate rails  24   b  or upper rails  24  (if no intermediate rails are required) would also be placed into position. Pickets  28  and/or screens  26  are also slidably positioned between rails  24 . Once all of the elements are suitably positioned, access holes  72  are drilled into posts  22  using fastening guides  70  for alignment and pilot holes  74  are drilled into sides  38  of component channels  34 , sides of rails  24  and through the respective reinforcement members  110  and  112  if applicable. Fasteners  76  are then inserted through access holes  72  and through pilot holes  74  to fasten rails  24  and posts  22  together. Plugs  78  are then inserted into access holes  72  to cover openings. Caps  60  are then fitted over posts  22  to complete the construction.  
         [0051]     Although the disclosure describes and illustrates preferred embodiments of the invention, it is to be understood that the invention is not limited to these particular embodiments. Many variations and modifications will now occur to those skilled in the art. For definition of the invention, reference is to be made to the appended claims.