Abstract:
Disclosed is a system and apparatus for reinforcing a fence structure for example, to resist the potentially detrimental forces caused by wind and other environmental factors. An elongate stiffening insert for reinforcing a fence structure is configured to appear in cross section to generally resemble a Z-shape. The stiffening insert fits inside a fence post to reinforce the fence structure. The stiffening insert generally extends below the ground to provide support.

Description:
BACKGROUND  
       [0001]     This disclosure generally relates to a post insert for reinforcing hollow-fence components. This disclosure also relates to reinforced fence structures and methods for reinforcing fence structures.  
         [0002]     Fence structures or railings made of wood or plastic such as, for example, polyvinyl chloride (PVC) are well-known in the art. PVC fencing systems are susceptible to warping, flexing, sagging, or swaying due to environmental conditions such as high winds because, PVC material in elongate, hollow fencing structures, may not withstand strong forces.  
         [0003]     Some fence installers pour concrete into the fence post to prevent sway. However, the concrete-spill on the outside of the post, causes discoloring and scratching. Further, such concrete-filled posts are subject to cracking and splitting of the fence material due to dissimilar expansion or contraction and other damages to the post and the cosmetic surface. Some installers use wood inserts, but wood is relatively expensive.  
       SUMMARY  
       [0004]     The current disclosure, relates to a system and apparatus for reinforcing hollow-fence components. In one embodiment, a stiffening insert for reinforcing fence components includes an elongate portion that resembles a “Z-shape” and fits inside a hollow cavity defined by the fence component, for example, a fence post. The hollow fence components are formed of a plastic or a resin material, such as PVC or other vinyl fencing materials. The angled design of the “Z-shaped” portion enables simpler manufacturing in an economical way and, yet offers substantial resistance to vertical fence post structures against forces, general wear and tear or any other stress.  
         [0005]     In one embodiment, the stiffening insert is formed with openings through which horizontally attached rails can be inserted. The openings may be configured sufficiently elongated along the central axis of the structure to accommodate a range of positions relative to corresponding openings in the hollow fence post structure to allow for horizontal rails to secured to the insert. In one embodiment, the insert is solid without any openings.  
         [0006]     A method to reinforce preexisting fence components includes installing the stiffening component inside the post while mounting the post in the ground. A portion of the stiffening component can extend from the buried end of the post. The extending component may interface with soil, sand, stone, gravel, cement or any other material in which the post is mounted.  
         [0007]     In one embodiment, the stiffening component may not extend the entire length of the vertical post and may extend only a partial distance, for example, three feet in a six-foot post. The stiffening component can be formed of any number of materials, including but not limited to rolled steel. Suitable metal material may be roll formed into the desired shape that resembles a “Z-shape”. The ends of the stiffening component, along the length of the edges, can be beveled so as to engage an internal surface of the post for retaining it in position. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The drawings are provided to illustrate some of the embodiments of the disclosure. It is envisioned that alternate configurations of the embodiments of the present disclosure maybe adopted without deviating from the disclosure as illustrated in these drawings.  
         [0009]      FIG. 1  shows a perspective view of a fence structure having two fence posts with stiffening inserts and three rails. The inserts buried below the surface are shown in phantom.  
         [0010]      FIG. 2  shows a partial fragmentary perspective view of an elongate stiffening insert having a plurality of openings inside the stiffening insert corresponding to openings in the post.  
         [0011]      FIG. 3  shows a top plan view of a stiffening insert and a fence post.  
         [0012]      FIG. 4  shows a top plan view of a stiffening insert with beveled edges and a fence post. 
     
    
     DETAILED DESCRIPTION  
       [0013]     While the present disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, embodiments with the understanding that the present description is to be considered an example of the principles of the disclosure and is not intended to be exhaustive, restrictive in character, or to limit the disclosure to the details of construction, the arrangements of components and methods set forth in the following description or illustrated in the drawings, and that all changes and modifications are incorporated herein.  
         [0014]      FIG. 1  shows a fence structure  10 . The fence structure  10  has a fence post  12  with an upper end  14  and a lower end  16 . The post is generally hollow having a wall  13  defining a cavity  15 . The fence post  12  has a stiffening insert  20  positioned inside the cavity  15 . The upper end  14  of the fence post  12  may be capped or removably covered to allow access for reinforcement. Rails  38  may be associated with the fence post  12  and the stiffening insert  20  through the openings  28  in the fence post  12 . The fence structure  10  is mounted on a surface  40 . The fence post  12  may be a corner post or an end post or an intermediary post in the fence structure  10 . The fence structure  10  may be by way of example, but not limitation, any form of vinyl fence, a picket fence, ornamental fence, and privacy fence.  
         [0015]     As shown in  FIG. 2 , the fence post  12  includes the hollow shell  13  defining the cavity  15 . The stiffening insert  20  has a first portion  22  having a first end  24  and a second end  26 . The second portion  30  of the stiffening insert  20  also has a first end  32  and a second end  34 . The first portion  22  and the second portion  30  are generally parallel to each other. The third portion  36  of the stiffening insert  20  intersects the first portion  22  at its second end  26  and the second portion  30  at its first end  32 . The third portion  36  need not be at right-angle to the first portion  22  and the second portion  30 . For example, the third portion  36  may intersect the first portion  22  at its second end  26  and the second portion  30  at its second end  32 , at an acute angle that is less than 90° (e.g., 75° as in a “Z-shape”) or at an obtuse angle that is slightly more than 90° (e.g., 100°) with respect to generally parallel surfaces.  
         [0016]     The stiffening insert  20  may be formed or configured to provide a snug-fit against an inside surface  17  of the fence post  12  defining the cavity  15 . Alternatively, stiffening insert  20  may be retained inside the fence post  12  with a securing device including, but not limited to latch, brace, nut and bolt, screw, pin, flange, sleeve, collar, adhesive, and adhesive tape. The securing device may be installed externally or can be designed into the fence post  12  or the stiffening insert  20  during manufacturing.  
         [0017]     In an embodiment shown in  FIG. 3 , in an embodiment, the first end  24  of the first portion  22  and the second end  34  of the second portion  30  are beveled  46  and  50  respectively, to generally engage the stiffening insert  20  inside the corners  44  and  48  of the shell  13  defining a cavity  15 . The angled edges  46  and  50  are beveled such that they fit inside the corners  44  and  48  to provide at least some degree of interference or gripping and to at least help retain the stiffening insert  20  in the post  12  and generally prevent or at least resist movement within the cavity  15 . Generally, the beveled edges  46  and  50  can be configured to fit the contours of standard fence posts. Such designs can be integrated into the stiffening inserts  20  during manufacture or can be implemented externally through post-manufacture tooling and designing. Additionally, the insert  20  may be configured with some degree of flexion between the members  22 ,  30 ,  36  so as to provide some degree of adjustment. Such adjustability allows the insert  20  to be used with posts having different internal dimensions or shapes. As such, one configuration of insert  20  may be used with a range of post dimensions and/or configurations. This feature also allows the insert to adjust to irregularities in the post as well as variations in manufacturing tolerances in the post.  
         [0018]     In the embodiment shown in  FIG. 4 , the stiffening insert  20  may be provided with multiple openings  54  positioned along a central axis  19  of the third portion  36 . These openings  54  can be aligned with the openings  28  present in the fence post  12  to engage rails  38  positioned horizontally as shown in  FIG. 1 . The openings  54  are of sufficient dimension to allow a range of access for engaging the rails  38 . Instead of multiple openings  54  on the stiffening insert  20 , a single opening that extends longitudinally along the central axis  19  and is large enough to engage multiple rails  38  can also be designed in to the stiffening insert  20 . This configuration is tolerant of variations in the placement and dimensions of the openings  28  in the post such that the elongated openings  54  along the central axis  19  will be able to align with at least one of the openings  28  in the shell  13 .  
         [0019]     The plurality of openings  54  in the insert  20  may enable securing the insert into a mounting surface  40  such as concrete. The openings  54  may also prevent damages to the insert  20  and/or the shell  13  due to expansion and contraction or any other impediments due to temperature fluctuations. An insert  20  without any openings  54  or a single opening may also withstand expansion and contraction issues due to temperature fluctuations.  
         [0020]     The fence post  12  having a hollow shell  13  defining a cavity  15  may be made of polyvinyl chloride (PVC) and may be manufactured by extrusion molding or by any other standard manufacturing techniques for PVC fence components. Manufacturing of PVC and other plastic components for fence structures are well known in the art. Other suitable fence materials include but are not limited to plastic, chlorinated polyvinyl chloride (CPVC), acrylic, vinyl polymers, and polyethylene. The fence post  12  may have a length and width that generally conform to industry standards for fence components.  
         [0021]     As shown in  FIG. 1 , the insert  20  may be provided with a formed leading end  21 . The leading end  21  is the end which will be imbedded in the construction material, as shown, the ground  40 . The leading end  21  as shown is formed with tapered sides so as to form a point which will help facilitate imbedding the insert  20  into the ground  40 . Other variations of the leading end  21  are envisioned and fully within the scope of this application.  
         [0022]     The stiffening insert  20  may be made of steel. Other suitable materials include but are not limited to galvanized steel, iron, cast iron, aluminum, or an alloy thereof. The stiffening insert of suitable thickness can be manufactured by casting, rolling, or by any other standard metal manufacturing processes. Other suitable materials include for example, reinforced polymer resin, composite material, or any other material that provides resistance to forces. The multiple openings  54  can be provided in the material that is formed into the insert or may be formed into the stiffening insert  20  during the manufacturing. The dimensions of the openings  54  and the spacing of the openings  54  conform to industry standard for fence components or can be determined depending upon the number of horizontal rails  38  desired and their dimensions. The stiffening insert  20  may also be coated with a protective layer such as, for example but not limited to, paint, powder coating, galvanizing, rubber, vinyl coating, or any other protective coating, treatment or layer to prevent corrosion or rust formation.  
         [0023]     A method for reinforcing the fence structure  10  includes the steps of providing fence post  12  having an elongate shell  13  having an upper end  14  and lower end  16  with a plurality of openings  28 . The method further includes providing a stiffening insert  20  having a plurality of openings  54  in the third portion  36  and providing a plurality of rails  38 . The stiffening insert  20  is positioned inside the shell  13  of the post  12 , such that the plurality of openings  28  of the fence post  12  and the plurality of openings  54  of the stiffening insert  20  align. The plurality of rails  38 , through the plurality of openings  28  and  54  in the shell  13  and in the stiffening insert  20  respectively, are engaged to form a reinforced fence structure  10 .  
         [0024]     In an embodiment, the stiffening insert  20  can extend below the mounting surface  40  to provide additional support as shown in phantom in  FIG. 1 . The depth of extension below the ground may depend upon the total height of the fence post  12 , the dimensions of the stiffening insert  20 , the prevailing environmental conditions, and the nature of the mounting surface  40 . For example, in high-wind environments and in a soil-laden back yard, the stiffening insert  20  can extend below ground up to one-third of the height of the fence post  12  that is exposed above the surface. In a paved mounting surface such as, for example, asphalt, the depth of extension may be less. The mounting surface  40  may be soil, gravel, cement, concrete, asphalt, wood, brick, or any other composite material. The fence post  12  along with the stiffening insert  20  can be mounted using standard techniques such as, for example, by burying the post, using a spiked support, using a foundation socket, or a socket with a base plate.  
         [0025]     In an embodiment, the stiffening insert  20  may not extend to the full length of the fence post  12 . For example, the stiffening insert  20  may extend up to three feet in a six-feet long fence post  12 . The length of extension may depend upon the total height of the fence post  12 , the dimensions of the stiffening insert  20 , the prevailing environmental conditions, and the nature of the mounting surface  40 . The length of extension may also depend upon the alignment of openings  54  with the openings of the fence post  28  for engaging horizontal rails  38 .  
         [0026]     Another method for reinforcing a fence structure includes the steps of providing the stiffening insert  20  and manufacturing the shell  13  of fence post  12 , such that the shell  13  encloses the stiffening insert  20 . For example, the first portion  22  and the second portion  30  of the stiffening insert  20  may be molded into the shell  13 .  
         [0027]     In an embodiment, the stiffening insert  20  may also be used to reinforce other fence components such as, for example, rails  38 . As disclosed herein for the fence post  12 , the stiffening insert  20  can be installed inside the rails  38 .  
         [0028]     While embodiments have been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. The applicant has provided description and figures which are intended as illustrations of embodiments of the disclosure, and are not intended to be construed as containing or implying limitation of the disclosure to those embodiments. There are a plurality of advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiments of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods, without undue experimentation, that incorporate one or more of the features and/or steps of the disclosure and fall within the spirit and scope of the present disclosure and the appended claims.