Engineered fence panels and process

A system and methods for manufacturing and constructing a fence panel or pickets using engineered wood products, including, but not limited to, oriented-strand board (OSB), fiber strand, or laminated strand lumber. An entire piece of durable, treated engineered wood panel is divided into multiple “fence blanks” of equal size. Each fence blank is then subjected to edge profiling on top and bottom edges, and top feature milling to create fence top features, with finishing, texture, printing, paper overlay, or combinations thereof, added to one or both faces of the blank. Blanks may be milled in a stack. Blanks may then have grooves or other finishing features added to create a finished fence panel. Alternatively, a fence blank can be slit or cut into multiple raw pickets, also with finishing treatments to one or both faces, to create a series of raw pickets. The resulting finished fence panel or pickets provide the authentic look and appeal of real wood, but with the advantages of treated engineered wood.

FIELD OF INVENTION

This invention relates to a system for an engineered fence panel comprising engineered wood components.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In various exemplary embodiments, the present invention comprises a system for constructing a fence panel or pickets using treated engineered wood products, including, but not limited to, oriented-strand board (OSB), fiberboard, laminated strand lumber (LSL), plywood or laminated veneer lumber (LVL). Engineered wood products provide the authentic look and appeal of real wood, but with the advantages of treated engineered wood. With the present invention, an improved fence can be assembled more quickly and cheaply than with any prior art materials, and the fence will be higher quality, with longer life, thinner and lighter, and minimal maintenance.

As seen inFIG. 1, the process begins with an entire piece of durable, treated, or premium grade engineered wood panel20, which comes out of a line press10with a wood texture or other texture (e.g., screen, smooth, cedar, or the like) on one or both faces of the panel. The panel also may or may not have a paper overlay on one or both faces. The paper overlay may be treated with resin or resin-impregnated, or may be primed. In the embodiment shown, the panel is approximately 8 feet by 24 feet in dimension, although the panel may be other sizes as well.

The panel then is sawn by one or more saws into multiple equal sections or “blanks”30. Where the panel is approximately 8 feet by 24 feet in dimension, the blanks may be four blanks approximately 6 feet by 8 feet in dimension (seeFIG. 1), or eight blanks approximately 4 feet by 6 feet in dimension (seeFIG. 2). The number and orientation of the blanks as cut may be based on the wood grain orientation in the panel. For example, the blanks may be cut so that the wood grain orientation with respect to the long side of the panel is maintained with respect to the long side of the blanks. The opposite orientation may be desired for some applications. Each blank is then subjected to further processing, as described below.

In one embodiment, where the blank30is intended for ultimate use as a finished fence panel50, the fence blank is sent to a milling machine or notching saw46, which mills one edge of the blank to create a top fence line (e.g., a series of notches, indentations, grooves, dog ears, curved ends, and the like as the top feature). In several embodiments, the fence blanks are aligned and stacked, and are then processed by the milling machine as a stack (i.e., the top fence line cuts are made to all blanks in the stack). In one embodiment, up to 90 blanks are processed as a stack. This provides greater efficiency in processing of the blanks.

Additional finishing or texture may be added to the face(s) of the blank as well (e.g., a saw or groove machine48may be used add lines or grooves in one or both faces of the blank to simulate pickets or other surface features). The resulting product is a finished fence panel50ready for installation.

Edge profiling may also be performed (at variable points in the process) on the top edge (i.e., what will be the top edge), to achieve a desired cross-section profile (e.g., a round or angled profile to promote water run-off, a watershed, a drip edge, or a desired aesthetic effect), as seen inFIGS. 3 and 4. While a square cut may be used, edge profiling also may be performed on the “bottom” edge (with the bottom edge trimmed as needed during installation to maintain an even top line). In one embodiment, the edge profile is at a 22-degree angle with respect to the edge plane or the face plane. Edge profiling may be performed on the blank prior to or after milling of the top features, and may be on some or all edges of the top feature.

Where the blank is intended for ultimate use as a plurality of fence pickets, the blank is sent to a slitting machine82and/or multiple saw or gang saw line84where the blank is cut into a number of long raw pickets80. All pickets from a blank may be cut simultaneously. The sides of the raw pickets generally extend downward from the corresponding low points in the milled top feature, with the long side of the picket aligned with the long side of the blank. In several embodiments, the raw pickets are 6 inches to 12 inches wide, and 6 feet in length. The raw pickets80are then directed to a milling machine86, where one end of each picket is milled as described above to create a top feature. Additional finishing or texture may be added to the face(s) of the pickets (or blank, pre-cutting) as well, and the top edge(s) may profiled, as described above. The resulting product is a number of finished fence pickets90ready for installation.

FIG. 2shows an alternative manufacturing line sequence. In this example, the panel20is sawn into eight 4′ by 6′ panels. Edge profiling144of each panel may then be performed. Panels may then be stacked and processed by a milling machine146to create a top fence line (e.g., a series of notches, indentations, grooves, dog ears, curved ends, and the like as the top feature), as described above, on the panels in the stack. After milling, each blank is then subjected to further processing, depending on the desired end product. Where the end product is a finished fence panel, the panel is processed by a groove machine or saw148to add vertical groove lines or other additional finishing or texture on one or both faces, as described above. Where the end produce is a set of finished fence pickets, the panel is then processed by a saw line84which saws the panel into a series of raw pickets which are then subject to finishing86, as described above.

Accordingly, the present invention provides an exterior fence with enhanced durability, weather-resistance, fade resistance, and aesthetics at a lower cost and faster installation as compared to prior art fences and materials.