Abstract:
A plastic extruded building material component formed as a hollow sleeve for fitting over a picket fence or rail component. The building material component is profile extruded to have texturing and color streaking to simulate a wood building material. A unique mechanism for dispersing and melting the streaking and texturing agents is provided for extruding the product.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to the field of building material components and particular for plastic material used for fencing, decking and other applications.  
       BACKGROUND OF THE INVENTION  
       [0002]     Traditionally, wood has been used as the primary structural and decorative component for fencing, decking and other applications. While wood has proven to be an acceptable material for these purposes, it does have drawbacks. Chief among these drawbacks includes the susceptibility to environmental degradation, such as weathering, ultra violet degradation, moisture and other damage. Also, wood is susceptible to rot, insects, fire and other types of damage. Frequent treatment, such as painting, staining, and other care is necessary to minimize the damage to wood products, particularly those used in outdoor applications.  
         [0003]     Plastic components are now becoming more accepted as a substitute for wood components in these applications. These plastic components typically are formed from polyvinyl chloride (PVC) or acylonitrile butadiene styrene (ABS) polymers. These types of plastic do not have sufficient rigidity, so they are often formed with an aluminum or steel channel inside the component. These plastic components fail to achieve the aesthetics of the actual wood components and are either flimsy, or if reinforced with metallic components, are heavy and difficult to cut and install.  
         [0004]     Another issue with the prior plastic components is their longevity and maintenance. Even though these components are formed from plastic, they still degrade over time and exposure to the environment. These materials do not have good cold weather characteristics, which can create costly repairs.  
         [0005]     These prior plastic components also do not have the appearance of a traditional wood material. These plastic materials fail to provide the appearance and texture of a wood material. Attempts have been made to simulate wood grain by embossing or other mechanical treatments of the surface of the wood but these fail to provide a realistic wood grain appearance.  
         [0006]     Another problem encountered with fencing and/or decking components is the difficulty in the installation process. Most typical plastic components and even wood component fencing systems require professional installation. While there are modular or kit systems presently available, these tend to be awkward to install and even then do not provide the aesthetics of a wood fencing system.  
         [0007]     Typical wood and plastic fences also have issues with repair of damage to the components. This normally requires the replacement of the entire component which may not even be available at that time. Also, the style of the fence may need to be updated as time passes. Often the house may be remodeled or updated and the surrounding fence may not longer be aesthetically compatible. This becomes an expensive process if the entire fence is to be replaced periodically.  
         [0008]     Another common problem with fencing is the cost. The cost of most composite fences may be quite prohibitive, particularly compared with wood, polyvinylchloride or structural metallic components that may already be in place.  
         [0009]     Thus a problem exists with the installation, replacement or refurbishing of fence systems.  
       SUMMARY OF THE INVENTION  
       [0010]     The present invention solves these problems and others by providing a sleeve component for fencing material components that has the appearance of a wood material. This allows the building material component to be used in applications that traditionally have used wooden components, such as pickets for picket and rail fences, decking and other uses.  
         [0011]     The fencing component of a preferred embodiment of the present invention includes a sleeve component. This sleeve component has an internal dimension that enables it to be mounted over less expensive, more rigid structural components, such as metal rails, dimensional lumber or existing fence components.  
         [0012]     In a preferred embodiment of this invention, the sleeves are formed of a durable, stable plastic material that has the look and texture of a wood material. This enables it to be used in place of wood components that may be susceptible to environmental degradation and that may be more expensive to install and keep maintained.  
         [0013]     The building material component of a preferred embodiment of the present invention is formed from a material that can be extruded into a desired shape, such as a picket, plank or other structural or decorative component. The material has the characteristics of being color and UV stable regardless of the exposure to the environment. In a preferred embodiment, polyethylene is used to provide these characteristics as well as exceptional cold weather impact strength.  
         [0014]     The building material component of a preferred embodiment has texture on the outer surface to simulate that of a wood material. The texture is uniquely created during the extrusion process. An agent, such as a blowing agent, is added during the extrusion process having a different melt temperature than the base material. This causes the texture to be created in the plastic material.  
         [0015]     Color streaking is also created during the extrusion process. Coloring agents are added during the extrusion process. The coloring agents have different melt temperatures or viscosities relative to one another and to the base material. This causes streaking to occur in the plastic material.  
         [0016]     A uniquely designed extruder screw is used during the extrusion process to control the rates and dispersion of the streaking agents, the coloring agents and the base material. The use of this unique extruder screw forms the component in a unique fashion to provide a simulated wood product.  
         [0017]     The building material component of the preferred embodiment of the present invention is extruded in the shape of a picket for use in a rail and picket fence assembly. The pickets, rails and posts are assembled through the use of unique fastening mechanisms. The assembled fence has the appearance of a traditional wood fence without the required maintenance and upkeep of the wood fences.  
         [0018]     These and other features of the present invention are evident from the ensuing detailed description of preferred embodiments and from the drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a perspective illustration of a sleeve component for a fence of a preferred embodiment of the present invention.  
         [0020]      FIG. 2  is an end view of  FIG. 1 .  
         [0021]      FIG. 3  is a perspective illustration of another sleeve component of a preferred embodiment.  
         [0022]      FIG. 4  is a perspective assembly drawing of the present invention.  
         [0023]      FIG. 5  building material component of a preferred embodiment of the present invention.  
         [0024]      FIG. 6  is a cross-sectional view of the component of  FIG. 6 .  
         [0025]      FIG. 7  is a schematic of a typical molding process.  
         [0026]      FIG. 8  is a side view of a preferred embodiment of an extruder screw for an profile extrusion machine for producing the component of  FIG. 1 .  
         [0027]      FIG. 9  is a perspective view of a fencing assembly section of a preferred embodiment of the present invention.  
         [0028]      FIG. 10  is a detail view of the post and rail assembly of the embodiment of  FIG. 8 .  
         [0029]      FIG. 11  is a detail view of the rail and post assembly of the embodiment of  FIG. 8 .  
         [0030]      FIG. 12  is a view of the fastener of post and rail assembly of  FIG. 10 .  
         [0031]      FIG. 13  is a view of the fastener of the rail and picket assembly of  FIG. 10 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0032]     The present invention, in a preferred embodiment, provides a plastic component system for use in fencing, skirting, barricading and other applications. The present invention also provides a fencing system as well. A preferred embodiment of the present invention is described below. It is to be expressly understood that this descriptive embodiment is provided for explanatory purposes only, and is not meant to unduly limit the scope of the present invention as set forth in the claims. Other embodiments of the present invention are considered to be within the scope of the claimed inventions, including not only those embodiments that would be within the scope of one skilled in the art, but also as encompassed in technology developed in the future.  
         [0033]     The descriptive embodiments provided herein describe a component system for use with fencing as well as other decorative applications. It is to be expressly understood that the components have application in many other uses beyond those described herein.  
         [0034]     A preferred embodiment of the components of the preferred embodiment of the present invention is illustrated in  FIGS. 1-4 . One example of the preferred embodiment includes sleeve  10 . Sleeve  10  is formed of an extruded thermoplastic material as discussed in greater detail below. Sleeve  10  as shown in  FIGS. 1 and 2  includes an exterior surface formed of polyethylene in a profile extrusion process. The use of polyethylene provides a component that is non-degradable and UV and color stable with exceptional cold weather characteristics. The component can be easily cleaned as well. There is little maintenance required once the component has been installed. The fencing system can be easily cleaned with soap and water. Numerous color pigments can be utilized in creating different colors of polyethylene products. In this preferred embodiment, the component is extruded from color pigments in a simulated wood coloration, such as redwood, cedar or other popular wood fencing products.  
         [0035]     The sleeve  10  in this preferred embodiment is used as a rail as shown in  FIGS. 1 and 2  and as shown in  FIGS. 3 and 4 . It can include texturing and streaking as discussed in greater detail below and shown in  FIGS. 1 and 2  or it can be relatively smooth as shown in  FIGS. 3 and 4 . The sleeve can be formed from polyethylene as discussed above, polyvinylchloride or other plastic or composite materials.  
         [0036]     The sleeve  10  itself has insufficient rigidity to act as a structural fence component. As shown in  FIGS. 2, 3  and  4 , the sleeve  10  includes a substantially hollow interior portion  12 . This interior portion includes dimensions that will enable it to be easily mounted over a structural fence component. Structural fence components can be standard sized steel rails, such as three-quarters inch, seven-eights inch, one inch by two inches, two inches by three inches or any other sizes of rails. Also, the structural fence component may be dimensional lumber such as a two by four (actually one and one-half by three and one-half inches), one by four or other sizes of dimensional lumber.  
         [0037]     In use, the sleeve  10  is simply cut to the appropriate length and slipped over the rail, dimensional lumber or other structural fence component  20 . Screws can be used to fasten the sleeve to the component, although if it is cut to the appropriate length, the standard fence mounting hardware will secure it in place. The fence component will provide sufficient rigidity and strength to the sleeve to form an effective fence component. The sleeve in turn will provide an aesthetic wood appearance to the fence. This greatly improves the appearance of a steel, plastic or other non-wood fence while providing a strong, long-lasting fence at a price much less than many existing plastic fence materials.  
         [0038]     In another preferred embodiment, the sleeve  10  is formed of a size that is capable of being mounted over an existing fence. For example, an existing fence formed from PVC (polyvinyl chloride), wood or metal that is no longer the appropriate style or color or that has weathered can be refurbished by slipping the sleeves  10  over the existing rails and/or pickets. This eliminates the need for the purchase of an entire fencing system as well as greatly reducing the labor associated with installing a new fencing system. Instead, the existing rails and pickets are simply removed or partially removed from the fence, sleeves are slipped over these components and the rails and pickets are refastened. The posts may be treated in a similar manner by slipping an appropriate sleeve over the existing post structure. An existing fence can be completely refurbished without great expense.  
         [0039]     Another preferred embodiment of the present invention is illustrated in  FIGS. 5-7 . This embodiment uses an integral picket system instead of the sleeve system discussed above. The structural rail picket  50 , shown in  FIG. 5 , is extruded in a size and shape to be used for a rail fence. It is to be expressly understood that other sizes and shapes of structural and/or decorative components may be used as well under the preferred embodiment of the present invention. The rail picket described herein is intended for descriptive purposes only. The rail picket  50  is approximately ¾ inch or ⅞ inch thick and four to six inches wide and six feet tall.  
         [0040]     In this preferred embodiment, the picket rail  50  is extruded from a thermoplastic material. In this embodiment, the picket is extruded from polyethylene in a profile extrusion process. The use of polyethylene provides a component that is non-degradable and UV and color stable with exceptional cold weather characteristics. The component can be easily cleaned as well. There is little maintenance required once the component has been installed. The fencing system can be easily cleaned with soap and water. Numerous color pigments can be utilized in creating different colors of polyethylene products. In this preferred embodiment, the component is extruded from color pigments in a simulated wood coloration, such as redwood, cedar or other popular wood fencing products.  
         [0041]     A unique feature of the preferred embodiment of the component is the texturing and coloring of the component. During the extrusion process, an agent is injected into the raw material to create a texturing effect on the surface of the picket or other component. The agent melts at a temperature different from the thermoplastic material in order to create the texture in the material. One type of agent that can be utilized is a blowing agent. Blowing agents are normally used to create cellular structure in foam plastics. The blowing agent decomposes or decompresses by heating to create a gas inside the base material to build up a cellular structure. In this embodiment, the blowing agent is used with polyethylene instead to create the textured effect on the surface of the material. Prior components having texturing are formed by embossing or otherwise mechanically treating the material to create the effect.  
         [0042]     The textured surface  52  on the component  50  provides a realistic impression of a wood material. An additional feature that further enhances the appearance of the component  50  is the color streaking in the surface as well. Several streaks of color are provided in the surface of the component  50  to create an impression of wood grain, particularly in combination with the textured surface of the component as discussed above. The streaking in the surface is created in this preferred embodiment by injecting different coloring agents during the extrusion process. Each of the coloring agents has a different melt and/or viscosity. As the extrusion process occurs, the agents move through the molten material at different rates at different times to create the streaking effect.  
         [0043]     In a preferred embodiment of the present invention, the picket or other building material component is able to be extruded having the above characteristics of streaking and texture by a novel profile extrusion process. A typical profile extrusion process is illustrated in  FIG. 7 . The plastic base material is fed through hopper  102  in system  100  into a heated extruder tube. A reciprocating screw  110  transports the base material through the heated tube so to melt the base material. The plasticized material is then fed into an extrusion die  104  to form the product. The present process uses a unique screw  120 , shown in  FIG. 8 , to feed the base material and the texturing and coloring agents in a controlled dispersed rate. Normally the agents are fed into the system at the same rate and heated at the same rate as the base material. The unique screw of the present invention disperses and melts the agents at a different rate in order to achieve the texturing and color streaking of the present invention. The screw  120  includes different screw sections and different slopes of contact surfaces that control the rate of heating and dispersement of the agents.  
         [0044]     The preferred embodiment of the picket  50  also includes features to provide impact strength and sturdiness. As shown in  FIG. 6 , the picket  50  has a relatively hollow core  56 . A series of spaced ribs  60 ,  62 ,  64 ,  66  extend longitudinally through the core  56 . These ribs create a rigid structure that not only minimizes compression of the surfaces of the picket  50  but also provides torsional stability.  
         [0045]     In use, the picket  50  is used for fencing, although it may be used in different forms for other uses, such as skirting, barricading, siding and other applications. As shown in  FIG. 9 , the pickets  50  are attached to rails  90  to form a section of fencing. It is to be expressly understood that other styles of fence could be created as well under the present inventive concept. The fencing section as shown in  FIG. 9  is intended for descriptive purposes only and not to limit the scope of the claimed invention.  
         [0046]     In the preferred embodiment illustrated in  FIGS. 9-13 , the fencing section includes pickets  50 , rails  70 ,  72 ,  74  and posts  80 ,  82 . The posts  80 ,  82  are secured in bases  60 ,  62 , such as concrete or other materials, that are mounted or formed in the ground. The posts  80 ,  82  may be manufactured from 16 gauge galvanized steel, or from wood or any other suitable material with the sleeves  50  slipped over them. Alternatively, the posts  80 ,  82  may be an integrated post formed as discussed above with the plastic coated over the steel or wood material. Post caps  84  are mounted over the tops of the posts  80 ,  82  to prevent moisture from collecting inside the posts as well as for providing aesthetic appeal. The post caps are formed from a resilient u/v resistant plastic material to stretch over the post and secured by a bead of silicon adhesive.  
         [0047]     Rails  70 ,  72 ,  74  are attached to the posts  80 ,  82  as illustrated in  FIGS. 10 and 11 . These rails may be made from the above-described material, wood, or any other suitable material and construction. The polyethylene coated galvanized steel rails  70 ,  72 ,  74  include slots  76  stamped in the ends of the outer surface of the rails  40 ,  42 ,  44 . Screws  120  (shown in  FIG. 12 ) are secured through the inner surface of the rails to the posts  80 ,  82 . The screws  120  in the preferred embodiment include self tapping threads  122  having a rubber washer  124  for sealing against the head  126  of the screw and the rail surface.  
         [0048]     Rail caps  78  are secured over the ends of the rails  70 ,  72 ,  74  as shown in  FIG. 9 . The rail caps  78  are formed form a resilient plastic material so that they can be either pulled back or slit for clearance over the end of the rail to allow the screws  120  to attach the rails to the posts.  
         [0049]     The pickets  50  are attached to the rails  70 ,  72 ,  74  by screws  130  (shown in  FIG. 13 ). The screws  130  have a self tapping thread  132 . The spacing of the rails is to be a maximum of 6″ above and below the top and bottom rail. The screws  120  and  130  are preferably zinc or stainless steel. In a preferred embodiment, the screws are secured through holes formed in the rails and pickets. Screw plugs formed from the polyethylene material in the color of the rails and pickets are then secured in those holes. This provides a uniform and aesthetic look for the fences.  
         [0050]     The assembled fence section as shown in  FIG. 9  allows additional sections to be assembled and interconnected by the use of rails  70 ,  72 ,  74  extending from the posts to form an additional section. The use of pickets  50  provide an aesthetic look that resembles a wooden picket fence yet does not require the maintenance of an actual wood fence.  
         [0051]     It is to be expressly understood that the above described embodiments are not to limit the scope of the claimed inventions. Other embodiments and features are considered to be within the scope of the claimed inventions.