Abstract:
A fencing system and method of manufacturing and installing a fencing system specifically designed to give the appearance of a traditional shadow box or privacy fence, wherein the system uses preformed non-corrosive, structurally sound corrugated panels, posts, posts mounts, channel mounts, and clips that mate and are securable using conventional fasteners.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation-in-part of Ser. No. 09/822,047 filed Mar. 30, 2001. 
     
    
     
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
         [0002]    N/A  
         COPYRIGHT NOTICE  
         [0003]    A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.  
         BACKGROUND OF THE INVENTION  
         [0004]    1. Field of the Invention  
           [0005]    The present invention relates generally to a fence panel and a fence assembly system, and more particularly, to a contoured rust-proof fence panel of symmetrical proportions, fence assembly system having mechanically cooperating parts that incorporate the panels, facilitate convenient fence installation and include linear and curvature designs, and method for making fence panels.  
           [0006]    2. Description of the Background Art  
           [0007]    Wood fences and shadow box designs for wood fences are known in the art. However, weather conditions affect the appearance and structural integrity of wood fences over time. Fences constructed from alternative materials, such as aluminum and plastic based material, are resistant to inclement weather, last longer and easily maintained, but are not available in shadow box or other panel-like designs and can not be easily customized. Rather, the typical aluminum fence comprises a prefabricated railing apparatus having a top and bottom rail and a plurality of posts bridging the top and bottom rails. Other metal fences known include horizontal panels that fit into post slots and various structure for joining vertical panels between two rails. The metal fences known can be difficult to construct, offer little options in design, such as shadow box, privacy designs and curved designs, and are relatively expensive. In addition, they fail to adequately address security issues, such as theft of fence components or sections. If a metal fence device and system could address these gaps in the prior art, such a fence design would be easier and quicker to construct than conventional wood fence designs and would be well received.  
           [0008]    Various fence designs are known in the art, but none of these addresses or solves the above-noted problems associated with metal fence designs and construction. For instance, U.S. Pat. No. 3,963,219 discloses an aluminum fence having a plurality of horizontally disposed panels and a plurality of support posts having slots for receiving the ends of the panels. U.S. Pat. No. 4,306,631 discloses a noise barrier wall and mounting assembly comprising posts, top and bottom girts and a plurality of vertically disposed panels that fit between and within the girts. U.S. Pat. No. 4,312,166 discloses a wall assembly comprising walls having connecting elements that interlock to join adjacent wall panels. U.S. Pat. No. 4,461,461 discloses a non-corrosive security railing comprising a lower railing and upper railing have holes for receiving vertical railing elements, posts formed by laminating a first pipe and second pipe and conventional connectors. U.S. Pat. No. 4,498,660 discloses a modular fence structure comprising modular panels having a rail portion and connector at each end for concentrically mounting over posts. U.S. Pat. No. 4,838,524 discloses a noise barrier system comprising a front corrugated panel, a rear corrugated panel, a central corrugated panel and noise absorbing material separating the panels. U.S. Pat. No. 5,149,061 discloses a panel for road construction comprising a plurality of interlocking panels and a base that mounts to a central road barrier. U.S. Pat. No. 5,301,926 comprises a prefabricated simulated wrought iron fencing system comprising iron fence rails, floor-anchored posts and T-connectors. U.S. Pat. No. 5,628,495 discloses a metal fence structure comprising corrugated panels, lateral stiffeners, posts and fasteners for securing the panel assemblies. U.S. Pat. No. 5,938,184 discloses a plastic fence construction comprising top, bottom and middle rails, channels defined by the rails for receiving panels, posts, and connectors for securing the rails to the posts. The patents found failed to disclose or suggest all the elements of the instant invention, such as C-channels, post mounts, panels and security devices as contemplated by the instant invention.  
           [0009]    As the above noted art fails to provide a fencing system that can be easily installed, is made of a non-corrosive material, provides for a shadow box or privacy fence appearance, has security devices and is structurally durable, there exists a need for such a fencing system. The instant invention addresses this need in the prior art. In addition, the method for making the fence panels and components may be used to prefabricate the fence panels remotely from the job site so panels may be delivered to the job site ready for convenient installation. The instant invention address the foregoing by providing a fencing system as described herein.  
         BRIEF SUMMARY OF THE INVENTION  
         [0010]    Based on the foregoing, it is a primary object of the instant invention to provide a fence system that is constructed for easy installation and method of manufacturing the same.  
           [0011]    It is an object of the instant invention to provide a fence system that is adaptable to multiple linear designs as well as curved designs.  
           [0012]    It is also an object of the present invention to provide a cost effective means for providing and erecting a fencing system.  
           [0013]    It is another object of the present invention to provide a fence system that may be customized for shadow box, curved or privacy designs.  
           [0014]    It is a further object of the present invention to provide a fencing system that can be installed by a person without experience in fence installation.  
           [0015]    It is an additional object of the instant to provide a unique panel design for use in shadow box or privacy fence construction.  
           [0016]    It is yet another object of the instant invention to provide panels that may be interlocked.  
           [0017]    Another object of the invention is to provide a flexible and cost-effective method for manufacturing corrugated fence panels.  
           [0018]    A further object of the instant invention is to provide a method for installing a shadow box or privacy fence using the fence system of the instant invention.  
           [0019]    An additional object of the instant invention is to provide a fence system having security devices for preventing the theft of fence sections or components.  
           [0020]    In light of these and other objects, the fence system of the instant invention preferably comprises a plurality of posts, corrugated panels, post mounts and lateral channel mounts. The posts are secured in the ground at a distance and in a manner that can securely support the weight of the post mounts, channels and panels, as well as external forces. Two post mounts have at least one ledge for attaching the lateral channel mounts and are preferably slid over and secured to the posts proximal the top and bottom of the posts, respectively, using conventional hardware. The lateral channel mounts are secured to corresponding post mounts in a manner that bridges the two posts for receiving the panels. The channel mounts may be straight, curved at a plurality of different radii, or substantially S-shaped to provide a plurality of fence design options. The panels comprise a corrugated construction and substantially symmetrical design and are secured vertically to the channel mounts at predetermined distances using conventional hardware. The panels are preferably constructed from a sheet-like aluminum, with specific bends to create a corrugated look and to allow the installation of a shadow box or privacy fence that is strong, uniform and aesthetically pleasing. The panels can comprise various lengths and widths, heights and looks. The edges of the panels may include a bend or hem across the length of the panel for directly or indirectly interlocking adjacent panels, providing a smooth reinforced edge and facilitating proper panel spacing. Thus, the invention may further include clips for interlocking adjacent panels. The clips may be relatively short or long and wide or narrow to achieve a shadow box or privacy design. The components of the fence panel system are preferably made from a non-corrosive, malleable material such as aluminum, stainless steel, plastic based materials, fiberglass material or alternative materials exhibiting non-corrosive, water resistant and durable characteristics.  
           [0021]    The system and method of the invention provides the installer with an easy to install fencing system designed to meet standard installation requirements. Moreover, the use of the fencing system will save time and money during the installation process. This is an import object of the present invention.  
           [0022]    The instant invention further comprises methods for making the fence panels and installing the fence of the instant invention. The method for making fence panels includes taking a malleable sheet-like material, as described herein, feeding it through a slicer for making multiple panels at once and a series of rollers that create symmetrical corrugated panels with at least two crests.  
           [0023]    The instant invention facilitates the prefabrication of fence panel sections comprising the panels attached to the channel mounts. The preferred method of installation comprises setting the posts in the ground or other surface, mounting the post mounts to the posts and, or attaching a channel mounting clip to a wall surface if starting a section from a wall-like surface. Another method of installation comprises obtaining the posts, post mounts, channels and panels that comprise the system of the invention, securing the post in a ground or floor like surface, securing two post mounts to each post, bridging the distance between the posts with lateral channel mounts secured to the post mounts near each end, resulting in the fence system frame, and securing the panels to the frame with our without a gap there between. The method of installation may further comprise the use of clips for uniformly controlling the distance or lack thereof between the panels and/or to facilitate a shadow box or privacy fence design.  
           [0024]    In accordance with these and other objects, which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0025]    [0025]FIG. 1 is a front perspective view of the preferred embodiment of the fence panel system of the instant invention arranged in a shadow box design.  
         [0026]    [0026]FIG. 2 is a front perspective view of the preferred embodiment of the fence panel system of the instant invention arranged in a privacy design.  
         [0027]    [0027]FIG. 3 is a front perspective view of the preferred embodiment of a fence panel in accordance with the instant invention.  
         [0028]    [0028]FIG. 4A is a plan view of a fence panel system of the instant invention.  
         [0029]    [0029]FIG. 4B is a plan view of another embodiment of the fence panel system of the instant invention illustrating an arcuate fence system.  
         [0030]    [0030]FIG. 4C is a plan view of another embodiment of the fence panel system of the instant invention illustrating an “S-like” structure.  
         [0031]    [0031]FIG. 5 is an end view of the preferred fence panel of the instant invention.  
         [0032]    [0032]FIG. 6 is an end view of an alternative fence panel of the instant invention.  
         [0033]    [0033]FIG. 7 is a front perspective view of the preferred embodiment of the fence panel assembly of the instant invention with the fence panels removed.  
         [0034]    [0034]FIG. 8 is a perspective view of a first embodiment of the post-mount of the instant invention illustrating a ledge projecting from opposite surfaces.  
         [0035]    [0035]FIG. 8A is a perspective view of a first embodiment of the post-mount of the instant invention illustrating a U-Shaped ledge projecting from opposite surfaces.  
         [0036]    [0036]FIG. 8B is a perspective view of a second embodiment of the post-mount of the instant invention illustrating one ledge projecting from a surface.  
         [0037]    [0037]FIG. 8C is a perspective view of a third embodiment of the post-mount of the instant invention illustrating a ledge projecting from adjacent surfaces.  
         [0038]    [0038]FIG. 8D is a perspective view of a fourth embodiment of the post-mount of the instant invention illustrating a ledge projecting from all surfaces.  
         [0039]    [0039]FIG. 9 is a perspective view of the preferred embodiment of the channel mount of the instant invention used with the first embodiment of the post mount.  
         [0040]    [0040]FIG. 9A is a perspective view of the preferred embodiment of the channel mount of the instant invention used with the second embodiment of the post mount.  
         [0041]    [0041]FIG. 10 is an end view of the preferred embodiment of the channel mount of the instant invention used with the first embodiment of the post mount.  
         [0042]    [0042]FIG. 10A is an end view of the preferred embodiment of the channel mount of the instant invention used with the second embodiment of the post mount.  
         [0043]    [0043]FIG. 11 is an elevational view of the preferred embodiment of the first roller of the machine used in the process of making the panels.  
         [0044]    [0044]FIG. 12 is an elevational view of a second roller corresponding to the first roller of the machine used in the process of making the panels.  
         [0045]    FIGS.  13 A- 13 I are end views of the preferred panel at each stage as it is formed in accordance with the instant invention.  
         [0046]    [0046]FIG. 14 is a perspective view of the preferred embodiment of the short clip used in the instant invention.  
         [0047]    [0047]FIG. 15 is a perspective view of the preferred embodiment of the long clip used in the instant invention.  
         [0048]    [0048]FIG. 16 is an end view of the preferred clip used in the instant invention.  
         [0049]    [0049]FIG. 17 is an end view of the preferred cap used in the instant invention.  
         [0050]    [0050]FIG. 18 is an end view and tabular depiction of the relative section sizes and angles of the preferred panel of the instant invention.  
         [0051]    FIGS.  19 A- 19 I are elevational illustrative views of the roller dies shaping panels ( 19 A- 19 D and  19 I) and the cam dies ( 19 E-H) in accordance with the preferred embodiment of the instant invention.  
         [0052]    [0052]FIG. 20 is a perspective view of a U-shaped channel support for use in lieu of the post mount in accordance with an alternative embodiment of the instant invention.  
         [0053]    [0053]FIG. 21 is a plan view of the security post rod used in the security system in accordance with an alternative embodiment of the instant invention.  
         [0054]    [0054]FIG. 22 is a perspective view of the security channel rod used in the security system in accordance with an alternative embodiment of the instant invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0055]    With reference to the drawings, FIGS.  1 - 22  depict the preferred and alternative embodiments of the instant invention, which is generally characterized by numeric character  10  and/or as a fence or fence system. Referring to FIG. 1, the Fence System  10  preferably comprises a plurality of Posts  12 , Panels  14 , Post Mounts  20  and Channel Mounts  30 . The Fence System  10  is designed to provide an economical, functional, easy to install and customizable fence, such as shadow box, curved or privacy designs. The Posts  12  are preferably rigid and square or rectangular in cross section to provide a flat outside securing surface for structural integrity and can comprise lengths that confirm with recognized standards in the industry, such as eight feet, or lengths that comport with local building codes. The Posts  12  are securable in a ground or ground like surface, such as with cement or dirt, and can comprise a substantially non-corrosive, waterproof and durable material. The preferred material for all components comprises aluminum or an aluminum based product, or alternatively may comprise plastic, plastic based or fiberglass type materials.  
         [0056]    The Post Mounts  20 , shown in detail in FIGS.  8 - 8 D, slide over the Post  12  and are securable thereto using conventional fasteners, such as screws, nuts and bolts and the like. The Post Mounts  20  preferably fit snuggly over the Post  12  to prevent chattering while providing stability in the fence structure. Each Post Mount  20  comprises at least one ledge  26 . The ledges  26  may comprise a tube, as shown in FIG. 8, or a U-shaped channel ledge, as shown in FIG. 8A. With reference to FIG. 8, a tube shaped ledge  26  preferably has the same width as the supporting vertical column for flush mounting of the Panels  14 . With reference to FIG. 8A, the U-shaped ledge  26  preferably has a smaller width than the supporting vertical column so that the Channel Mount  30  lies flush with the center support column when installed. With reference to FIGS. 8, 8A,  8 B,  8 C and  8 D, the ledges  26 , whether constructed as a tube or U-shaped channel, may project from two opposite surfaces ( 8  and  8 A), one surface ( 8 B), two adjacent surfaces ( 8 C) or every surface ( 8 D), respectively. The Ledges  26  preferably have dimensions that firmly support the Channel Mount  30  in a manner that prevents or limits potential vibration and chatter.  
         [0057]    With reference to FIGS.  4 A- 4 C,  9 ,  9 A and  10 A, the Channel Mounts  30  comprise crossing support members that span between Posts  12  and attach to the Post Mount Ledges  26 . With reference to FIGS. 9 and 10, the Channel Mount  30  may be U-shaped in cross-section for snugly mounting over the tube-shaped Ledge  26 , preferably with the open side down. With reference to FIGS. 9A and 10A, the Channel Mount  30  may be tube-shaped in cross-section for snugly mounting inside the U-shaped Ledge  26 . The Channel Mounts  30  preferably conceal the hardware. With reference to FIGS.  4 A- 4 C, the Channel Mounts  30  may be straight, curved or S-shaped to accommodate different geometric layouts. As shown in FIGS. 1, 2 and  4 A- 4 C, a Channel Mount  30  is secured to the Post Mount  20  to provide a lateral support surface for affixing the Panels  14 . The Channel Mounts  30  extend between two posts per section of fence to provide a lateral support surface for securing the Panels  14 . Each fence section preferably employs two (2) Posts  12 , two (2) Post Mounts  20  securely affixed to each post, two (2) Channel Mounts  30  laterally extending between the Posts  12  and secured to corresponding Post Mounts  20  and a plurality of Panels  14  vertically secured to the Channel Mounts  30  and/or Post Mounts  20 . As shown in FIG. 1, Short Clips  40  may be used to secure and properly space adjacent Panels  14  and to assist in preventing chattering of the Panels  14 . The Short Clips  40  are preferably used in a shadow box design in a manner that does not comprise the shadow box look.  
         [0058]    With reference to FIG. 2, a fence section of the instant invention  10  is shown in a privacy design. As in the preferred embodiment, each section of fence preferably includes two (2) Posts  12  spaced apart at a predetermined distance, two (2) Post Mounts  20  per post, two (2) Channel Mounts  30  laterally bridging the post and connected to corresponding Post Mounts  20  and a plurality of Fence Panels  14  affixed to the Channel Mounts and/or Post Mounts  20  in a manner that eliminates gaps between the Panels  14 . In one embodiment, the Panels  14  in the privacy design may be juxtaposed such that there is no space there between. In this design, additional stability and security may be provided by employing either the Small Clips  40  or Large Clips  42  to keep the panels joined together. In another embodiment, the Large Clips  42  may be used to secure the Panels  14  while filling the space between adjacent Panels  14  so as to eliminate any gaps there between. With reference to FIGS. 4B and 4C, the Fence System  10  may be curved, including S-shaped, by using the corresponding Channel Mounts  30 .  
         [0059]    With reference to FIG. 3, a typical Fence Panel  14  is shown. Although shown in full size, the Panel  14  may comprise a fraction of the width shown, such as half, for completing smaller sections or starting a section. The Fence Panel  14  comprises at least one and preferably two Crests  15 , an intervening Panel Trough  17 , a Trough Channel  18  and at Edge Segments  19  which form Flange  16 . The Crests  15  preferably rise above opposite edges of the Panel Trough  17  so as to define the Trough Section  17 . The Crests  15  are preferably trapezoidal in shape, but may vary. The Panel Trough  17  is preferably defined by the valley formed between opposing Crests  15 . The Edge Segments  19  are defined on opposite outside edges of the Crests  15 , which define the overall width of a particular Panel  14 . Each Edge Segment  19  defines a Flange  16 . The Flange  16  is formed by folding a segment of the Edge Segment  19  over itself such that the folded section is substantially in parallel with the remaining Edge Segment  19 , as shown in FIG. 3. The Flange  16  enhances the structural integrity of the Panel  14  at the Edge Sections  19 , provides a smooth finished edge and creates a dimensional characteristic in the Fence  10  that facilitates proper spacing between the Panels  14  in a shadow box design. The Flanges  16  also provide structure for securely interlocking adjacent Panels  14 .  
         [0060]    As shown in FIG. 3, the panels  14  are substantially uniform and symmetrical. Segment D 1  is equal to segment D 5  and segments D 2 , D 3  and D 4  are equal. In the preferred embodiment, D 1  and D 5  are equal to one-fourth (¼) of D 2 , D 3  and D 4 . The preferred Fence Panel  14  has approximately five (5) well defined segment dimensions that create a uniform and substantially symmetrical panel. The segments designated D 1  and D 5  are equal and comprise approximately ¼ the dimensions of D 2 , D 3  and D 4 , respectively. The panel sections designated D 2 , D 3  and D 4  are each equal in width and are four times the dimension of D 1  and D 5 . These comparative dimensions may vary without departing from the main teachings of the instant invention. The Panel  14  also includes a Trough Channel  18  extending between the upper and lower ends of the Panel  14  and essentially located within the Trough  17 . The Trough Channel  18  is recessed into and below the Trough  17  to achieve uniformity across the fence in comparison to the pre-designed gaps between adjacent Panels  14 . The width of the Trough Channel  18  is intended to coincide with the width of the gap left between adjacent Panels  14  secured to the Fence  10 .  
         [0061]    In the preferred embodiment, as shown in FIG. 3, a Small Clip  40  is preferably used to interlock adjacent Panels  14 . The Short Clips  40 , as shown in FIG. 14, can be used to secure adjacent Panels  14  to prevent or alleviate chatter while providing uniform spacing between Panels  14  throughout the Fence  10 . Alternatively, the Clips  40  may be used to securely abut adjacent Panels  14  for a privacy-like design that eliminates all gaps between the panels. A uniform look can be achieved in either a privacy or shadow box fence design depending on the clips employed. For instance, in a shadow box design, the Small Clips  40  would be used so as to maintain the look of a gap between adjacent panels. Conversely, in a privacy fence design, a Large Clip  42  would be used to fill in the gap from the top edge to the bottom edge between adjacent panels so as to securely join two panels at a predetermined distance while filling in the gap there between. Accordingly, the Clips  40  and  42  have a width and dimensions that facilitate uniform and proper spacing between adjacent Panels  14  in a manner that coincides with the width of the Trough Channel  18 . Alternatively, the Clips  40 ,  42  may vary in length and, or width to adjust the size of the gap and, or spacing between the Panels  14  for different design looks.  
         [0062]    In an alternative embodiment, the Panels  14 , Clips  40 ,  42 , Posts  12 , Post Mounts  20  and, or Channel Mounts  30  may be pre-punched or pre-drilled with mounting holes or apertures  81  that allow clearance for fasteners and wires. The Panels  14  would preferably have two mounting holes. The Clip  40 ,  42  would preferably have one mounting hole.  
         [0063]    In an alternative embodiment, the Panel  14  may be perforated with venting holes, such as or similar to holes  81 , but in various locations across the Panel to create a single sided or double sided ventilated Fence  10 . The Clips  40  and, or  42  may also be perforated with venting holes. By using center perforated Panels  14  with Short Clips  40 , a single or double sided ventilated Fence  10  may be constructed. Various unique looks may be achieved by using Panels  14  with one or more rows of perforation holes. A symmetrical look may be obtained by properly positioning the perforations uniformly on the Crests  15  and, or Troughs  17 .  
         [0064]    With reference to FIG. 4, the preferred Fence System  10  is shown in a plan view. As shown, the Panels  14  are preferably affixed to the Channel Mount  30  and/or Post Mount  20  on both sides using conventional fasteners. As shown, a Gap  11  is left between adjacent panels. The Gap  11  preferably has a width that is substantially equal to the width of the Trough Channel  18  to achieve a uniform look. As shown in FIG. 4, the Channel Mounts  30  are securely mounted to the Post Mounts  20  in a manner that facilitates the secure attachment of Panels  14 . The small clips  40  may be used for securing the panels  14  while facilitating a shadow box look. The large clips  42  may be used for facilitating a privacy fence design.  
         [0065]    With reference to FIG. 6, alternative panel designs are shown. Referring to FIG. 6, an end view of the preferred Panel  14  is shown, illustrating flanges, which bend inward behind the Edge Segments  19 . With reference to FIG. 6, an alternative Panel  14 ′ is shown. The alternative Panel Design  14  Prime comprises a First Flange  16  which bends behind Edge Segment  19  as previously described and an alternative Flange  16 ′ bends over and in front of the opposite Edge  19 . This alternative Panel Design  14 ′ allows adjacent Panels  14  to be directly interlocked to create a privacy fence design. It should also be noted that although Panels  14  are shown as being secured to both sides of a Fence Structure  10 , the Panels  14  may be secured to only one side of the Fence  10 .  
         [0066]    Referring to FIG. 7, a typical fence frame in accordance with the instant invention is shown. The fence frame basically comprises at least one pair of Posts  12 , two Post Mounts  20  securely mounted to each Post  12 , and a Channel Mount  30  securely mounted and affixed to opposing Post Mounts  20  positioned at corresponding levels on the Posts  12 . The Post Mounts  20  and Channel Mounts  30  may be securely fastened using conventional fasteners. The fence frame provides a chassis for securely affixing the Panels  14  thereto.  
         [0067]    With reference to FIG. 8, a preferred Post Mount  20  is shown. The preferred Post Mount  20  comprises a Post Sleeve  22  defined by four Sidewalls  23 , a Post Barrel  24  defined by the interior surfaces of the Sidewalls  23  and two Channel Ledges  26  projecting outward from opposite Sidewalls  23 . The Post Mounts Barrel  24  defines a shape and dimensions that coincide with the Post  12  for facilitating a snug fit therewith to eliminate chattering. The Post Mounts  20  are preferably secured to Posts  12  using conventional hardware, such as screw or bolt fasteners. At least two fasteners per Sidewall  23  are preferred. In an alternative embodiment, the Post Mounts  20  may be secured by cooperating latches, snaps and/or dimples found on or formed in the Posts  12  and Post Mounts  20 . The preferred Channel Ledge  26  comprises lateral projections that extend outward from opposite Sidewalls  23  of the Sleeve  22 . The Channel Ledge  26  preferably has a square or rectangular cross section that facilitates a mating, and preferably snug, connection with the Channel Mount  30 . In an alternative embodiment, the Channel Ledge  26  may comprise an upwardly oriented “U” shaped channel for receiving the Channel Mounts  30 . In this embodiment, the Ledger  26  would preferably have drainage ports for draining collected water, such as rain. The alternative design can conceal the hardware used for securing the Channel Ledge  26  and Channel Mount  30  to alleviate the risk of injury.  
         [0068]    With reference to FIG. 9, the preferred Channel Mount  30  is shown and comprises two opposing Sidewalls  34  depending from a Top Wall  36 . The Sidewalls  34  and Top Wall  36  form a channel adapted for snugly mounting over the Post Mount Ledges  26 . Thereafter, the Channel Mounts  30  may be secured with conventional hardware, such as screw or bolt fasteners. Alternatively, the Channel Mounts  30  may be secured to the Ledges  26  by cooperating latches, snaps and/or dimples found on or formed in the mounts  30  and ledges  26 . The Channel Mount Ends  32  preferably abuts the Post Mounts  20  to maximize the support of the ledge  26 . In an alternative embodiment, the Channel Mounts  30  may comprise a square or rectangular cross section that facilitates mating, and preferably snugly, with the alternative post ledges  26 .  
         [0069]    With reference to FIG. 10, an end view of the Channel Mount End  32  is shown and comprises a substantially “U” shaped configuration. The Channel Mount  30  defines a channel of a predetermined width between the Sidewalls  32  that corresponds to the width of the Channel Ledge  26 . The Channel Mount Sidewalls  34  preferably have a height that corresponds to the height of the Channel Ledge  26  for completely enclosing the Channel Ledge  26  within a corresponding end of a Channel Mount  30 . In alternative embodiments, the Channel Ledge  26  and corresponding Channel Mount  30  may comprise cross-sectional dimensions and shapes that are other than rectangular or square. However, a square or rectangular cross-section is desired for enhanced structural integrity. The Channel Mounts  30  may further comprise drainage ports, if necessary, for draining collected water, such as rain.  
         [0070]    With reference to FIGS.  14 - 16 , the preferred securing Clips  40  and  42  are shown. In one embodiment, the securing clip comprises a Small Clip  40  that is primarily used for shadow box like designs. In a privacy fence design, the Large Clip  42  is preferably used to completely close off any gap between adjacent Panels  14 . The Small and Clips  40 ,  42  both comprise the folded edges or hems that correspond to the Panel Flanges  16  as defined by the Panels  14 . Accordingly, the thickness of the flanges defined by the Clips  40 ,  40  correspond to the gap defined by the Flanges  16  and the Panels  14 . The Clips  40  or  42  are installed by aligning a clip end with opposing Flanges  16  of adjacently positioned Panels  14 . If the smaller Clip  40  is used, it is preferably slid down over the Flanges  16  into alignment with the Channel Mount  30 . The larger Clip  42  has a length that coincides with the length of the Panels  14 , such that when the large clip is engaged with adjacent Panels  14  it will substantially fill in the gap between adjacent panels between the top and lower ends. The width and, or length of the clips may vary for different looks.  
         [0071]    The Panel Edges  19  and Flanges  16  provide a folded edge or hem edge that increases the rigidity of the panels and aides in reduction of chatter. Moreover, the Edge and Flange Segments  19 ,  16  provide a smoother edge that is easier to handle during installation. Without a folded hem edge as depicted by the Flange  16  of the Panels  14 , wind passing through the fence  10  could cause unwanted vibration and chatter. This is alleviated by the Panel Flanges  16 .  
         [0072]    The components of the fence panel system  10  are preferably made from a non-corrosive, malleable material such as aluminum, stainless steel, plastic based materials, fiberglass material or alternative materials exhibiting non-corrosive, water resistant and durable characteristics. The Panel Sheet  14  preferably comprises a standard mill coil of the desired material. The Fence System  10  may also include components or be adapted to place adjacent sections at various angles or to traverse curves, such as by using arcuate Channel Mounts  30 , Clips  40 ,  42 , and, or Post Mount Ledges  26 .  
         [0073]    The instant invention further comprises a machine and method for making the Fence Panels  14  of the instant invention and a method for installing the Fence  10  of the instant invention. The process of forming Fence Panels  14  comprises determining the appropriate panel size for field installation given the various design perimeters of the fence to be constructed. However, the present invention may also contemplate manufacturing standard size Panels  14  that could be modified in the field during installation. The method of forming Panels  14  further comprises choosing the appropriate fencing material to be fed into a bending machine, which preferably comprises aluminum, or other suitable non-corrosive, waterproof and durable material, such as plastics or fiberglass. The selected sheet for the Panels  14  are then fed through the bending machine which comprises a series or plurality of uniquely designed and positioned pairs of rollers and, or pairs of cams, as shown in FIGS.  19 A- 19 I, to create the desired bends in the Panel  14 , as shown in FIGS.  13 A- 13 J.  
         [0074]    Each stage has a pair of cooperating rollers, except for the cam stage, with various contours to create the desired bends at each stage for ultimately defining the panel  14 . For instance, with reference to FIGS. 11 and 12, rollers  50  and  60  are used in stage nine, as shown. Roller  50 , as shown in FIG. 11, comprises Crests Forming Molds  52  and a valley there between having surface dimensions and contours that correspond to the Panel Trough  17  and Trough Channel  18 . With reference to FIG. 12, a Cooperating Roller  60  is shown. The Cooperating Roller  60  comprises dimensions that correspond and mate with the First Roller  50 , as shown. Thus, Roller  60  defines a Valley  62  that corresponds and mates with the Crests Mounts  52 . Likewise, the Second Roller Central Mold  64  and End Molds  66  correspond to the valleys or recessions defined between and outside the Crests Molds  52  as defined by Roller  50 . Rollers  50  and  60  are positioned and aligned to receive the Panel  14  therebetween in stage nine to complete the panel&#39;s  14  shape while passing therethrough. Accordingly, each stage has at least one pair of similar cooperating rollers and, or cams for creating the bends in stages. Consequently, the Panel  14  comprises a malleable material for facilitating the formation of the corrugated design.  
         [0075]    The bending machine of the instant invention  10  preferably comprises a plurality of roller stations or stages, such as five to nine stations, that contribute to the various bends in the Panels  14 , as shown in FIGS.  13 A-J and  19 A-I. Each roller stage comprises rollers having unique contours for creating bends in the sheet in stages. The method of making the Panels  14  shapes the sheet as it passes through each roller stage. With reference to FIGS. 13A to  13 I, a flat sheet of non-corrosive, waterproof material is converted into the corrugated Panel  14  by being fed through each stage. Referring to FIG. 13A, a mill coil of a flat sheet of material, preferably aluminum or other stainless alloy, is fed into the first stage by an unrolling machine. The bending machine of the instant invention supports the rollers at each stage and includes a sprocket, motor and gear system that rotates the rollers to draw and urge the sheet  14  through the rollers.  
         [0076]    The first stage preferably has three electric shears that cut the sheet  14  into four pieces for making four Panels  14 . The number of shears may vary for simultaneously making a different number of Panels  14 . In the second stage, approximately fifty percent of the two inner or center bends are formed by the second stage rollers  51 ,  61 , as shown in FIGS. 13B and 19A. In the third stage, the rollers  53 ,  63  form approximately one-hundred-percent of the inner bends to complete the center bends, as shown in FIGS. 13C and 19B. Referring to FIGS. 13D and 19C, the fourth stage rollers  55 ,  66  repeats 100% of the inner bends and fifty percent of the outer bends. In the fifth stage, the outer bends are completed to a hundred percent by rollers  57 ,  67 , as shown in FIGS. 13E and 19D. The sixth, seventh, eighth and ninth stages form the flanges/hems  16  with cam pairs, as shown in FIGS.  13 F-I and  19 E-H. A pair of cams is used in each of these stages for creating the hems  16  along both side edges  19 . In stage six, the pair of cams  58  bend the panel edges  19  approximately forty-five ( 45 ) degrees. In stage seven, the pair of cams  59  bend the panel edges  19  approximately ninety ( 90 ) degrees. In stage eight, the pair of cams  68  bend the panel edges  19  approximately one-hundred-thirty-five (135) degrees. In stage nine, a pair of cams  69  or the rollers  50  and  60  bend the panel edges to one-hundred-eighty (180) degrees to complete the hems  16 , as shown in FIGS. 19H,I and  13 I, J. The ninth or final stage fine tunes the bends and forms the channel  18  in the Panels  14 , as shown in FIGS. 11 and 12. Thereafter the Panel  14  is cut into desired lengths.  
         [0077]    Referring to FIG. 18, the Panel  14  has various sections with predetermined angles and lengths. These sections are designed to result in a substantially symmetrical Panel  14 . The lengths and angles of the various sections, as shown in FIG. 18, may vary so long as the overall structural integrity and look of the Panels  14  are not compromised.  
         [0078]    The method of installing the Fence  10  of the instant invention comprises obtaining the Posts  12 , Post Mounts  20  and prefabricated fence sections comprising Channel Mounts  30  with pre-mounted Panels  14  or obtaining the Channel Mounts  30  and Panels  14  of the Fence System  10  and building the section at the site. The first step is securing the posts in the ground or ground like surface and securing two (2) Post Mounts  30  to each Posts  12 . If a prefabricated fence section is used, then it is attached to the Post Mounts  14  by connecting and fastening the Channel Mounts  30  to or in the Post Mount Ledges  26  utilizing predrilled holes  81 , if available, and conventional fasteners. If the section is built on site then the next step is bridging the distance between the Posts  12  with the lateral Channel Mounts  30 , securing the Channel Mounts  30  at each End  32  to or in the Post Mount Channel Ledges  26  at each end and securing the panels to the frame with or without a gap there between depending on the preferred design. For a curved design, a curved Channel Mount  30  may be used. The posts  12  are secured in a ground like surface using conventional methods such as cement and/or dirt. The Post Mounts  20  are slid over the posts, preferably two Post Mounts  20  per Posts  12 , and positioned at predetermined levels preferably spaced evenly on the Posts  12  at distances that enhance the structural integrity thereof. The Post Mounts  20  are secured to the Posts  12  using conventional fasteners. The Post Mounts  20  secured to a corresponding Posts  12  should be positioned at corresponding heights for creating a substantially level in the Fence  10 . Thereafter, Channel Mounts  30  are mounted over the Post Mount Channel Ledges  26  at each end of the Channel Mounts  30 . The Channel Mounts should have a length that bridges completely across and between the Posts  12  and Post Mounts  20 . The Channel Mount  30  is secured to the Post Mount Channel Ledges  26  using conventional fasteners. Once the Channel Mounts  30  and Post Mounts  20  have been firmly secured, the installer may begin to affix the Panels  14  to the resulting fence frame assembly. A level line should be drawn across the top of the posts or at least at a level for dictating where the tops of the Panels  14  should terminate. The Panels  14  are secured to the fence assembly using conventional fasteners. The Panels  14  may be positioned on the fence frame with a defined gap there between. In order to more firmly secure the Panels  14  to the fence frame so as to prevent chattering and panel movement, the Small Clips  40  may be employed. To use the Small Clips  40 , the method contemplates aligning and sliding the Clips  40  over opposing Flanges  16  of adjacently positioned Panels  14 . The Clips  40  would preferably reside in alignment with the Channel Mounts  30  so as to not comprise the shadow box look. In a privacy design, the panels may be placed in touching engagement such that there is no gap there between with or without the use of Small or Large Clips  40 ,  42 . In the preferred embodiment, the privacy design employs the Large Clip  42  for closing the gap between adjacent Panels  14 . The Large Clip  42  is aligned and slidably engaged with corresponding Flanges  16  as described in reference to the Small Clips  40 . The caps  40  or  42  are installed by mounting them over the panels  14 .  
         [0079]    The instant invention may further comprise railing caps, as shown in FIG. 17, to provide a railing system in the Fence System  10 . The Railing Caps  80  may be employed to finish off the upper edges of the fence to provide a smooth rail-like finish. The Fence Caps  80  preferably comprise elongated caps that have lengths that correspond to the length of the Channel Mounts  30  and/or the distance between cooperating posts  12 , and widths that correspond to the distance between Panels  14  secured on opposite sides of the Channel Mounts  30 . Alternatively, the Railing Caps  80  may comprise a plurality of shorter caps that are used to finish off the upper and/or lower edge of the Fence  10 .  
         [0080]    It should be noted that the instant invention  10  can be employed as a fence system or a railing system. As a fence system, the Posts  12  are preferably secured in the ground. As a railing system, the Posts  12  are preferably mounted to or in a floor-like surface, such as a balcony, stairs or patio. As a railing system or in fence systems starting against a wall or other flat surface, a U-Shaped Channel Mount  70  may be used in place of the Post Mount  20 . With reference to FIG. 20, the Channel Mount  70  comprises a Back Plate  71 , U-Shaped Channel Support  73  adapted for receiving and supporting the Channel Mount  30  and at least one aperture  75  in the Back Plate  71  for securing the Channel Mount  70  to a surface. The Channel Mount  70  may comprise a single molded part or the Channel Support  73  may be welded to the Back Plate  71  or attached with pop rivets or other conventional fasteners. The Channel Mount  30  preferably fits flush with and securely in the Channel Support  73  to prevent vibration and chatter between the parts. The Wall Mount  70  is used on flat structural surfaces, such as walls and columns, to support opposite ends of the Channel Mounts  30  across balconies, stairs and other areas that require a railing system. The Wall Mount  70  may also be used as a starter mount.  
         [0081]    In the preferred embodiment, the Fence System  10  may also include structure for securing the fence  10  or portions thereof from theft and vandalism with the dual benefit of providing a crash barrier. With reference to FIG. 21, the Fence System comprises a cylinder  84  with a hardened solid round Rod  85  loosely encapsulated in the cylinder  84  so that it rotates if there is any attempt to saw or otherwise cut through the Post  12 . With reference to FIG. 22, the Fence System  10  may also include or alternatively include a steel strand cable  86  inserted or insertable through the Channel Mounts  30 , Post Mount Ledges  26 , and Posts to strengthen the Ledges  26  and Channel Mounts  30  as well. The designs shown in FIGS. 21 and 22 prevent fence penetration and provide crash or impact resistance.  
         [0082]    In another embodiment and, or in conjunction with other embodiments, the Fence System  10  may include low voltage security electrical sensors, switches and, or trip wires that cause an alarm to be sounded if electrical continuity is broken and, or the sensors are triggered. Wires may be run through the hollow passages of the Channel Mounts  30 , Posts  12  and, or Post Mounts  20 . As the Fence Panels  14  are corrosion resistant they may be submerged in the ground or concrete.  
         [0083]    The Fence System may include barbed wire, which can be attached to the Fence Panels  12 , Channel Mounts  30  and or Posts  12 . The barbed wire may be one-sided or double sided with three, six or nine wires. The barbed wire is preferably attached to the Posts  12  with a wedge lock anchor or insert, U-shaped cap  80  with thru-bolts or U-Shaped cap  80  that is welded to the Post  12 .  
         [0084]    The Fence System  10  may also include light or lamp post attachments, with or without electrical capability, that accommodate a plurality of different lamp styles. An electrical junction box may also be included, preferably mounted or mountable to the Post  12  proximal the top end, to isolate wiring for lighting, alarm systems and other electrical accessories.  
         [0085]    In an alternative embodiment, the instant invention  10  may be adapted for use as a sound barrier. The Panels  14  would preferably comprise a material conducive for repelling, baffling and, or absorbing sound.  
         [0086]    The Fence System  10  of the instant invention may include gates made with the same or similar material and components. The gate includes hinges for attachment to a Post  12 . The gates may include locks and, or latches.  
         [0087]    The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious structural and/or functional modifications will occur to a person skilled in the art.