Abstract:
A new fencing system is provided in the present disclosure that is constructed from durable polymer components that are sufficiently rigid and durable while providing an integrated modular assembly that is easy to assembly and well suited to a do-it-yourself marketplace. In particular, the present invention provides an integrated system of interfitting vinyl components and a unique polycarbonate or ABS clip for interconnection thereof. The fence includes vertical posts with horizontal members extending therebetween. The horizontal members include grooves therein to support fence panels in the form of web panels. The horizontal members are connected to the vertical members utilizing a novel and uniquely configured connector element.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation in part of U.S. patent application Ser. No. 11/382,941, filed on May 12, 2006, which is a continuation in part of U.S. patent application Ser. No. 10/687,182, filed on Oct. 16, 2003, which is related to and claims priority from earlier filed provisional patent application No. 60/419,502, filed Oct. 18, 2002. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to a system and method for creating fencing systems. More specifically, the this invention relates to a new modular configuration that is particularly suited for fabricating and assembling vinyl fencing systems that are easier to install and are tailored to the do-it-yourself marketplace.  
         [0003]     In the prior art, the vertical post members and the horizontal rail supports used in constructing fences have typically been made of wood. However, the traditional wood construction has become less desirable for several reasons. A primary drawback is that the overall cost of installing and maintaining a wooden fence system is relatively high due to the escalation in the cost of lumber materials in recent years and the fact that wood fences require constant maintenance such as painting or staining and prevention of rot. This is particularly true when wooden posts supporting a fence are anchored in the ground. If the posts fail due to rot, the entire fence is rendered useless. Although anchoring the posts in concrete can postpone these effects, it does not eliminate them. In addressing the preservation of the wood materials, the industry has created a secondary drawback related to the use of highly toxic preservatives to prevent the wood from rotting.  
         [0004]     Further, fences have historically been designed and erected as permanent structures, without providing for subsequent removal or alteration. These permanent structures are been built on-site from the desired fencing materials, such as chain link or raw lumber, yielding integrated structures that cannot be easily dismantled without damaging the materials. The result is that most of these prior art fences that are constructed “on site” as unitary structures, are highly labor intensive and quite expensive to have initially installed. Additionally, wood fences constructed in this manner from raw lumber can also be non-uniform in appearance, detracting from their aesthetic qualities. This problem is further amplified when the installation process is attempted by a do-it-yourself installer who has relatively little experience in working with traditional fencing systems.  
         [0005]     As an alternative to the wood fencing systems, fences having plastic horizontal rails that snap into vertical plastic posts are known. Typically, these plastic rails have snap-in connections formed on their ends and they “snap-in” directly to the plastic posts. Problems typically encountered with this type of plastic fence construction include the fact that these constructions do not take into account the expansion and contraction of the plastic and also that the support rails may tend to rotate in response to varying thermal conditions. Further, some of these plastic fences are made of a material that has sufficient plasticity to result in sagging rails and bending posts over time.  
         [0006]     There is therefore a need to provide an esthetically pleasing fence that overcomes the above noted drawbacks associated with wood fencing systems. Further there is a need for a fencing system that is relatively inexpensive and durable, yet can be dismantled and reassembled in sections by a do-it-yourself consumer, if desired.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     In this regard, the present invention provides for a new fencing system constructed from durable polymer components that is sufficiently rigid and durable while providing an integrated modular assembly that is easy to assembly and well suited to a do-it-yourself marketplace. In particular, the present invention provides an integrated system of interfitting vinyl components and a unique polycarbonate or ABS clip for interconnection thereof. The entire fencing system is configured to snap together in a manner that eliminates the need for the use of tools during assembly.  
         [0008]     The present invention includes vertical post elements, top and bottom horizontal rail elements, a novel connector clip and a webbing panel that is retained therein. The vertical posts are extruded material and may be of any suitable profile for fencing posts. At least two openings are provided in the sidewall of the vertical posts. Retention clips are inserted in to each of the openings in the vertical posts. When the clips are inserted into the openings in the posts, a portion of the clips momentarily deflect and then return to their undeflected state to engage the wall of the vertical tube. Due to the shape of the clips and the manner in which they engage the wall of the vertical tube, the clips resist being withdrawn from the vertical tubes and resist deflection or rotation.  
         [0009]     The top and bottom horizontal rails each have openings in the ends thereof, allowing these members to slide over the retention clips. Small detent openings are provided in the sidewall of these tubes that engage a mating configuration on the retention clips when the rails are snapped into place. In this manner, the top and bottom rails are also firmly retained forming a unitary structure between the vertical fence posts and the top and bottom rails. The top and bottom rails also include a continuous longitudinal groove therein for receiving fencing panels.  
         [0010]     The present invention also anticipates the possibility of employing intermediate rail members. In this manner the intermediate rails would have longitudinal grooves provided in both their top and bottom sides for receiving the top edge of one panel and the bottom edge of another thereby allowing two or more different panels to be employed in the same section of fence.  
         [0011]     Accordingly, one of the objects of the present invention is the provision of an integrated modular vinyl fencing system. Another object of the present invention is the provision of a durable vinyl fence system that exhibits improved structural characteristics as compared to the prior art. Yet another object of the present invention is the provision of a vinyl fencing system that is constructed of modular components that can be made to be easily interchangeable and reconfigurable. A further object of the present invention is the provision of a modular vinyl fence system that includes standardized construction components that is further capable of being easily disassembled and reused in alternate configurations.  
         [0012]     Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:  
         [0014]      FIG. 1  is a perspective view of the assembled fence system of the present invention;  
         [0015]      FIG. 2  is a detailed perspective view of the connection between the horizontal rail and the vertical support;  
         [0016]      FIG. 3  is a cross-sectional view thereof taken along line  3 - 3  of  FIG. 2 ;  
         [0017]      FIG. 3   a  is an alternative cross-sectional view thereof taken along line  3 - 3  of  FIG. 2 ;  
         [0018]      FIG. 4  is a perspective view of the rail connector mounted to the vertical support with the horizontal rail removed;  
         [0019]      FIG. 5  is a side elevational view of the connector element of the present invention;  
         [0020]      FIG. 6  is a cross-sectional view of the connector element installed in the vertical support as taken along line  6 - 6  of  FIG. 2 ;  
         [0021]      FIG. 7  is a perspective view of an alternate embodiment of the present invention;  
         [0022]      FIG. 8  is a perspective view of an alternate embodiment connector element of the present invention;  
         [0023]      FIG. 9  is a perspective view of a hinge assembly manufactured in accordance with the modular principals of the system of the present invention;  
         [0024]      FIG. 10  is an assembled view of a latch assembly for use in the modular fence system of the present invention;  
         [0025]      FIG. 11  is an exploded view of a latch assembly for use in the modular fence system of the present invention; and  
         [0026]      FIG. 12  is a perspective view of a corner connector use in the modular fence system of the present invention;  
         [0027]      FIG. 13A  is a front elevational view of an alternate embodiment connector element of the present invention;  
         [0028]      FIG. 13B  is a plan view of the connector element of  FIG. 13A ; and  
         [0029]      FIG. 13C  is a cross-sectional view of the connector element taken along the line  13 C- 13 C in  FIG. 13B .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]     Referring now to the drawings, the fencing system of the present invention is illustrated and generally indicated at  10  in  FIGS. 1-6 . Further, an alternate embodiment of the present invention is illustrated and generally indicated at  100  in  FIG. 7 . In addition, various other components such as alternate rail connectors, a hinge, a latch and a corner connector are depicted in  FIGS. 8-13 . As will hereinafter be more fully described, the fencing system  10  is assembled in sections wherein each section includes at least two vertical support posts  12  with at least two horizontal rails  14  extending therebetween. Each section of the fence system  10  may also include a fencing panel  16  supported between the horizontal rails  14  and caps  18  installed onto the vertical supports  12 . The present invention therefore provides a convenient and economical modular fencing system  10  that is easily assembled and installed making the system convenient for both permanent and temporary fence installations that has not been previously available in the prior art. It should be further noted that the fencing system  10  of the present invention is particularly advantageous as compared to the prior art in that every component is arranged to be snap fit while eliminating the need for using tools during assembly thereof.  
         [0031]     Turning now to  FIG. 1 , several adjacent sections of the fencing system  10  of the present invention are shown fully assembled. The fencing system  10  is configured to be a modular system that is equally effective when installed as a single section, two linear adjacent sections or any conceivable arrangement of any number of interconnected sections. The adjacent sections of fencing may be disposed linearly, at 90° to one another, in a “T” configuration or at any relative angle required in a particular installation. For the purposes of the detailed description the interrelationship of the various components will be described in the context of a single fencing section although the concepts and principals of this disclosure can be extrapolated to any of the configurations described above with equal success.  
         [0032]     As stated above, the fencing system  10  includes vertical supports  12  or fence posts. The vertical supports  12  in the present invention are tubular shaped members. While in the preferred embodiment the tubular members are shown to have a square cross-sectional profile, the tubes could be formed in any desired cross-section including but not limited to rectangular, circular, elliptical, hexagonal, octagonal and combinations thereof. The vertical support members  12  are installed in a parallel spaced apart relation in the desired location where the fencing will be installed. The vertical supports  12  could be installed by directly burying a portion of the support  12  into the ground or could be installed into support member (not shown) that may or may not be fastened to the ground. By using a support member the reconfigurability and temporary installation of the fence system  10  of the present invention may be enhanced. It should be understood that the manner in which the vertical posts  12  are anchored to the environment where the fence system  10  is installed is not critical to the present invention. Additionally, if desired for aesthetic purposes or to prevent moisture from entering the vertical supports  12 , caps  18  can be installed on the top of the vertical supports  12 .  
         [0033]     Turning now to  FIGS. 2 , a detailed view of the connection between the horizontal rails  14  and the vertical supports  12  is shown. The ends  18  of the horizontal rail  14  contact the outer face of two of the vertical posts  12  and the horizontal rails  14  are retained and supported therebetween. Preferably, the present invention includes at least two horizontal rails  14  extending between each pair of vertical supports  12 . It should be appreciated that when the present invention is assembled in configurations of multiple adjacent sections, each section does not require two distinct and separate vertical supports  12  as the second support for a preceding section serves also as a first support for a following section. The horizontal rails  14  are supported by rail connectors  20  as will be more fully described below. As can best be seen in  FIG. 3 , the horizontal rails  14  are also tubular sections. While the cross-sectional profile is shown as being square, as stated above any suitable or desirable profile may be used for the horizontal rails  14 .  
         [0034]     It can be further seen in  FIG. 3  that the horizontal rails  14  include linear grooves  22  therein to receive a fencing panel  16  should one be desired in the particular fencing application. The fencing panel  16  is a flexible sheet of fabric material having pockets  24  extending along the top and bottom edges thereof. The pockets  24  have a retention member  26  placed therein to increase the overall thickness of the pocket  24  along the top and bottom edges. The retention tube  26  may be a dowel, a fiberglass rod, a piece of polymer tubing or any other suitable material for this application. To install the panel  16  into the system, the top pocket  24  including the installed retention member  26  is slid into the groove  22  in the top horizontal member  14  and the bottom pocket  24  is similarly slid into the groove  22  in the bottom horizontal rail  14  and the top and bottom rails  14  are installed between the vertical supports  12 . In this manner the panel  16  is held in a taughtly stretched manner creating a fully closed fencing section. Optionally, as illustrated in  FIG. 3   a,  the horizontal rail  14  may include a reinforcing wall  28  extending on its interior to maintain the dimensional stability of the cross section of the horizontal rail  14  and prevent the groove  22  from opening and releasing the panel  16  when under load. Further, in place of a continuous pocket  24  along the edge of the panels  16 , a plurality of tabs that each include retention members could extend from the top and bottom edges thereof and be retained within the groove  22  in the horizontal rails  14 .  
         [0035]     The fencing panel  16  may be formed from a woven or knit fabric in any desired pattern of color. While the preferred material is polymer based, any other material such as canvas, laminated sheet goods or coated canvas could also be used and fall within the scope of the invention. Further the panel  16  may be formed using interwoven polymer webbing strips to form a basket weave pattern. As can be appreciated the above disclosure related to the general pattern and configuration of the panels  16  is meant to be illustrative and not limiting in any manner.  
         [0036]     Turning now to  FIGS. 4, 5  and  6  details of the rail connector  20  are shown. The rail connector  20  is installed into holes located in the sidewalls  30  of the vertical supports  12 . The rail connector  20  includes a retention member  32  that extends outwardly from the vertical support  12  when the rail connector  20  is in assembled relation with the vertical post  12 . The retention member  32  is configured to frictionally receive and retain the ends  18  of the horizontal rails  14 . As can be seen the tubular configuration of the horizontal rails  14  provide openings in the ends  18  thereof that are received onto the retention member  32  of the rail connector  20 . The rail connector  20  includes retention clips  34  that extend from the back of the retention member  32 . When the rail connector  20  is installed onto the vertical post  12 , the retention clips  34  extend into the hole in the wall  30  of the vertical support  12  and engage the wall  30  to securely hold the rail connector  20  in assembled relation with the vertical support  12 . As can best be seen in  FIG. 6 , the rail connector  20  includes shoulders  36  that contact the outer surface of the vertical supports  12  and cooperate with the retention clips  34  to engage the wall  30  of the vertical support  12 . The retention clips  34  are spring biased allowing them to deflect as the rail connector  20  is inserted into the hole in the vertical support  12  and return to their original, undeflected state wherein the tabs  38  at the ends of the retention clips  34  engage the wall  30  of the vertical support  12 . Additionally, the rail connector  20  may include a detent  40  on the side of the retention member  32 . The purpose of the detent  40  is to engage a hole located in the side wall of the horizontal rail  14  to prevent it from becoming dislodged from the rail connector  20 .  
         [0037]     The materials utilized for the vertical posts  12 , horizontal rails  14  and rail connectors  20  may be either metallic or polymer based. In the preferred embodiment of the preset invention, polymer materials are utilized to reduce the cost, make the parts easier to handle and provide longer term durability and a cleaner appearance. The vertical supports  12  and the horizontal rails  14  are preferably formed from extruded vinyl and PVC, although any other suitable polymer may be employed. Further the rail connector  20  is preferably formed from a polymer material such as ABS, PVC, HDPE or polycarbonate.  
         [0038]     Turning now to  FIG. 7 , an alternate embodiment  100  of the present invention is shown. This embodiment is intended to illustrate a configuration wherein three horizontal rails  102   a - c  are used in conjunction with two panels  104   a - b  to create a customized fence appearance. As described above, at least two vertical supports  106  are arranged is spaced parallel relationship. Three horizontal rails  102   a - c  are installed between the two vertical supports  106  utilizing rail connectors  20  as described above. While the top  102   c  and bottom  102   a  rails each include one longitudinal groove in the walls thereof, the middle rail  102   b  includes a groove in both its top and bottom surface. In this manner a top panel  104   b  can extend between the top rail  102   c  and the middle rail  102   b  and be retained in the groove in the top of the middle rail  102   b.  Further, a bottom panel  104   a  extends between the bottom rail  102   a  and the groove in the bottom of the middle rail  102   b.  In this manner, the installed fencing system  100  can have a custom appearance and can include two panels  104   a - b  having two different patterns, textures or appearances.  
         [0039]      FIG. 8  depicts an alternate embodiment rail connector  200 . As was provided above, the rail connector  200  is installed into holes located in the sidewalls  30  of the vertical supports  12 . This embodiment of the rail connector  200  includes a retention member  210  that extends outwardly from the vertical support  12  when the rail connector  200  is in assembled relation with the vertical post  12 . The retention member  210  is configured to frictionally receive and retain the ends  18  of the horizontal rails  14 . As can be seen the tubular configuration of the horizontal rails  14  provide openings in the ends  18  thereof that are received onto the retention member  210  of the rail connector  200 . The rail connector  200  includes two opposing retention clips  212  that extend from the back of the retention member  210 . When the rail connector  200  is installed onto the vertical post  12 , the opposing pair of retention clips  212  extend into the hole in the wall  30  of the vertical support  12  and engage the wall  30  to securely hold the rail connector  200  in assembled relation with the vertical support  12 . The rail connector  200  includes shoulders  214  that contact the outer surface of the vertical supports  12  and cooperate with the retention clips  212  to engage the wall  30  of the vertical support  12 . The retention clips  214  are spring biased allowing them to deflect as the rail connector  200  is inserted into the hole in the vertical support  12  and return to their original, undeflected state wherein the tabs  216  at the ends of the retention clips  214  engage the interior of the wall  30  of the vertical support  11 . In its installed position, the shoulders  214  can be seen to contact the exterior surface of the wall of the vertical support  12  and the tabs  216  on the retention clips  212  can be seen to engage the interior surface of the vertical support  12  thereby ensuring that the rail connector  200  is securely retained in position on the vertical support  12 . Additionally, the rail connector  200  may include detents  218  on the sides of the shoulders  214  extending from the rear of the retention member  210 . The purpose of the detents  218  is to engage corresponding holes located in the sidewall of the horizontal rail  14  to prevent it from becoming dislodged from the rail connector  200 .  
         [0040]     Turning now to  FIG. 9 , a hinge  300  is depicted that employs the teachings of the system of the present invention thereby allowing its modular incorporation into the fencing system of the present invention. The hinge  300  can be seen to include two opposing hinge panels  302 ,  304  each of which respectively includes an upper and lower pivot assembly  306  along a common edge. A pin  308  is inserted into a hole  310  in each of the upper and lower pivot assemblies  306  thereby fastening the opposing hinge panels  302 ,  304  in pivoting relationship to one another. It can be further seen that an optional spring  312  may also be included that is installed at the juncture between the upper and lower pivot assemblies  306 . The spring  312  can be seen to include first  314  and second  316  actuator arms that engage the opposing hinge panels  302 ,  304  in a manner that creates a spring bias urging the two opposing hinge panels  302 ,  304  together in a normally closed position. The opposing hinge panels  302 ,  304  can also be seen to include two opposing retention clips  318  that extend from the back surface of each of the hinge panels  302 ,  304 . When the opposing hinge panels  302 ,  304  are installed onto the vertical post and or a side rail of a gate, the opposing pair of retention clips  318  extend into the hole in the wall  30  of the vertical support  12  as described above and engage the wall  30  to securely hold the hinge  300  in assembled relation with the vertical support  12 . The retention clips  318  are spring biased allowing them to deflect as the hinge  300  is inserted into the hole in the vertical support  12  and return to their original, undeflected state wherein the tabs  320  at the ends of the retention clips  318  engage the interior of the wall  30  of the vertical support  11 . In its installed position, the rear surface  322  of the hinge panels  302 ,  304  contact the exterior surface of the wall of the vertical support  12  and the tabs  320  on the retention clips  318  engage the interior surface of the vertical support  12  thereby ensuring that the hinge  300  is securely retained in position on the vertical support  12 .  
         [0041]      FIGS. 10 and 11  illustrate a snap together latch assembly  400  for use in conjunction with the system of the present invention. The latch  400  includes a latch faceplate  402  that is received into a hole in the sidewall of a tubular extrusion. The latch faceplate  402  has two retention clips  404  with tabs  406  on the ends thereof that are configured to engage the walls of the tubular extension as has been described in detail above. Additionally, the latch faceplate  402  includes a cylindrical bore  408  extending therethrough that slidably receives a latch body  410 . The latch body  410  can be seen to include a latch pin  412  that is slidably received into the cylindrical bore  410  in the latch faceplate  402  and has an interface means  414  for receiving and engaging at least one actuator  416 . The latch body  410  is urged into a first engaged position by a spring  418  that extends from the latch body  410  to the latch faceplate  402 . The at least one actuator  416  extends through a slotted hole in the sidewall of the tubular extrusion and is received into the interface means  414  on the latch body  410 . A user actuates the latch  400  by sliding the actuator  416  rearwardly, which in turn displaces the latch body  410  rearwardly against the spring tension causing the latch pin  412  to be withdrawn into the bore  408  in the latch faceplate  402 . When the user releases the actuator  416 , the spring  418  causes the latch body  410  to return to the engaged position.  
         [0042]      FIG. 12  depicts a corner connector  500  that facilitates the connection of two tubular rail members at a 90° angle to one another without the need for a vertical support post. The corner connecter  500  includes two rail interfaces  502  extending from a body  504  and can be seen also to include detents  506  to retain a rail in the installed position as described above.  
         [0043]     Turning now to  FIG. 13 , a second alternate embodiment rail connector  600  is provided. As was provided above, the rail connector  600  is installed into holes located in the sidewalls  30  of the vertical supports  12 . The rail connector  600 , as described above, includes two opposing retention clips  618  that extend from the back of the rail connector  600 . When the rail connector  600  is installed onto the vertical post  12 , the opposing pair of retention clips  618  extend into the hole in the wall  30  of the vertical support  12  and engage the wall  30  to securely hold the rail connector  600  in assembled relation with the vertical support  12 . The rail connector  600  includes shoulders  620  that contact the outer surface of the vertical supports  12  and cooperate with the retention clips  618  to engage the wall  30  of the vertical support  12 . The retention clips  618  are spring biased allowing them to deflect as the rail connector  600  is inserted into the hole in the vertical support  12  and return to their original, undeflected state wherein retention clips  618  engage the interior of the wall  30  of the vertical support  11 . In its installed position, the shoulders  620  can be seen to contact the exterior surface of the wall of the vertical support  12  and the retention clips  618  can be seen to engage the interior surface of the vertical support  12  thereby ensuring that the rail connector  600  is securely retained in position on the vertical support  12 .  
         [0044]     This embodiment of the rail connector  600  includes a retention member  610  that extends outwardly from the vertical support  12  when the rail connector  600  is in assembled relation with the vertical post  12 . The retention member  610  includes an inner support  612  and an outer support  614  to receive and retain the ends  18  of the horizontal rails  14 . As can be seen the tubular configuration of the horizontal rails  14  provide openings in the ends  18  thereof that are received onto and about the inner support  612  while the outer support  614  has side walls that encircle the outer surface of the ends  18  of the horizontal rails  14 . In this manner, the retention member  610  portion of the rail connector  600  fully supports the end of the horizontal rails  14 . Beneficially, this allows the horizontal rails  14  be cut shorter thereby leaving a gap  616  at the ends thereof that allow room for thermal expansion of the horizontal rails  14  while also concealing the gap  616  at the end of the horizontal rails  14  within the outer support  614  walls. Additionally, the rail connector  600  may include detents  622  on the inner surface of the outer support  614 . The purpose of the detents  622  is to engage corresponding holes located in the sidewall of the horizontal rail  14  to prevent it from becoming dislodged from the rail connector  600 .  
         [0045]     It can therefore be seen that the present invention provides a unique modular fencing system  10  that is inexpensive to fabricate yet is highly durable and requires little maintenance. The fencing system  10  is easy to install, reconfigure and remove as required and is well suited to a do-it yourself installer. Further, the present invention can be modified and reused as required to facilitate temporary installations. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.  
         [0046]     While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.