Abstract:
A method of manufacturing a decorative fencing system for use as a small fence or decorative accent fence for a yard or garden. The fencing system comprises several different structural components that may be joined in various combinations so as to create a nearly limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be attached to the other components in any combination thereof. Each of these components are attached to post sections which are removably and interchangeably inserted through post rings or post hinges or welded onto the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections are removably and interchangeably secured to the ground by means of stakes that are driven into the ground and the post section is then inserted into a sleeve in the stake, or alternately onto a post-receiving extension on the stake to thereby provide support and stability for the fencing system, with the post section being held by the stake, either removably or permanently.

Description:
[0001]     This is a continuation-in-part of U.S. patent application Ser. No. 10/797,410, filed Mar. 10, 2004, which is currently pending, the contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates generally to a method of manufacturing a decorative fencing system, and, more particularly, to a method of manufacturing a decorative fencing system that includes multiple components and may be arranged in a potentially unlimited number of combinations and permutations, to be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or a combination thereof.  
         [0004]     2. Description of the Related Art  
         [0005]     The art fails to specifically address either the problem or the solution reached by the applicant. Decorative fencing systems have long been known in the industry, as has the use of sectional fence structures to create various configurations for fencing systems. Some examples of such fencing systems are shown in references that date back to the mid to late 1800s.  
         [0006]     A common shortcoming in the related art is inflexibility. In many systems, the fence can be assembled by the user in only a single configuration. In other systems, while more than one configuration is possible, it is complicated and time consuming for the user, after assembling the fence in one configuration, to disassemble it and reassemble it in another configuration.  
         [0007]     There has long been a need for a decorative fencing system, which can be easily and quickly assembled in one configuration, easily and quickly disassembled, then easily and quickly reassembled in any one of a nearly limitless variety of different configurations.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention relates to a method of manufacturing a decorative fencing system having several components that may easily and quickly be arranged in one of a nearly limitless number of configurations or combinations, easily and quickly disassembled, and easily and quickly reassembled in another one of the nearly limitless number of configurations or combinations.  
         [0009]     The present invention provides a method of manufacturing such a decorative fencing system that may be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or even a combination thereof.  
         [0010]     The present invention further provides a method of manufacturing such a decorative fencing system that allows a user to purchase and use only those elements necessary to create the design or shape of his or her choosing.  
         [0011]     The present invention further provides a method of manufacturing such a decorative fencing system that may be either permanently or temporarily affixed to the ground.  
         [0012]     The present invention further provides a method of manufacturing such a decorative fencing system which includes all the elements necessary to create a standard fence, including base units, gates and end units.  
         [0013]     The present invention further provides a method of manufacturing such a decorative fencing system which may include a variety of interchangeable, structural, functional, and decorative elements.  
         [0014]     The present invention further provides a method of manufacturing such a decorative fencing system in which the individual components are manufactured from a variety of materials or be provided with a variety of finishes.  
         [0015]     The present invention, as broadly disclosed herein, comprises a method of manufacturing a decorative fencing system, designed to be used as a small fence or decorative accent fence for an outdoor yard, or a combination thereof. The fencing system is manufactured to include several different components that may be joined in various combinations so as to create a limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be removably and interchangeably attached to the other components in any combination thereof. Each of these components are removably and interchangeably attached to post sections which are inserted through post rings or post hinges on the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections can be removably and interchangeably secured to the ground by means of stakes that are first driven into the ground.  
         [0016]     In one embodiment, the post sections are removably and interchangeably insertable into respective sleeves in the stakes, to thereby provide support and stability for the fencing system. The fence components are removably and interchangeably attachable to selected post sections to create a desired fence configuration.  
         [0017]     In another embodiment, the post sections are manufactured to be friction-fit to the stakes, the stakes driven into the ground, and the fence components are then removably and interchangeably attached to selected post sections, in order to create a desired fence configuration.  
         [0018]     In still another embodiment, a lower portion of the posts are manufactured to be hollow, and the stakes are configured with a protruding extension. The hollow lower portions of the posts are removably and interchangeably insertable over a respective protruding portion of selected stakes, and the fence components are removably attachable to selected post sections to interchangeably create a desired fence configuration. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]     The objects and advantages of the present invention will be apparent from the detailed explanation of the preferred embodiments of the invention in connection with the accompanying drawings, wherein:  
         [0020]      FIG. 1  is a front elevational view of a portion of the decorative fencing system of the present invention showing various components thereof.  
         [0021]      FIG. 1A  is a top view of a post ring attached to a structural fencing portion in  FIG. 1 .  
         [0022]      FIG. 2  is an exploded side view of one embodiment of a post and stake of the present invention, wherein a diameter of a removable post is smaller than an internal diameter of a stake sleeve.  
         [0023]      FIG. 2A  is an exploded side view of another embodiment of a post and stake of the present invention, where an internal diameter of a removable post is substantially identical to an internal diameter of a stake sleeve.  
         [0024]      FIG. 3  is an exploded side view of one embodiment of a post and stake of the present invention, wherein an internal diameter of a removable post is larger than a diameter of a post receiving extension on the stake.  
         [0025]      FIG. 4  is a front elevational view of a fence base unit.  
         [0026]      FIG. 5  is a front elevational view of a fence end unit.  
         [0027]      FIG. 5A  is a front elevational view of another embodiment of a fence end unit.  
         [0028]      FIG. 6  is a front elevational view of fence gate units.  
         [0029]      FIG. 7  is a front view of a decorative fence system in accordance with the invention.  
         [0030]      FIG. 8  is a top perspective view depicting different arrangements of the decorative fence system of the invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]     Referring to the drawings and, in particular, to  FIGS. 1, 1A , and  2 , the decorative fencing system of the present invention, referred to generally by reference numeral  10 , is illustrated. The fencing system  10  comprises separate structural components  12  including a base unit  14 , a gate unit  16 , and an end unit  18 , which are arranged and combined with each other so as to create a potentially limitless number of configurations for the decorative fencing system  10 .  
         [0032]     The fence structural components  12  are manufactured to be attached to each other by means of one or more posts  20  to which the fence structural components  12  may be removably and interchangeably attached. In the preferred embodiment, the means for attaching the fence structural components  12  comprises post rings  22 , depicted in  FIGS. 1 and 1 A, which are disposed on either end of the base units  14  or on one end of the end units  18 , shown in  FIG. 5 , or by post hinges  24 , which are disposed on the outside edges of the gate units  16  shown in  FIG. 6 . The post rings  22  are annular elements having an inner diameter slightly larger than the diameter or width of the posts  20  such that post  20  may be slidably inserted within the post rings  22  to thereby engage either the base unit  14  or end unit  18 . As broadly embodied herein, the inner diameter of the post rings  22  is approximately 21 mm and the diameter of the posts  20  is approximately 19.76 mm. Similarly the post hinges  24 , include annular elements similar to the post rings  22  coupled with a hinge  26 , that allows the individual gate elements  28  of the gate unit  16  to swing open and shut. In the preferred embodiment, the gate elements  16  comprise a pair of complementary doors that may be operated independently or concurrently, although other designs are possible so as to fit with the design and theme of the decorative fencing system  10 .  
         [0033]     As illustrated in  FIGS. 1 and 4 - 6 , each of the structural components  12  includes two post rings  22  or post hinges  24  at each end at which the component  12  may be attached to the post  20 . For example, the base unit  14  includes two post rings  22  on either side thereof, the gate unit  16  includes two post hinges  24  on the outside edge of each gate element  28 , and the end unit  18  includes two post rings  22  on one side thereof. In the preferred embodiment, the post rings  22  or post hinges  24  are attachable to a substantially vertical element  30  so that the post rings  22  or post hinges  24  are in alignment when receiving the posts  20 . Alternate embodiments are possible in which either the post rings  22  or post hinges  24  are attachable to horizontal components or other elements provided, however, that the post rings  22  or post hinges  24  are in alignment. Furthermore, while in the preferred embodiment only two post rings  22  or post hinges  24  are disposed along each vertical element  30 , more may be provided so as to further strengthen and secure the attachment of the structural components  12  to the posts  20 .  
         [0034]     It should also be appreciated that while in the preferred embodiment, the post rings  22  and post hinges  24  are disposed at the top and the bottom of the vertical elements  30 , as shown in  FIGS. 1 and 4 - 6 , they may be positioned at various heights along the length of the vertical elements  30  as may be desired. For example, as illustrated in  FIGS. 1 and 4 - 6 , the height of the upper post ring  32  on the base unit  14  is higher than that of the upper post ring  22  on the end unit  18 , which, in turn, is higher than upper post hinge  24  on the gate unit  16 . This configuration facilitates the combination of two or more structural components  12  since the post rings  22  or post hinges  24  will not necessarily interfere with each other. It should also be appreciated that, in the preferred embodiment, contact should be avoided between the post hinges  24  and the post rings  22  so as to prevent interference with the operation of the hinges. Toward that end, it may be preferred to mount the lower post hinges  24  of the gate unit  16  as broadly depicted in  FIG. 6 , above the lower post rings  22  of either the base unit  14  or the end unit  18 .  
         [0035]     The decorative fencing system  10  is secured to the ground by means of one or more stakes  40 . The stakes  40  are designed to be driven into the ground and receive the posts  20  to thereby support the structural components  12  in place. In the preferred embodiment, the stakes  40  are manufactured to be wedge shaped or to include a plurality of fins so as to facilitate their insertion into the ground, although a variety of alternative designs are possible. Preferably, the stakes  40  are pointed at one end, so that the stakes can be forcibly driven into the ground. However, if the user prefers to dig a hole for the stakes  40 , this can be done, and these elements could be of practically any shape or size, provided they could receive and retain the posts  20 .  
         [0036]     In one preferred embodiment, as broadly depicted in  FIG. 2 , the stakes  40  receive and retain the posts  20  by means of a stake sleeve  42 , essentially a cylindrical recess or cavity within the body of the stake  40  having an internal diameter slightly larger than the diameter or width of the post  20  such that the post  20  will be received within and retained by the stake sleeve  42  only by means of frictional contact therebetween. The posts  20  preferably are manufactured to be removably held only by friction, so that they are removable from each stake sleeve  42  and insertable into another stake sleeve  42 , as desired. They are not welded or otherwise permanently affixed in place. As broadly embodied herein, in this embodiment the preferred internal diameter of the stake sleeves  42  is approximately 22 cm-22.5 cm, and the preferred external diameter is approximately 26.5-28 cm. There is some clearance between the post  20  and the internal surface of the stake sleeve  42 . In this embodiment, post  20  can be removed from stake  40 , leaving stake  40  in the ground, and reinserted into another stake  40  driven into the ground at a different selected location.  
         [0037]     Alternatively, in another preferred embodiment, as broadly depicted in  FIG. 2A , the posts are made larger, so that the diameter of the posts  20  are substantially identical to an internal diameter of the stake sleeve  42 . In this embodiment, the posts  20  are permanently friction-fit into the stake sleeves  42 . In this embodiment, removal of post  20  from the ground for movement to another selected location, also requires removal of the stake  40  from the ground.  
         [0038]     In another preferred embodiment, as depicted broadly in  FIG. 3 , stake  40  is manufactured with an extending solid post-receiving portion  44 , and the post  20  has a hollow portion  48  at its lower distal end, with a diameter larger than the diameter of the post receiving portion  44 . In this embodiment, each selected post hollow portion  48  fits over each selected post-receiving portion  44 , and the posts  20  are supported thereby. In this embodiment, like the embodiment of  FIG. 2 , post  20  can be removed from stake  40 , without removing stake  40  from the ground, and moved to another stake  40 , which is driven into the ground at a different location.  
         [0039]     Ideally, the stake sleeve  42  or post-receiving portion  44  should be of sufficient length so as to securely receive the post  20 , and the length of the portion of the stake  40  that is inserted into the ground, or the length of post hollow portion  48  that sits on top of post-receiving portion  44  should be sufficient to prevent the post  20  from toppling over when the decorative fencing system  10  is assembled. In a preferred embodiment, the length of the portion of the stake  40  that is inserted into the ground, or that sits on top of post-receiving portion  44  is approximately 10 cm, although longer stakes  40  may function just as well, and shorter ones may also serve effectively, provided the weight of the structural components and posts  20  are not too great, and the ground itself is firm enough to retain the stake  40  therein. Also in the preferred embodiment, the stake sleeve  42  should extend above the ground level by a sufficient height to allow the desired clearance between the bottom of the structural components  12  and the ground. As broadly embodied herein, a preferred height of the stake sleeves  42  is approximately 15-20 cm, with a height above the ground of approximately 5 cm-8 cm. This is most significant for the gate unit  16 , since the gate elements must clear any uneven ground in order to allow the gate elements to open and close properly. Furthermore, the combined weight of the post  20  and any structural components  12  attached thereto serve to force the post  20  within the stake sleeve  42  and prevent the post from sliding out prematurely.  
         [0040]     The end units  18 , broadly depicted in  FIGS. 5 and 5 A, serve to provide decorative termination points for the decorative fencing system  10 , and as such, include a decorative termination point  44  on the side opposite the vertical element  30  or the side to which the post rings  22  are attached. Rather than use a separate post  20  to anchor the termination point  44  to the ground, a separate stake pin  50  can be provided at the termination point  44 . The stake pin  50  extends below ground level when the end unit  18  is attached, thereby securing the end of the end unit  18  to the ground. As illustrated in  FIGS. 5 and 5 A, in preferred embodiments the stake pin  50  can be thin to facilitate its insertion into the ground. It also is of approximately the same length as the stake  40 , although a shorter stake pin  50  would work just as effectively.  
         [0041]     In the preferred embodiment of the method of manufacturing fencing system  10 , the components of fencing system  10  are manufactured from tubular steel, and both square and round stock. A powder coat finish may be provided on some or all of the elements. For example, a separate color or finish or a different material, such as bronze colored cast iron, may be used for decorative accents  48  such as finials  51  or decorative ball caps  52 .  
         [0042]     Preferably, jigs are set up and all of the component pieces are cut from tubular steel, wire rod, and flat stock, i.e., the stakes  40 , the posts  20 , structural components  12 , post rings  22 , post hinges  24 , and so on.  
         [0043]     Curved pieces are then formed at appropriate locations in the end structural components  12 , and some structural components  12  are shaped into end units  18  or gate units  16 .  
         [0044]     The post rings  22  are cut, and stamped into their final shape.  
         [0045]     Holding the components in jigs, decorative finials  50  may be welded into ends of the posts  20  or vertical pieces of structural components  12 , and hinges  24  are welded into place on gate units  16 . Rings  22  are also welded into appropriate locations on structural components  12 .  
         [0046]     The components are prepared for powder coating either through insertion into a metal pellet sand blast chamber or through the use of an acid wash sequence that ends with drying to eliminate water in the crevices prior to coating.  
         [0047]     Individual pieces are then powder coated.  
         [0048]     Alternative manufacturing methods, or minor variations on the above method, are also contemplated, including manufacturing individual components out of solid iron or steel pieces, then welding and then finishing by powder coating or painting. The components may be produced as individual cast iron pieces and finished with various paint techniques to create different appearances.  
         [0049]     It should be appreciated that the design of the individual structural components shown in the drawings represent one possible design for the decorative fencing system  10  of the present invention. A variety of different designs and decorative accents  48  are contemplated, such as a Victorian design or a more modern design. The only limitation is that the design of the system  10  is embodied by the structural components  12  and tied together by the posts  20 , post rings  22  and post hinges  24 , and that the structural components  12  and posts  20  are removable and interchangeable so that a wide variety of fence configurations can be assembled, as explained below.  
         [0050]     The process of assembling the fencing system  10  is designed to be simple and easy to alter. In the preferred embodiment, a stake  40  is driven into the ground, and the individual structural components  12  are held into place above the stake  40 . A post  20  is inserted through the post rings  22  and/or post hinges  24 , are then removably inserted into the stake sleeve  42  of the stake  40 , or in another embodiment friction-fit into the stake sleeve. The process is repeated as necessary until the desired configuration is achieved, allowing for a potentially infinite number of combinations and angles between the structural components. Some examples of these variations are illustrated in  FIGS. 7 and 8 . Since each of the structural components  12  may be purchased separately, the decorative fencing system  10  may be as large or as small as the user.  
         [0051]     Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.