Patent Publication Number: US-2004051093-A1

Title: Extruded fence post and modular fence assembly

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates to an extruded plastic modular fence assembly including a novel post member for use with various combinations of rails, pickets, raft members, spacers, panels, filler members and channel members. The post member is designed to be used with an optional internal reinforcing member in high-stress areas of the fence assembly adjacent, for example, fence gates.  
       BACKGROUND OF THE INVENTION  
       [0002] Fencing is available in a number of materials and designs to be typically used to restrict entry to a piece of land, to provide privacy and/or provide decorative landscape accents. It is often an object of fencing to provide these benefits, while being sturdy, maintenance free and aesthetically pleasing as well.  
       [0003] Until recently, wood components have been assembled into fences in an attempt to fulfill the above requirements. Wood fences are strong, relatively easy to install and pleasing to view. However, wood fences tend to be expensive, prone to decay in moist conditions and require periodic maintenance if expected to achieve a reasonable lifespan.  
       [0004] The deficiencies of wood fencing have been addressed to some extent by using alternate materials and construction methods. For example, molded or extruded plastic fence elements have been used with some success. While, plastic can provide good resistance to challenges like extended exposure to moisture, ordinary hollow, plastic posts and other plastic members may lack the strength and durability to resist strong winds, and support heavy loads from gates and heavy ice and snow, for example.  
       [0005] There is a demand for a modular plastic fence assembly that combines superior performance and low manufacturing and maintenance costs. The present invention satisfies the demand.  
       SUMMARY OF THE INVENTION  
       [0006] The present invention contemplates a fence assembly that may be assembled and selectively configured into a number of various forms due to the modular nature of the elements or components. The elements of the fence assembly are preferably formed of a polymeric material, such as plastic, by extrusion or molding, for example. The thickness of the sidewalls of the fence assembly components may be any desired thickness, preferably from about one-eighth of an inch to about one-quarter of an inch, such that the element is provided with sufficient physical rigidity and other properties. The components may be extruded or formed by any other suitable method. The material from which the fence components are made is preferably an extrudable thermoplastic material, such as polyvinyl chloride (PVC), including outdoor grade rigid PVC.  
       [0007] According to an aspect of the invention, a post for a fence assembly includes an elongated hollow member having an outer wall. The outer wall has a generally H-shaped cross-section and includes a first side and a second side. The first and second sides are oriented opposite each other on the elongated member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated member.  
       [0008] Other aspects of the invention may provide a first channel formed along the first side and a second channel formed along the second side. Both first and second channels are defined by the H-shaped cross-section. The one or more inner ribs may be a pair of spaced ribs. The first channel may include a first upper sidewall, a first inner sidewall and a first lower sidewall. The second channel may include a second upper sidewall, a second inner sidewall and a second lower sidewall. A first inner rib may extend between a first and second point on an inside surface of the outer wall. The first point may be located adjacent an intersection of the first upper sidewall and the first inner sidewall and the second point may be located adjacent an intersection of the second upper sidewall and the second inner sidewall. A second inner rib may extend between a third and fourth point on an inside surface of the outer wall. The third point may be located adjacent an intersection of the first inner sidewall and the first lower sidewall and the fourth point may be located adjacent an intersection of the second inner sidewall and the second lower sidewall. The middle chamber may have a rectangular cross-section. The first and second ribs and the first and second inner walls may define the middle chamber. The outer wall may include a generally planar third side and a fourth side of the elongated member.  
       [0009] Another aspect of the invention provides a post assembly for a fence including an elongated post member having an outer wall. The outer wall has a generally H-shaped cross-section defining a first channel along a first side of the elongated member and a second channel along a second side of the elongated member. The first and second sides are oriented opposite each other on the elongated member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated member. A reinforcing member is shaped and sized to be received within the middle chamber for reinforcing the post member.  
       [0010] Other aspects of the invention provide a rigid foot plate connected to a lower end of the reinforcing member. The foot plate may be adapted to be fastened to a footing.  
       [0011] Another aspect of the invention provides a fence assembly including a plurality of spaced, elongated hollow post members. Each of the plurality of elongated hollow post members has an outer wall. The outer wall has a generally H-shaped cross-section. The elongated post member includes a first side and a second side. The first and second sides are oriented opposite each other on the elongated post member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated hollow post member. One or more reinforcing member is positioned in the middle chamber of one or more of the plurality of elongated hollow members to provide support. A plurality of fence panels is fastened between adjacent pairs of the plurality of spaced, elongated hollow post members.  
       [0012] Other aspects of the invention provide fence panel components fastened into the first and second channels. Filler members may be provided, which are sized and shaped to be received by one of the first channel and the second channel. The fence assembly may further include one or more channel member attachable to the elongated hollow post members and sized and shaped for receiving an edge of a fence panel.  
       [0013] These and other advantages, as well as the invention itself, will become apparent in the details of construction and operation as more fully described and claimed below. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0014]FIG. 1 is a side elevational view of one embodiment of a fence assembly according to the present invention;  
     [0015]FIG. 2 is a side elevational view of a mounted reinforcing member for a post according to one embodiment of the present invention;  
     [0016]FIG. 3 is a cross-sectional view of one embodiment of a post of the present invention;  
     [0017]FIG. 4 is a cross-sectional view on the post of FIG. 3 illustrated a technique for attaching fence panel components to the post;  
     [0018]FIG. 5 is a cross-sectional view of a channel member;  
     [0019]FIG. 6 is a cross-sectional view of a filler member;  
     [0020]FIG. 7 is a cross-sectional view of a board member;  
     [0021]FIG. 8 is a cross-sectional view of another embodiment of a board member with a tongue and groove configuration;  
     [0022]FIG. 9 is a cross-sectional view of a top rail member including a narrow channel;  
     [0023]FIG. 10 is a cross-sectional view of an intermediate rail member including a narrow channel and a relatively large channel member opposite the narrow channel; and  
     [0024]FIG. 11 is a cross-sectional view of a bottom rail member.  
    
    
     DETAILED DESCRIPTION OF A PRESENTLY PREFERRED EMBODIMENT  
     [0025] In the description that follows, like elements are marked throughout the specification and drawings with the same reference character, respectively. The drawing figures are not necessarily to scale. Further, description of the assembly and various elements, components or portions of the assembly are provided according to their orientation as depicted in the drawings and are not meant to be limiting in any way.  
     [0026] An embodiment of a portion of a fence assembly according to the present invention is presented generally at  10  in FIG. 1. Generally, fence assembly  10  includes a plurality of elongate post members, one of which is depicted at  12 . It will be understood that the posts in any fence assembly may include one or more posts positioned at an end, corner or intermediate position in the assembly as necessary, depending on the configuration of the fence, i.e. number of ends, corners and the overall length of the fence assembly.  
     [0027] In the illustrated embodiment, an end post  12  is positioned at a left fence end  14  of the assembly  10 . The post  12  is an elongate member generally having an H-shaped cross-section. The post  12  includes an optional central reinforcing member  13 . Both the post  12  and reinforcing member  13  may be anchored by embedding within a standard concrete footing  15  or slab formed within or on the ground  17 . The top  19  of the post  12  includes a cap member  21 . The end post  12  may include an insert or filler member  18  (shown in FIG. 6) applied to a left channel  20  formed in left post side  26  opposite the right channel  24 .  
     [0028] The reinforcing member  13  is intended to provide reinforcement to a post  12  in which the member  13  is inserted. The post  13 , thus reinforced, may be used in any or all positions within an assembled fence. However, it will be understood that the post  12 , thus reinforced, will preferably by used in areas of the fence where greater stresses are produced, such as at fence gate areas, fence ends, fence corners and so on. It ma be necessary, due to wind or snow conditions, for example, to provide every post  12  with a reinforcing member  13 .  
     [0029] The end post  12  receives a panel, generally indicated at  16 , which includes an assembly of various different fence components to form a plane extending between adjacent posts, as will be described more fully below. The panels  16  may include an assembly of many differing types of members. Typically, each panel will include rails that extend between posts positioned at top and bottom positions of each panel. Vertical pickets or horizontal boards may be attached or inserted between the top and bottom rails. Horizontal rails referred to as mid-rails or intermediate rails may be used along or between the top and bottom rails. Lattice members, and other various panel members may be substituted for vertical and/or horizontal boards.  
     [0030] The illustrated panel  16  extends from a right side  22  of the post  12 . As will be described more fully below, the right post side  22  of post  12  is configured so as to present a vertical channel  24  along its length. The channel  24  is sized to receive the components of the panel  16 . The panel  16  may include virtually limitless combinations of components to provide the various support and screening features of the fence assembly  10 . Thus, the components illustrated herein should be considered as exemplary and not limiting in nature.  
     [0031] The panel  16  includes a bottom rail  30  positioned at a bottom edge  32  of the panel  16 . The bottom rail  30  includes a bottom rail channel  34  formed horizontally along the span of the rail  30  and positioned at an upper edge  35  of the rail so as to receive components of the panel  16  and provide alignment and support.  
     [0032] The panel includes a plurality of extruded vertical board members  36 . Lower edges  38  of the vertical board members  36  are disposed in the bottom rail channel  34 . The vertical board members  36  are positioned parallel and edge-to-edge in the plane of the panel  16  and extend upwardly from the bottom rail  30 .  
     [0033] Upper ends  40  of each of the plurality of vertical board members  36  are disposed in an under channel  42  formed in a lower edge  44  of intermediate rail  46 . The under channel  42  is sized to receive the upper edges of the vertical board members  36 . In the illustrated embodiment, the under channel  42  has a size, which is the same or similar to that of the bottom rail channel  34  to accommodate the vertical board members  36 .  
     [0034] Intermediate rail  46  also includes an over channel  48  formed in an upper edge  50  of the intermediate rail  46 . The over channel  48  may be the same or a different width as that of the under channel  42 . As the name suggests, intermediate rail  46  extends horizontally at an intermediate position of panel  16 , or in other words, at a position between top edge  52  and bottom edge  32  of panel  16 .  
     [0035] A lattice member  54  may be positioned in the over channel  48  of the intermediate rail  46  and extends upwardly to be positioned in a bottom channel  56  of top rail  58 . Top rail  58  effectively caps the panel at top edge  52 .  
     [0036] The horizontal members, including bottom, intermediate and top rails  30 ,  46  and  58 , are fastened to the post  12  by any suitable fastening mechanism. In a preferred embodiment, self-tapping screws (not shown) are inserted through the post  12  and corresponding horizontal or vertical members to engage and fasten the members to the post  12 . Plugs  60  are used to plug the openings provided or created in the post  12  for the fasteners.  
     [0037] It will be understood that if the fence assembly includes corners, the assembly includes corner posts (not shown) adjoining angled panels of the fence assembly and, dependent upon the overall length of the fence, the assembly will include intermediate posts (not shown) joining adjacent panels of the fence.  
     [0038] An alternate anchoring technique is shown in FIG. 2. Reinforcing member  13  is welded or otherwise fastened to plate  62 . Plate  62  may be a steel plate or other suitable material. Plate  62  is fastened to the concrete footing or slab by way of bolts or studs  64  or any other suitable fastener. Prior to the process of assembling the fence assembly, the footing  15  is poured. The plate  62  may be affixed to the footing  15  or if the plate is already fastened to the reinforcing member  13 , the plate  62  and member  13  are fastened to the footing  15 . In the alternate, the footing  15  is a concrete slab, or the like, which may be preferred to a footing in areas where digging is not convenient, for example. A post (not shown) is positioned upon the reinforcing member  13 , and the remainder of the fence assembly is affixed to the post.  
     [0039] The post  12  of the present invention is illustrated in FIG. 3 wherein the post  12  includes an H-shaped continuous outer wall  66 , which forms the H-shaped post. The post outer wall  66  defines an outer left channel  20  and an outer right channel  24 . Each of the left and right channels  20 ,  24  is defined by an upper sidewall  71 , an inner sidewall  72  and a lower sidewall  73 . On sides of the post not occupied by channels are an upper outer face  74  and a lower outer face  75 .  
     [0040] A pair of inner ribs  76 ,  77  extends from an inside surface  78  of the outer wall  66 . A first rib  76  extends from a point where the left channel  20  upper sidewall  71 L and inner sidewall  72 L join to a point where the right channel  24  upper sidewall  71 R and inner sidewall  72 L join. The second rib  77  extends from a point where the left channel  20  inner sidewall  72 L joins the lower sidewall  73 L to a point where the right channel  24  inner sidewall  72 R joins the lower sidewall  73 R. The first and second ribs  76 ,  77  divide an interior compartment  79  (formed by the continuous outer sidewall) into an upper post compartment  80 , a post middle compartment  81  and a lower post compartment  82 .  
     [0041] The first and second ribs  76 ,  77  function to provide structural stiffness to the post  12  when used alone in a fence assembly and further provides the post with a middle compartment  81  sized and shaped to closely bracket the reinforcing member  13  (see FIG. 1). The reinforcing member  13  may be any suitable rigid reinforcing member. Preferably, the reinforcing member  13  is a galvanized steel rod, which is rectangular in cross-section, although any suitable material and cross-section may be used, for example, circular, oval, triangular, pentagonal and hexagonal.  
     [0042] It will be understood that the middle compartment  81  will be configured to closely match that of the reinforcing member  13  cross-section. In other words, if the member  13  is rectangular, the middle compartment  81  is defined by the ribs  76 ,  77  and inner wall  78  of left portion  72 L and right portion  72 R so as to be similarly rectangular. Likewise, if the member  13  is circular, the ribs  76 ,  77  and inner wall  78  will be designed and extruded so as to provide a circular middle compartment  81  to match that of member  13 .  
     [0043] A technique for fastening various components to the post of FIG. 3 is illustrated in FIG. 4. One or more of rail ( 30 ,  46 ,  52 ) is inserted into one of the left and right channels  20 ,  24  (right channel  24  illustrated) of post  12 . First and second self-tapping screws  83 ,  84  are inserted through the upper outer face  74  and a lower outer face  75 . The screws  83 ,  84  further are inserted to upper sidewall  71 R and lower sidewall  73 R, respectively, and rail  46  to retain the rail to the post  12 . Plugs  60  may be used to close the openings left by the screws  83 ,  84  passing through the outer faces  74 ,  75  of the post  12  outer wall  66 .  
     [0044] In the event that post  12  is used as a corner post, a panel  16  will be connected to one of the left and right channels  20 ,  24  and another panel  16  will be connected to one of the outer faces  74 ,  75  so as to form an angled configuration, preferably perpendicular. It is further possible that one or more of channels  20 ,  24  will include a panel  16  and one or both of the outer faces  74 ,  75  will include an attached panel  16 . Thus, the post  12  may be used in a number of fence assembly configurations wherein  1 - 4  fence panels may be secured to a single post.  
     [0045] When a panel  16  is attached to an outer face, it is advantageous to provide the face with an attachable channel member  85 , as illustrated in FIG. 5, so as to provide the post outer face a structure to which the panel members may be attached in the same way as panel members are attached to the channels  20 ,  24  of the post  12 . Accordingly, the channel member  85  is an elongate U-shaped channel member that is attached along an outer face  74 ,  75  (see FIG. 3) of post  12 .  
     [0046] Standard self-tapping screws, as shown in FIG. 4, may be used to attach the channel member  85  to post  12 . The channel member includes a back wall  86  and first and second channel sidewalls  87 ,  88 . A panel (not shown) is attached in a similar fashion to that of FIG. 4, by attaching the channel member  85  the post, inserting the panel or panel member into the channel member and driving self-tapping screws inwardly through the channel sidewalls  87 ,  88  through the panel members.  
     [0047]FIG. 6 illustrates a filler member  89  of the present invention. The filler member  89  is a hollow elongate rectangular member in cross-section, sized and shaped to be received by channels  20  and  24  of post  12 . The filler member  89  may be applied to the post  12  in order to fill one or more of the channels  20 ,  24  so as to present a relative smooth side of the post in the event that the channel is not used to receive panel components.  
     [0048] The filler member  89  may include a wood or metal or other suitable insert for enhanced structural, enhanced attachment and other reasons. In the event that the filler member  89  is inserted into a post  12  adjacent a gate of the fence, the filler may be provided with internal reinforcement, like a wood insert (not shown). The gate (not shown) may then be affixed to the filler and/or the post  12  by way of hinges, latches or the like. In the event that the fence is intended to abut a wall of a home or garage or the like, the filler member  89  and insert may be first attached to the wall. The post  12  is attached to the filler member  89 . In this example, the filler and post ( 89 ,  12 ) may be referred to a lag post.  
     [0049]FIG. 7 illustrates a board member  36  of the present invention. The board member  36  is a hollow elongate rectangular member in cross-section. In one embodiment, the board member  36  is sized to have the dimensions of a 1×6 or any suitable dimension. The board member  36  may be used as one or more of a plurality of panel components, (See FIG. 1). It will be understood that board member  36  may be oriented in a vertical direction (as in FIG. 1) or horizontally.  
     [0050]FIG. 8 illustrates a hollow, generally rectangular, interlocking tongue-and-groove panel member  90  for use as a panel component. The interlocking member  90  includes an upper surface  91  with a tongue  92  extending from a central portion of the upper surface  91 . A lower surface  93  opposite the upper surface  91  includes a groove  94  sized and shaped to receive a tongue  92  of an adjacent interlocking member or the like.  
     [0051]FIG. 9 illustrates an upper or top rail  52 . Top rail  52  is a hollow generally rectangular panel component. A narrow top rail groove  56  is formed on an underside of the rail  52  sized to receive a narrow panel component such as a lattice member  54 , for example. It will be understood that the top rail  52  may be used in a bottom position  32  of the panel  16  in the event that a narrow panel component is used in place of a component such as boards  36 .  
     [0052]FIG. 10 illustrates an intermediate or mid-rail  46 . Intermediate rail  46  is a generally rectangular panel component in cross-section and is intended to be oriented in a horizontally in the panel  16 . The intermediate rail  46  may be positioned at a point in the panel  16  between the upper rail  30  and lower rail  58  to receive panel components therebetween. The intermediate rail  46  may include over channel  48  and under channel  42  as described above.  
     [0053]FIG. 11 illustrates a bottom rail  30 . Bottom rail  30  is a hollow generally rectangular panel component. A bottom rail channel  34  is formed on an upper edge thereof. For example, the bottom rail channel  34  may receive one or more boards  36  depending on the orientation thereof. It will be understood that the bottom rail  30  may be used in an upper position of the panel  16  in the event that a wide panel component is used at the top of the panel  16 .  
     [0054] While the apparatus and method herein disclosed forms a preferred embodiment of this invention, this invention is not limited to that specific apparatus and method, and changes can be made therein without departing from the scope of this invention, which is defined in the appended claims.