Patent Abstract:
A fence system including a fence post and a rail inserted into and supported by the fence post. The rail being an elongated member having a channel or U-shaped cross section defined by a web member and parallel leg members attached to the web member. The rail is inserted into an aperture located in a sidewall of the post. The aperture having a shape or configuration that is substantially the same as the cross-sectional shape of the rail. Accordingly, any gaps between the opening or aperture in the post and the rail, once the rail is inserted into the post, are minimized.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a rail type fence system including a fence post and rails. More specifically, the invention is directed to a rail type fence system having a configuration that limits access to the interior of the fence post and rail components to prevent formation of insect nests. 
         [0004]    2. Description of Related Art 
         [0005]    Fences are almost as old as humanity. Over the years, fences of all types and kinds, from rock walls to barbed wire, were built with one of two purposes in mind, keep things in or keep them out. For instance, fences are used to keep livestock in a certain area or are placed around a particular area to prevent access thereto. Today, fences also provide a decorative touch or provide privacy. 
         [0006]    One of the more common fence systems presently used is a fence post and rail combination, wherein the fence posts are placed at spaced intervals. Horizontal rails are placed between the fence posts. One example of a fence post and rail combination is the standard split rail fence seen throughout much of rural America typically used to contain livestock. In many instances, attached to the rails are fence elements or pickets forming what we refer to today as a picket fence. 
         [0007]    Like many of our products today, fences are manufactured and sold as a component system, including a plurality of preformed fence posts as well as a plurality of rails designed to fit, connect, or interlock to the fence posts. Typically, these fence systems utilize a tubular fence posts made of metal or plastic having a plurality of shaped apertures located in the sidewalls thereof to receive the rails, including appropriate hardware to interlock the components together. 
         [0008]    One example of such a fence system is illustrated in U.S. Pat. No. 5,651,534 to Yoder. Yoder teaches a plurality of hollow, extruded fence posts as well as a number of hollow, extruded fence rails. A pair of rectangular shaped openings located on opposed walls of the fence posts receive the rails of the fence system. As shown in Yoder, the rails have a rectangular shape with a closed cross section. Thus, the rails fit securely within the rectangular shaped apertures in the fence posts without leaving any appreciable gaps. A cap closes the upper end of the fence post and further prevents access to the hollow interior thereof. 
         [0009]    Another example of a fence system is disclosed in U.S. Pat. No. 4,609,185 to Prater et al. Prater et al. discloses a fence post and rail configuration including tubular fence posts containing a plurality of apertures in the sidewalls thereof for receiving the rails. The rails are formed with a generally channel or U-shaped cross section formed of a web and sidewalls extending therefrom. Accordingly, when the rail is inserted into the tubular fence post, a gap or opening exists that extends between the lower edge or sides of the rectangular shaped aperture and the web of the rail. This gap or opening provides access to the interior of the hollow fence post. 
         [0010]    One drawback of such a modular fence design using a rail having a channel or U-shaped cross section is that insects, particularly bees or hornets have access to the interior of the hollow fence post and often build nests within the fence posts. This can be very problematic, especially when such fence systems are used around homes and recreation areas, particularly pools and playgrounds. 
         [0011]    Accordingly, in an attempt to reduce the possibility of insect infestation, including the opportunity for insects to build nests within the hollow fence post, it is desirable to reduce the opportunity for insects to have access to the hollow interior of the fence posts by somehow closing the gap or opening. 
         [0012]      FIGS. 4-5  illustrate a prior art design for closing the gap or opening. Specifically, a plurality of preformed plugs are inserted into the channel or U-shaped rail, between the sidewalls and up to the web member thereof. The plugs operate to form a seal that reduces access to the interior of the fence post. The plugs are formed in accordance with the specific size and configuration of the rail. Thus, a stock of variably sized plugs is necessary depending upon the design and parameters of the fence system. In addition, the cost of manufacturing and storing the plugs can make such a system too expensive for all but very small uses. Further, it should be taken into account that inserting a plug in each rail at every fence post and rail junction is a time-consuming and laborious procedure, which, for large amounts of fencing, can be cost prohibitive. 
         [0013]    From the above, it can be appreciated that modular fence systems are not fully optimized to provide a simpler, less costly fence system that reduces the opportunity for insect infestation in the fence components, particularly the fence posts. Therefore, what is needed is a fence post and rail system that fits together without any appreciable gap or opening between the fence post and rail and thereby reduces the opportunity for insect infestation within the fence post. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    According to the preferred embodiment of the present invention, there is provided a fence system including a fence post and a rail for insertion into an aperture in the fence post. The rail has a channel or U-shaped cross section that results in one side being open. The aperture in the fence post is configured similar to the cross section of the rail and includes an upstanding portion or tab. The upstanding portion or tab is sized such that it fits within the channel or interior of the U-shaped cross section to block access to the interior of the fence post. Thus, the present invention is capable of successfully incorporating the benefits of a fence system with an integrated insect barrier without the need for additional plugs or stop members. 
         [0015]    It is an object of the present invention to provide a fence system for use with rails having generally a channel or U-shaped cross section. The fence post includes an aperture having an upstanding portion or tab that fits within the channel. Wherein the rails fit snugly into the aperture in the fence post to block access to the interior of the fence post and prevent insect infestation, including the creation of nests within the interior of the fence post. 
         [0016]    It is a further object of the present invention to provide a fence system including fence posts and rails, wherein the fence post includes an aperture for receiving the rail. The aperture in the fence post for receiving the rail corresponds to the shape or configuration of the cross section of the rail such that the rail fits securely within the fence post without any appreciable gaps or openings that would allow for possible insect infestation within the hollow area of the fence post. 
         [0017]    These objects and other features, aspects and advantages of this invention will be more apparent after a reading of the following detailed description, appended claims and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is an exploded perspective view of a fence system according to the preferred embodiment of the present invention; 
           [0019]      FIG. 2  is a partial side view of the fence post of  FIG. 1  illustrating an aperture configured in accordance with the present invention; 
           [0020]      FIG. 3  is a partial, cross-sectional side view of the fence post of  FIG. 1  illustrating a rail having a substantially U-shaped cross section disposed within the aperture in accordance with the present invention; 
           [0021]      FIG. 4  is a partial side view of a prior art fence system utilizing a plug placed within the channel of the rail; and 
           [0022]      FIG. 5  is a cross-sectional view of the prior art fence system taken along lines  5 - 5  of  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    As discussed above,  FIGS. 4-5  illustrate a prior art fence systems  102  that utilizes a rail  104  having a substantially U-shaped cross section  106 . The rail  104  is inserted into an aperture  108  located in a hollow fence post  110 . The aperture  108  is typically a rectangular or square opening of a size suitable to accept the three sides of the U-shaped rail  104 , specifically, the web  112  and two legs or sides  114  of the U-shaped cross section. Therefore, this type of fence system  102  inherently has a problem in that it provides a gap or opening that allows access to the interior of the fence post  110 . 
         [0024]    In an attempt to solve this problem, plugs  116  sized to fit between the leg or sides  114  of the U-shaped rail  104  are inserted adjacent the fence post  110 . Use of the plug  116 , while closing the gap or opening, creates additional costs associated with both manufacturing the plugs  116  and the labor to insert the plugs  116  at each and every joint between the fence post  110  and rail  104 . Since this plug is inserted using only an interference fit, it is unknown at this time, whether exposure to the elements, over time, will work its way loose and expose the gap or opening in the rail. 
         [0025]    Referring now to  FIG. 1 , there is shown a perspective view of a modular fence system  10  according to an embodiment of the present invention. The modular fence system  10  in includes a fence post  12 . The fence post  12  includes an upper end  14  and a lower end  16  that is embedded in the ground  18  using well known prior art teachings for anchoring the post. The fence post  12  is hollow or tubular and includes a front sidewall  20  and a right sidewall  22 . It should be understood that the fence post  12  shown in the present invention has a square configuration or cross section and thus includes a rear and left sidewall that is not shown in the drawings. As the fence post  12  is hollow or tubular, each of the front and right sidewalls  20 ,  22 , along with the rear and left sidewalls (not shown) will have interior and exterior surfaces. It should also be understood that although the preferred embodiment describes a square post, other geometric configurations for the post are contemplated in practicing the invention as described herein. 
         [0026]    The fence post  12  shown in  FIG. 1  is used as an end post and includes three apertures  24  located in the right sidewall  22 . If the fence post  12  were to be used as an in-line post it would include additional openings or apertures  24  formed in the left sidewall. If used as a corner post, additional openings or apertures  24  are formed in either the front  20  or rear sidewall depending upon the particular corner formed by the fence post  12 . While shown with three openings or apertures  24 , the fence post  12  according to the present invention may include a lesser or greater number of openings or apertures  24  depending upon the amount or number of rails  28  forming the fence assembly or system  10 . A cap  26  is placed on the upper end  14  of the fence post  12  to cover the upper or open end  14  thereof. 
         [0027]    The modular fence system  10  further includes a rail  28 . The rail  28  is an elongated substantially U-shaped channel member having an end or web member  30  and side flange members  32  extending substantially perpendicular from the end or web member  30 . The side flange members  32  define a gap or opening  34  therebetween. As shown herein, the edges  36 ,  38  of the end or web member  30  are rounded and extend slightly past the side flange members  32 . The rail  28  further includes a plurality of apertures  40  located in the respective side flange members  32 . 
         [0028]    As shown in  FIG. 1  a plurality of fence elements or pickets  42  are fastened to the rails  28 . The fence elements or pickets  42  extend up to or through the end or web member  30 , and are fastened to the rail  28  by fasteners extending through the apertures  40  located in the side flange members  32  of the rails  28 . The number of fence elements or pickets  42  along with the placement or spacing thereof is a design choice. The invention set forth herein is suitable for use with out fence elements or pickets  42  extending between the respective rails  28 . 
         [0029]    Turning now to  FIG. 2  there is shown the aperture or opening  24  in the post in detail. Specifically, an upstanding portion or tab  44  extends upwardly into the aperture or opening  24 . The upstanding portion or tab  44  has a shape or configuration complementary to the shape or configuration of the gap or opening  34  located between the respective side flange members  32  of the rail  28 . The upstanding portion or tab  44  has a length substantially equal to the length of the respective side flange members  32  such that it ends in close proximity to the end or web member  30  of the rail  28 . It will be apparent that the configuration or shape of the opening or aperture  24  is substantially the same as a cross-sectional shape of the inner configuration of the U-shaped channel of the rail  28 . Accordingly, as shown in  FIG. 3  when the rail  28 , shown in cross-section, is inserted into the opening or aperture  24 , it fits such that there is no significant gap or opening between the outer periphery of the rail and the inner periphery of the aperture  24  in the post to allow access to the interior of the fence post  12 . As shown in  FIG. 3 , the peripheral edge  25  of the opening or aperture  24  substantially corresponds with the outer configuration of the rail  28  to prevent access and thereby avoid insect infestation within the hollow interior of the fence post  12 . 
         [0030]    It should be understood that the present invention provides an aperture or opening  24  that substantially corresponds to both the outer configuration or shape of the rail  28  and the inner configuration or shape of the rail  28 . That is, the shape of the aperture or opening  24  substantially corresponds to the cross-section of the rail  28 . Accordingly, the rail  28  is shown herein as having a substantially U-shaped cross-section with a gap or opening  34  formed by the side flange members  32  of the rail  28 . Correspondingly, the aperture or opening  24  of the post  12  includes having an upstanding portion or tab  44  extending upward into the aperture  24 . The upstanding portion or tab  44  is sized to fit within the gap or opening  34 . 
         [0031]    Other configurations, such as a concave polygon shape can be used as long as the aperture or opening  24  has a corresponding concave polygon shape such that any gap existing between the aperture or opening  24  and the rail  28 , when the rail  28  is inserted into the post  12  is minimal. Making the gap minimal reduces the opportunity for insects to access the interior of and build nests within the interior of the post  12 . For example, if the rail  28  had an L-shape or angle configuration or cross-section, then the opening or aperture  24  should have the same configuration. 
         [0032]    According to the present invention, the opening or apertures  24  in the fence post  12  are stamped or cut into the sidewall, shown in  FIG. 1  as the right sidewall  22 , of the fence post  12  in a configuration corresponding to the particular cross-section of the rail  28 . Doing so provides a snug fit between the rail  28  and the fence post  12  while at the same time limiting access to the interior or hollow portion of the fence post  12 . Furthermore, the present invention does not require any additional parts or components in the form of plugs or other parts to reduce the possibility of insect infestation within various components of the fence system  10 . In addition, the foregoing invention may be used with other components of a fence system  10 . For example, depending upon the shape and configuration of the rails, the fence elements or pickets  42  may be installed in the rails in a similar manner. 
         [0033]    While the present invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. In other words, the teachings of the present invention encompass any reasonable substitutions or equivalents of claim limitations. Accordingly the scope of the present invention is to be limited only by the following claims.

Technology Classification (CPC): 8