The invention relates generally to channeled fence post for building horizontal fence, several methods for constructing a horizontal wood fence, and method of manufacturing a metal fence post.
Currently there are a number of solutions for construction of a horizontal wood fence. The traditional method is to use wood posts, wherein horizontal wood boards are fixed directly into the wood post, but the wood post is prone to rot and decay. To combat this problem, metal posts have been used to create horizontal fences, each also having limitations. Round metal posts can be used with clips to affix support boards and the horizontal boards are fastened to support boards. However, the use of round metal posts is not aesthetically pleasing, are not “good neighbor” fences as one side will feature unattractive metal posts and the other side will not, and the posts cannot be easily hidden. The support boards can also rot and decay and are cumbersome method of construction. The other method is to use a square metal post, and sandwich two support boards on the side of that metal post, which are drilled into the metal post, and affix horizontal boards to the support boards. However, the aesthetics again are not as pleasing because there is no way to hide the metal post, and support boards have to be drilled into the square post which is cumbersome. The wood support posts are also prone to rot and decay. Another method is to use the Halco postmaster to construct a horizontal wood fence, which is a hat channel metal post. However, construction is cumbersome. Like using a square metal post, wood support boards have to be fastened to the post, and horizontal boards then are attached to the support boards. Another design is the “slipfence”, which has metal U channels that affix to a metal square post or a wood post, with boards that slide into the U channels. However, this solution again does not allow the metal post or the channel posts to be hidden and the construction is cumbersome, the metal post and u channels are very noticeable which may not be aesthetically pleasing. None of the solutions avoid the necessity of wood support boards or allow the post to be hidden, nor do any of these solutions allow an alternative construction where all fasteners and all posts are hidden.
The present invention relates to (1) an improved metal fence post (2) improved method for construction of a fence in which fence boards are positioned horizontally, and (3) and a method for manufacture of a metal fence post. Metal is a preferred material, but the present invention contemplates specific alternative embodiments having non-metallic materials. With respect to the device, it is preferably a metal fence post constructed of 2 back facing metal J channels, which allows for the easy construction of a horizontal wood fence in multiple designs. Each J-channel post is shaped to have a long arm and a short arm which form a channel between them. Back-to-back connection of the J-channel posts means they are connected such that the short arms are one a first side and the long arms are on a second side. Additional decorative panels can be clipped onto the post after the wood boards are placed in the channel. This metal fence post is superior to traditional methods of constructing horizontal wood fences which require the use of wood posts or round metal posts. The core components of the invention are two J channel metal posts, which are positioned back to back, and are permanently fastened together, and which have holes along the post used to fasten boards along the post. With respect to the device it should be further noted that once the two J channels are fastened together, a metal post is created with two planes of faces of different widths. The difference in the widths of the front face and back face allows greater flexibility in positioning the boards in the channel, and also allows the user the space to maneuver the drill to fasten boards easily to the face of the post, to achieve a fence with hidden fasteners. Specifically, a wood board can be fastened directly to the face of the post, by back drilling into the board with a fastener. A further advantage of the present fencing system is that it provides a modular post to which fence boards and decorative covers can be selectively attached to a front side, a rear side and in the channels of the posts.
With respect to the associated method for construction of a horizontal fence, In order to carry out the method the following core steps are followed: the metal post is secured into the ground along the proposed fence line. Wood boards are slid into the channels and fastened with screws. The boards can be adjusted vertically while in the channel before they are fastened, to achieve different designs created by spacing the boards as the user sees fit. The post is then covered with a decorative metal strip, with attaches with a clip or other method, to cover the post and the fasteners attached to the post or can be covered with a narrow wood board placed vertically. Alternatively, a horizontal fence can be created by placing a wood board horizontally on the face of the post (and not inside the channel) then fastening the wood board from behind, such that the screws are not visible from the front of the fence. A fence with hidden fasteners is very desirable with high end woods such as Ipe so that the beauty of the wood is not marred by the appearance of fasteners. Ultimately, at the conclusion of these steps, a horizontal fence is created on metal posts, which is superior in stability to wood posts.
It is desirable to have a device that supports the creation of a modular horizontal wood fence that is stable and resistant to rot. Furthermore, it would also be desirable to have a device that allows for the wood boards to placed inside the channel where they can be easily fastened or adjusted vertically for decorative effect, and further where decorative panel could be applied over the post for a seamless appearance that obscures the fasteners and the post. Still further, it would be desirable to have a device that also allows a horizontal fence to be created with hidden fasteners. The disclosed device and associated method advantageously fill these need and addresses the aforementioned deficiencies by providing a multi-functional metal post, superior to wood posts, that allows wood boards to be placed in the channel which is then covered in several ways, but which also allows the user to create fence where all fasteners are hidden on at least one side, by placing the boards outside the channel on the face of the post, where screws are fastened from behind.
This disclosure will now provide a more detailed and specific description that will refer to the accompanying drawings. The drawings and specific descriptions of the drawings, as well as any specific or alternative embodiments discussed, are intended to be read in conjunction with the entirety of this disclosure. The Channeled Fence Post for Building Horizontal Fence and Method of Creating Same may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and fully convey understanding to those skilled in the art.
The present invention is directed to a channeled fence post for building horizontal fence and method of creating same.
In its most complete form, the device is made up of the following components: two J channel metal posts joined to form a dual channeled unitary post, with holes punched in the posts, and a decorative panel that fasten onto the post. The most complete form of performing the method associated with the disclosed device consists of the following steps: two J Channel posts are formed out of metal, then fastened back to back through rivets or laser welding, such that two faces are formed—a front face, and a back face that is wider than the front face, with two channels created between and a perpendicular plane. A horizontal wood fence is then constructed by placing wood boards is the channels and fastening them with screws. A decorative cover panel is then optionally fastened to the post to cover the screws. For simplicity the fence member will mostly be referred to as a “board,” typically of wood. However, it will be understood that any suitable planar member can be use to create a fence, including in addition to wood materials such as plastic, resin, composite, metal and so forth. To acknowledge the diversity of suitable materials, the term “backing member” may be used herein to refer to a board that is fastened to the post or disposed within the channel of the posts. Similarly, although a post of the present fencing system is described herein as being made of metal, it will be understood a suitable non-metallic material can be used, including plastic, wood, composite and so on.
Wood board 410 is placed horizontally by fastening it to the post 440. Post 440 has a long face of the post and a short face 450. Board 410 is fastened to post 440 with screw fastener 420 using drill 430 for example. The drawing illustrates that a horizontal board can be fastened to the front face of the post 440 by drilling behind, where the face of 450 is narrow enough to give the drill clearance to drill the screw into the wood board. The resulting fence is a wood horizontal fence where all fasteners are completely hidden from one side.
The present invention further provides covers for the posts, which covers can be selectively affixed to the posts described above, as well as a fencing system that includes post covers. Covers are adapted to fit posts where the fence boards are mounted either in the post channels or fastened to the exterior of the post. A Cover is selectively attached to a post by one or more magnets where both the post and cover are made at least partially of metal. Additionally or alternatively, covers provide one or more bore holes to accommodate screws are nails so that the covers can be screwed or nailed into one or more boards mounted to posts.
Disclosed is a metal fence post, which is made up of the following components: two J Channel metal posts, with one or more holes. These components are connected as follows: the two J Channel metal posts are positioned back to back and permanently fastened, such that a single metal post is created, with a first face and a second face wider than the first face, and two channels in between. One or more holes are punched into the metal post. Optional decorative post covers and methods for mounting the covers are provided.
The device may also have one or more of the following: (1) a selection of holes along the vertical length of each side, (2) a selection of holes along the vertical length of each side that are alternating in position such that holes on the front face are offset from holes from the second face, and (3) decorative strips that attach over the post to conceal the post and fasteners, which are fastened to the post.
The disclosed device is advantageous when compared with other known devices and solutions because it provides: (1) an easy method to create a horizontal wood fence by placing horizontal boards in the channels between two posts; (2) where the post and channel can easily be hidden with a decorative panel that fastens to the metal post or alternatively, a thin piece of wood; (3) avoids any secondary wood support boards which can rot and decay; where such post can also be used to create a horizontal wood fence with completely hidden fasteners by placing the wood board on the front face of the post and fastening from behind. Similarly, the associated method to make the post is advantageous in that it: (1) creates the post by fastening two J channel posts back to back; (2) creates an optional decorative panel that hides the post but easily fastens to the post through a clip.
The present fencing system provides a modular channeled fencing system consisting of two or more dual channeled posts. Each of the dual channeled posts has a long arm side and a short arm side and each long arm side and short arm side has one or more guide holes. A plurality of mounting connectors sized to fit in the one or more guide holes are used to fasten fencing boards to the posts. The dual channeled posts can be formed by joining two single channel J posts or can be a unitary piece formed from extruded aluminum. One or more backing members, such as wood boards, for example, can be modularly and selectively mounted to the long arm side, the short arm side or disposed in one or more channels of the dual channels of the post.
The disclosed device is advantageous when compared with other known devices and solutions because it provides: (1) an easy method to create a horizontal wood fence by placing horizontal boards in the channels between two posts; (2) where the post and channel can easily be hidden with a decorative panel that fastens to the metal post or alternatively, a thin piece of wood; (3) avoids any secondary wood support boards which can rot and decay; where such post can also be used to create a horizontal wood fence with completely hidden fasteners by placing the wood board on the front face of the post and fastening from behind. Similarly, the associated method to make the post is advantageous in that it: (1) creates the post by fastening two J channel posts back to back; (2) creates an optional decorative panel that hides the post but easily fastens to the post through a clip.
The disclosed device is advantageous in that it is structurally different from other known devices or solutions. More specifically, the device is advantageous due to the presence of: (1) front face (2) a back face that is wider than the front face and (3) two channels created between the front face and back face.
Furthermore, the process associated with the aforementioned apparatus is likewise advantageous. More specifically, the disclosed process owes its advantages to the fact that it is created by forming two J channels out of metal and then fastening those J Channels back to back with rivets or welding. This is unique because the resulting shape—an unequal I beam shape—cannot be easily created directly out of metal unless it is made by directly extruding hot metal. This is a very difficult process for steel. The disclosed method for manufacturer allows existing strips of preformed metal to be simply shaped and then fastened.
Different features, variations and multiple different embodiments have been shown and described with various details. What has been described in this application at times in terms of specific embodiments is done for illustrative purposes only and without the intent to limit or suggest that what has been conceived is only one particular embodiment or specific embodiments. It is to be understood that this disclosure is not limited to any single specific embodiments or enumerated variations. Many modifications, variations and other embodiments will come to mind of those skilled in the art, and which are intended to be and are in fact covered by both this disclosure. It is indeed intended that the scope of this disclosure should be determined by a proper legal interpretation and construction of the disclosure, including equivalents, as understood by those of skill in the art relying upon the complete disclosure present at the time of filing.
This application is related to, is a continuation-in-part of, and claims the benefit of and priority from U.S. patent application Ser. No. 16/886,361, filed May 28, 2020 and claims the benefit of and priority from provisional application Ser. No. 62/853,922, filed May 29, 2019, by the same inventor, the disclosures of which applications are incorporate herein by reference.
Number | Date | Country | |
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62854922 | May 2019 | US |
Number | Date | Country | |
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Parent | 16886361 | May 2020 | US |
Child | 17848303 | US |