COMPOSITE FENCING COMPONENTS

Abstract

A plastic extruded building material component formed as a hollow sleeve for fitting over a picket fence or rail component. The building material component is profile extruded to have texturing and color streaking to simulate a wood building material. A unique mechanism for dispersing and melting the streaking and texturing agents is provided for extruding the product.

Description

FIELD OF THE INVENTION

This invention relates to the field of building material components and particular for plastic material used for fencing, decking and other applications.

BACKGROUND OF THE INVENTION

Traditionally, wood has been used as the primary structural and decorative component for fencing, decking and other applications. While wood has proven to be an acceptable material for these purposes, it does have drawbacks. Chief among these drawbacks includes the susceptibility to environmental degradation, such as weathering, ultra violet degradation, moisture and other damage. Also, wood is susceptible to rot, insects, fire and other types of damage. Frequent treatment, such as painting, staining, and other care is necessary to minimize the damage to wood products, particularly those used in outdoor applications.

Plastic components are now becoming more accepted as a substitute for wood components in these applications. These plastic components typically are formed from polyvinyl chloride (PVC) or acylonitrile butadiene styrene (ABS) polymers. These types of plastic do not have sufficient rigidity, so they are often formed with an aluminum or steel channel inside the component. These plastic components fail to achieve the aesthetics of the actual wood components and are either flimsy, or if reinforced with metallic components, are heavy and difficult to cut and install.

Another issue with the prior plastic components is their longevity and maintenance. Even though these components are formed from plastic, they still degrade over time and exposure to the environment. These materials do not have good cold weather characteristics, which can create costly repairs.

These prior plastic components also do not have the appearance of a traditional wood material. These plastic materials fail to provide the appearance and texture of a wood material. Attempts have been made to simulate wood grain by embossing or other mechanical treatments of the surface of the wood but these fail to provide a realistic wood grain appearance.

Another problem encountered with fencing and/or decking components is the difficulty in the installation process. Most typical plastic components and even wood component fencing systems require professional installation. While there are modular or kit systems presently available, these tend to be awkward to install and even then do not provide the aesthetics of a wood fencing system.

Typical wood and plastic fences also have issues with repair of damage to the components. This normally requires the replacement of the entire component which may not even be available at that time. Also, the style of the fence may need to be updated as time passes. Often the house may be remodeled or updated and the surrounding fence may not longer be aesthetically compatible. This becomes an expensive process if the entire fence is to be replaced periodically.

Another common problem with fencing is the cost. The cost of most composite fences may be quite prohibitive, particularly compared with wood, polyvinylchloride or structural metallic components that may already be in place.

Thus a problem exists with the installation, replacement or refurbishing of fence systems.

SUMMARY OF THE INVENTION

The present invention solves these problems and others by providing a sleeve component for fencing material components that has the appearance of a wood material. This allows the building material component to be used in applications that traditionally have used wooden components, such as pickets for picket and rail fences, decking and other uses.

The fencing component of a preferred embodiment of the present invention includes a sleeve component. This sleeve component has an internal dimension that enables it to be mounted over less expensive, more rigid structural components, such as metal rails, dimensional lumber or existing fence components.

In a preferred embodiment of this invention, the sleeves are formed of a durable, stable plastic material that has the look and texture of a wood material. This enables it to be used in place of wood components that may be susceptible to environmental degradation and that may be more expensive to install and keep maintained.

The building material component of a preferred embodiment of the present invention is formed from a material that can be extruded into a desired shape, such as a picket, plank or other structural or decorative component. The material has the characteristics of being color and UV stable regardless of the exposure to the environment. In a preferred embodiment, polyethylene is used to provide these characteristics as well as exceptional cold weather impact strength.

The building material component of a preferred embodiment has texture on the outer surface to simulate that of a wood material. The texture is uniquely created during the extrusion process. An agent, such as a blowing agent, is added during the extrusion process having a different melt temperature than the base material. This causes the texture to be created in the plastic material.

Color streaking is also created during the extrusion process. Coloring agents are added during the extrusion process. The coloring agents have different melt temperatures or viscosities relative to one another and to the base material. This causes streaking to occur in the plastic material.

A uniquely designed extruder screw is used during the extrusion process to control the rates and dispersion of the streaking agents, the coloring agents and the base material. The use of this unique extruder screw forms the component in a unique fashion to provide a simulated wood product.

The building material component of the preferred embodiment of the present invention is extruded in the shape of a picket for use in a rail and picket fence assembly. The pickets, rails and posts are assembled through the use of unique fastening mechanisms. The assembled fence has the appearance of a traditional wood fence without the required maintenance and upkeep of the wood fences.

These and other features of the present invention are evident from the ensuing detailed description of preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective illustration of a sleeve component for a fence of a preferred embodiment of the present invention.

FIG. 2 is an end view of FIG. 1.

FIG. 3 is a perspective illustration of another sleeve component of a preferred embodiment.

FIG. 4 is a perspective assembly drawing of the present invention.

FIG. 5 building material component of a preferred embodiment of the present invention.

FIG. 6 is a cross-sectional view of the component of FIG. 6.

FIG. 7 is a schematic of a typical molding process.

FIG. 8 is a side view of a preferred embodiment of an extruder screw for an profile extrusion machine for producing the component of FIG. 1.

FIG. 9 is a perspective view of a fencing assembly section of a preferred embodiment of the present invention.

FIG. 10 is a detail view of the post and rail assembly of the embodiment of FIG. 8.

FIG. 11 is a detail view of the rail and post assembly of the embodiment of FIG. 8.

FIG. 12 is a view of the fastener of post and rail assembly of FIG. 10.

FIG. 13 is a view of the fastener of the rail and picket assembly of FIG. 10.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention, in a preferred embodiment, provides a plastic component system for use in fencing, skirting, barricading and other applications. The present invention also provides a fencing system as well. A preferred embodiment of the present invention is described below. It is to be expressly understood that this descriptive embodiment is provided for explanatory purposes only, and is not meant to unduly limit the scope of the present invention as set forth in the claims. Other embodiments of the present invention are considered to be within the scope of the claimed inventions, including not only those embodiments that would be within the scope of one skilled in the art, but also as encompassed in technology developed in the future.

The descriptive embodiments provided herein describe a component system for use with fencing as well as other decorative applications. It is to be expressly understood that the components have application in many other uses beyond those described herein.

A preferred embodiment of the components of the preferred embodiment of the present invention is illustrated in FIGS. 1-4. One example of the preferred embodiment includes sleeve 10. Sleeve 10 is formed of an extruded thermoplastic material as discussed in greater detail below. Sleeve 10 as shown in FIGS. 1 and 2 includes an exterior surface formed of polyethylene in a profile extrusion process. The use of polyethylene provides a component that is non-degradable and UV and color stable with exceptional cold weather characteristics. The component can be easily cleaned as well. There is little maintenance required once the component has been installed. The fencing system can be easily cleaned with soap and water. Numerous color pigments can be utilized in creating different colors of polyethylene products. In this preferred embodiment, the component is extruded from color pigments in a simulated wood coloration, such as redwood, cedar or other popular wood fencing products.

The sleeve 10 in this preferred embodiment is used as a rail as shown in FIGS. 1 and 2 and as shown in FIGS. 3 and 4. It can include texturing and streaking as discussed in greater detail below and shown in FIGS. 1 and 2 or it can be relatively smooth as shown in FIGS. 3 and 4. The sleeve can be formed from polyethylene as discussed above, polyvinylchloride or other plastic or composite materials.

The sleeve 10 itself has insufficient rigidity to act as a structural fence component. As shown in FIGS. 2, 3 and 4, the sleeve 10 includes a substantially hollow interior portion 12. This interior portion includes dimensions that will enable it to be easily mounted over a structural fence component. Structural fence components can be standard sized steel rails, such as three-quarters inch, seven-eights inch, one inch by two inches, two inches by three inches or any other sizes of rails. Also, the structural fence component may be dimensional lumber such as a two by four (actually one and one-half by three and one-half inches), one by four or other sizes of dimensional lumber.

In use, the sleeve 10 is simply cut to the appropriate length and slipped over the rail, dimensional lumber or other structural fence component 20. Screws can be used to fasten the sleeve to the component, although if it is cut to the appropriate length, the standard fence mounting hardware will secure it in place. The fence component will provide sufficient rigidity and strength to the sleeve to form an effective fence component. The sleeve in turn will provide an aesthetic wood appearance to the fence. This greatly improves the appearance of a steel, plastic or other non-wood fence while providing a strong, long-lasting fence at a price much less than many existing plastic fence materials.

In another preferred embodiment, the sleeve 10 is formed of a size that is capable of being mounted over an existing fence. For example, an existing fence formed from PVC (polyvinyl chloride), wood or metal that is no longer the appropriate style or color or that has weathered can be refurbished by slipping the sleeves 10 over the existing rails and/or pickets. This eliminates the need for the purchase of an entire fencing system as well as greatly reducing the labor associated with installing a new fencing system. Instead, the existing rails and pickets are simply removed or partially removed from the fence, sleeves are slipped over these components and the rails and pickets are refastened. The posts may be treated in a similar manner by slipping an appropriate sleeve over the existing post structure. An existing fence can be completely refurbished without great expense.

Another preferred embodiment of the present invention is illustrated in FIGS. 5-7. This embodiment uses an integral picket system instead of the sleeve system discussed above. The structural rail picket 50, shown in FIG. 5, is extruded in a size and shape to be used for a rail fence. It is to be expressly understood that other sizes and shapes of structural and/or decorative components may be used as well under the preferred embodiment of the present invention. The rail picket described herein is intended for descriptive purposes only. The rail picket 50 is approximately ¾ inch or ⅞ inch thick and four to six inches wide and six feet tall.

In this preferred embodiment, the picket rail 50 is extruded from a thermoplastic material. In this embodiment, the picket is extruded from polyethylene in a profile extrusion process. The use of polyethylene provides a component that is non-degradable and UV and color stable with exceptional cold weather characteristics. The component can be easily cleaned as well. There is little maintenance required once the component has been installed. The fencing system can be easily cleaned with soap and water. Numerous color pigments can be utilized in creating different colors of polyethylene products. In this preferred embodiment, the component is extruded from color pigments in a simulated wood coloration, such as redwood, cedar or other popular wood fencing products.

A unique feature of the preferred embodiment of the component is the texturing and coloring of the component. During the extrusion process, an agent is injected into the raw material to create a texturing effect on the surface of the picket or other component. The agent melts at a temperature different from the thermoplastic material in order to create the texture in the material. One type of agent that can be utilized is a blowing agent. Blowing agents are normally used to create cellular structure in foam plastics. The blowing agent decomposes or decompresses by heating to create a gas inside the base material to build up a cellular structure. In this embodiment, the blowing agent is used with polyethylene instead to create the textured effect on the surface of the material. Prior components having texturing are formed by embossing or otherwise mechanically treating the material to create the effect.

The textured surface 52 on the component 50 provides a realistic impression of a wood material. An additional feature that further enhances the appearance of the component 50 is the color streaking in the surface as well. Several streaks of color are provided in the surface of the component 50 to create an impression of wood grain, particularly in combination with the textured surface of the component as discussed above. The streaking in the surface is created in this preferred embodiment by injecting different coloring agents during the extrusion process. Each of the coloring agents has a different melt and/or viscosity. As the extrusion process occurs, the agents move through the molten material at different rates at different times to create the streaking effect.

In a preferred embodiment of the present invention, the picket or other building material component is able to be extruded having the above characteristics of streaking and texture by a novel profile extrusion process. A typical profile extrusion process is illustrated in FIG. 7. The plastic base material is fed through hopper 102 in system 100 into a heated extruder tube. A reciprocating screw 110 transports the base material through the heated tube so to melt the base material. The plasticized material is then fed into an extrusion die 104 to form the product. The present process uses a unique screw 120, shown in FIG. 8, to feed the base material and the texturing and coloring agents in a controlled dispersed rate. Normally the agents are fed into the system at the same rate and heated at the same rate as the base material. The unique screw of the present invention disperses and melts the agents at a different rate in order to achieve the texturing and color streaking of the present invention. The screw 120 includes different screw sections and different slopes of contact surfaces that control the rate of heating and dispersement of the agents.

The preferred embodiment of the picket 50 also includes features to provide impact strength and sturdiness. As shown in FIG. 6, the picket 50 has a relatively hollow core 56. A series of spaced ribs 60, 62, 64, 66 extend longitudinally through the core 56. These ribs create a rigid structure that not only minimizes compression of the surfaces of the picket 50 but also provides torsional stability.

In use, the picket 50 is used for fencing, although it may be used in different forms for other uses, such as skirting, barricading, siding and other applications. As shown in FIG. 9, the pickets 50 are attached to rails 90 to form a section of fencing. It is to be expressly understood that other styles of fence could be created as well under the present inventive concept. The fencing section as shown in FIG. 9 is intended for descriptive purposes only and not to limit the scope of the claimed invention.

In the preferred embodiment illustrated in FIGS. 9-13, the fencing section includes pickets 50, rails 70, 72, 74 and posts 80, 82. The posts 80, 82 are secured in bases 60, 62, such as concrete or other materials, that are mounted or formed in the ground. The posts 80, 82 may be manufactured from 16 gauge galvanized steel, or from wood or any other suitable material with the sleeves 50 slipped over them. Alternatively, the posts 80, 82 may be an integrated post formed as discussed above with the plastic coated over the steel or wood material. Post caps 84 are mounted over the tops of the posts 80, 82 to prevent moisture from collecting inside the posts as well as for providing aesthetic appeal. The post caps are formed from a resilient u/v resistant plastic material to stretch over the post and secured by a bead of silicon adhesive.

Rails 70, 72, 74 are attached to the posts 80, 82 as illustrated in FIGS. 10 and 11. These rails may be made from the above-described material, wood, or any other suitable material and construction. The polyethylene coated galvanized steel rails 70, 72, 74 include slots 76 stamped in the ends of the outer surface of the rails 40, 42, 44. Screws 120 (shown in FIG. 12) are secured through the inner surface of the rails to the posts 80, 82. The screws 120 in the preferred embodiment include self tapping threads 122 having a rubber washer 124 for sealing against the head 126 of the screw and the rail surface.

Rail caps 78 are secured over the ends of the rails 70, 72, 74 as shown in FIG. 9. The rail caps 78 are formed form a resilient plastic material so that they can be either pulled back or slit for clearance over the end of the rail to allow the screws 120 to attach the rails to the posts.

The pickets 50 are attached to the rails 70, 72, 74 by screws 130 (shown in FIG. 13). The screws 130 have a self tapping thread 132. The spacing of the rails is to be a maximum of 6″ above and below the top and bottom rail. The screws 120 and 130 are preferably zinc or stainless steel. In a preferred embodiment, the screws are secured through holes formed in the rails and pickets. Screw plugs formed from the polyethylene material in the color of the rails and pickets are then secured in those holes. This provides a uniform and aesthetic look for the fences.

The assembled fence section as shown in FIG. 9 allows additional sections to be assembled and interconnected by the use of rails 70, 72, 74 extending from the posts to form an additional section. The use of pickets 50 provide an aesthetic look that resembles a wooden picket fence yet does not require the maintenance of an actual wood fence.

It is to be expressly understood that the above described embodiments are not to limit the scope of the claimed inventions. Other embodiments and features are considered to be within the scope of the claimed inventions.

Claims

1. A building material component, said building material component comprising: a sleeve component; and an interior dimension in said sleeve component that enables the sleeve component to fit over a rigid structural component.

2. The building material component of claim 1 wherein said interior dimension includes: allowing said sleeve component to fit over a standard fence rail component.

3. The building material component of claim 1 wherein said interior dimension includes: allowing said sleeve component to fit over standard dimensional lumber.

4. The building material component of claim 1 wherein said interior dimension includes: allowing said sleeve component to fit over existing fence rail components.

5. The building material component of claim 1 wherein said sleeve component includes: an exterior textured surface formed on said sleeve component; and colored streaks extending through said textured surface.

6. The building material component of claim 1 wherein said sleeve component is made from ultraviolet stabilized polyethylene.

7. The building material component of claim 5 wherein said textured surface is created from injecting an agent having a melt temperature different than that of the base material of the component during the extrusion process.

8. The building material component of claim 5 wherein said textured surface is created from injecting a blowing agent having a melt temperature different than that of the base material of the component during the thermoforming process.

9. The building material component of claim 5 wherein said colored streaks are created by adding one or more coloring agents having different melt temperatures.

10. The building material component of claim 5 wherein said colored streaks are created by adding one or more coloring agents having differing viscosities.

11. The building material component of claim 1 wherein said sleeve component is used to create a fencing section.

12. A fencing assembly wherein said fencing assembly comprises: one or more rails; at least one building material components having an interior dimension sized to fit over said one or more rails; and each of said building material components extruded of a plastic material having a textured surface and colored streaking to resemble a wood material.

13. The fencing assembly of claim 12 wherein said at least one rails are made of steel.

14. The fencing assembly of claim 12 wherein said at least one rails are made of dimensional lumber.

15. The fencing assembly of claim 12 wherein said at least one rails are made of existing fencing rails.

16. The fencing assembly of claim 12 wherein said at least one building material components are extruded from ultra violet stabilized polyethylene.

17. The fencing assembly of claim 12 wherein said textured surface is created from injecting an agent having a melt temperature different than that of the base material of the component during the thermoforming process.

18. The fencing assembly of claim 12 wherein said textured surface is created from injecting a blowing agent having a melt temperature different than that of the base material of the component during the extrusion process.

19. The fencing assembly of claim 12 wherein said colored streaks are created by adding one or more coloring agents having different melt temperatures.

20. The fencing assembly of claim 12 wherein said colored streaks are created by adding one or more coloring agents having differing viscosities.