Not Applicable.
1. The Field of the Invention
The present invention relates generally to modular fence systems. More particularly, it concerns a modular fence plank that is lockably insertable into an open channel of a fence rail.
2. The Background Art
Modular fence systems are becoming increasingly popular with home owners and businesses. Vinyl polymeric fence components have been designed for use in assembling an attractive, durable fence that is much more resistant to weathering than traditional fencing.
The prior art modular fence systems are characterized by a number of disadvantages. Some systems require the laborious and time consuming practice of fastening the fence components with nuts and bolts or other fastening devices. Some of the more decorative-oriented fence systems utilize a lower fence rail to support substantially the entire weight of the planks of the fence, a design that requires a higher frequency of intermittent support posts to inhibit sagging in the lower fence rail.
The prior art is thus characterized by several disadvantages that are addressed by the present invention. The present invention minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.
It is therefore an object of the present invention to provide a fence system that is simple in design and easy to assemble.
It is another object of the invention, in accordance with one aspect thereof, to provide such a fence system that supports at least some of the weight of the planks by holding the upper ends of the planks in combination with resting them upon a lower fence rail, thereby requiring fewer intermittent support posts.
It is a further object of the invention to provide such a fence system having fence planks that are lockably insertable into supporting fence rails.
The above objects and others not specifically recited are realized in a specific illustrative embodiment of a modular fence system. The system includes fence planks designed for insertion into open channels of upper and lower fence rails. The fence rails are supported in a horizontal orientation between intermittent fence posts, with the fence planks extending vertically between the rails. The planks include resilient protrusions, called plank-projections, at their upper ends. The plank-projections are designed to engage with channel-projections formed in the open channels of the upper fence rail and lower fence rail, to inhibit inadvertent removal of the planks from the upper rail. Alternatively, the plank-projections may be eliminated in favor of having the channel-projections simply grip the planks frictionally, or, vice versa, the channel-projections could be eliminated in favor of having the plank-projections press frictionally against the walls of, the open channels in the upper rail or lower rail or both. Accordingly, the engagement between the upper rail and the planks takes some weight off the lower rail such that fewer support posts are needed, and that engagement can be provided with just the channel-projections, or just the plank-projections, or both.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. The objects and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
The above and other objects, features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
For the purposes of promoting an understanding of the principles in accordance with the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed.
Applicant has discovered that a modular fence system can be designed that is easier to assemble, and requires a lower frequency of intermittent support posts. Applicant's inventive combinations as disclosed herein provide a fence system that requires less time to install, yet is structurally sound and aesthetically pleasing.
Referring now to
The upper fence rail 12 comprises a first side 20, an opposing second side 22, a top side 23 and a bottom side 25. A first interior, channel sidewall surface 24 and an opposing second interior, channel sidewall surface 26 define an open channel 28 therebetween having an elongate channel entrance 28a extending along a majority length of the bottom side 25 of the rail 12. The upper fence rail 12 includes ledges or channel-projections 30 protruding outwardly from the first and second interior channel sidewall surfaces 24 and 26, respectively, for supporting the fence planks 18 thereon. Each channel-projection 30 defines a passage 32.
Each plank 18 preferably includes a first exterior end section 34 configured for inserting into the open channel 28 of the upper fence rail 12. Protrusions or plank-projections 36 are preferably formed as part of the planks 18 and extend outwardly from exterior surfaces of the first exterior end section 34 of the plank 18 for engaging with the channel-projections 30, preferably by protruding into the passages 32 defined by the channel-projections 30 on the first and second interior channel sidewall surfaces 24 and 26, respectively. The plank-projections 36 thereby engage against the channel-projections 30 to inhibit inadvertent removal of the planks 18 from the upper fence rail 12.
In this manner, the upper fence rail 12 provides structural support for the fence planks 18. The planks 18 are thus supported by both the upper and lower fence rails 12 and 14, as opposed to prior art fence systems wherein only the lower fence rail supports the planks. The fence posts 16 are spaced close enough together to inhibit substantially sagging of the lower fence rail 14. Since the fence system 10 distributes the weight of the planks 18 between both the upper rail 12 and the lower rail 14, the frequency of the fence posts 16 is less and thus fewer fence posts 16 are required, resulting in a saving of material cost and labor of installation.
Each fence plank 18 further includes a second end section 38 opposite the first end section 34. The lower fence rail 14 also has an open channel 40 formed therein for receiving the second end sections 38 of the planks 18 thereinto. The lower fence rail 14 is preferably identical to the upper fence rail 12 in design, and includes the ledges and passages, as shown in
The ledges or channel-projections 30 preferably comprise first and second arrays of elongate ledges extending lengthwise along the first and second interior sidewalls 24 and 26, respectively, to enable selective engagement of the plank-projections 36 of the fence planks 18 against the ledges 30 of the first and second arrays, respectively. Preferably, each array of elongate ledges 30 comprises at least two ledges disposed in substantial parallel orientation as shown. The ledges 30 of the first and second arrays are equal in number to define pairs of ledges, each pair comprising a ledge from the first array and a ledge from the second array, such that the ledges in each pair are substantially parallel and reside common to a single plane extending substantially perpendicular to the sides 20 and 22 of the rail 12.
The upper fence rail 12 and the sidewalls 20, 22 and ledges 30 thereof preferably comprise a one-piece, unitary member made of a resilient material having elastic memory, such as vinyl. The plank-projections 36 of the planks 18 also preferably comprise a resilient material having elastic memory. The feature of resilient material having elastic memory operates to permit a locking engagement of the plank-projections 36 into the passages 32. The plank-projections 36 can be “snapped” into place into the passages 32 and against the tops of the ledges or channel-projections 30.
Referring more particularly to
The front and rear walls 50 and 52 of each plank 18 include an exterior surface 66 and an interior surface 68, and preferably an elongate groove 70 is formed in each of said front and rear walls extending lengthwise along the plank 18. The elongate grooves 70 in the front and rear walls comprise a crease in said front and rear walls, defined by a furrow 72 formed in the exterior surface 66, and an opposing ridge 74 formed in the interior surface 68. The grooves 70 are optional, and the front and rear walls 50 and 52 may alternatively comprise substantially planer walls characterized by an absence of grooves or other nonplaner structure.
The grooves 70 define a kind of “V” shape as shown in
Regarding the plank-projections 36, the front and rear walls 66 and 68 of the planks 18 each include an opening 80 formed in the first end section 34 of the plank 18, such that a circumferential edge 82 defines said opening 80. The plank-projections 36 extend outwardly from a portion of said circumferential edges 82. Most preferably, the plank-projections 36 each comprise a severed portion of the walls 50 and 52 of the planks 18, whereby the plank-projections 36 are simply cut apart from the front and rear walls 50 and 52 to form the openings 80, and the plank-projections 36 are crimped into an outwardly extending orientation. The plank-projections 36 might therefore also be referred to as tab pieces.
It is to be understood that one aspect of the present invention contemplates the plank 18 as in
For example, and in further reference to the alternative design in which the planks 18 would be constructed without the plank-projections 36 formed thereon, it is shown most clearly by
The fence planks 18 may be described as a plurality of fence planks having free end sections 34 and 38 that are configured and dimensioned to extend through the elongate entrance 28a of the open channel 28 and reside slidably within said open channel 28 to thereby enable the fence planks 18 to be slidable toward and away from each other along the open channel 28 when their free ends 34 and 38 are positioned through the entrance 28a and into the open channel 28.
The channel-projections 30 may be described as at least one channel-projection formed as part of at least one of the channel-sidewalls 24 or 26 of the rail 12, said channel-projection extending outwardly from a surface of the channel-sidewall 24 or 26 into engagement with the fence planks 18 when said fence planks 18 are placed into the open channel 28, for increased support of the fence planks 18.
Referring now to
In other words and in accordance with the drawings and the descriptions above, a supportive engagement between the rails and the planks can be accomplished by engagement of plank-projections 36 against the channel-sidewalls 24 and 26 in the absence of any channel-projections 30, or conversely by engagement of channel-projections 30 in a grip against the opposing exterior surfaces of a free end of the planks 18 in the absence of any plank-projections 36. Either of these alternatives can be designed in connection with either the upper rail 12, or the lower rail 14, or both.
The fence system 10 can be assembled in any suitable manner. Referring now to
(a) coupling a first end 90 of an upper fence rail 12 and a first end 92 of a lower fence rail 14 to a fence post 16, and maintaining an opposing second end 95 of the upper fence rail 12 in an elevated orientation with relative to the first end 90 of said upper fence rail 12;
(b) placing a lower end 19 of a first fence plank 18a into an open channel 40 of the lower fence rail 14, and an opposing upper end 21 of said first fence plank 18a into an open channel 28 of the upper fence rail 12;
(c) placing a lower end 19b of a following fence plank 18b into the open channel 40 of the lower fence rail 14 and sliding said following fence plank 18b toward the first fence plank 18a (as illustrated by arrow A);
(d) gradually lowering the second end 95 of the upper fence rail 12 (as illustrated by arrow B) such that an upper end 21b of the following fence plank 18b becomes received into the open channel 28 of the upper fence rail 12;
(e) repeating steps (c) and (d) as many times as desired to thereby situate an array of fence planks 18 into position between the upper and lower fence rails 12 and 14.
The method set forth immediately above may be further augmented, wherein step (b) further comprises placing a projection 36 of the first fence plank 18a into an internal passage 32 (see
Referring now to
(a) coupling a first end 92 of a lower fence rail 14 to a support post 16;
(b) placing lower ends 19 of a plurality of fence planks 18 into an open channel 40 of the lower fence rail 14; and
(c) sliding an upper fence rail 12 onto upper ends 21 of the plurality of fence planks 18 (illustrated by arrow C) such that said upper ends 21 of the planks 18 reside in an open channel 28 of the upper fence rail 12 with plank-projection 36 on said upper ends 21 extending into an internal passage 32 (shown in
The method set forth immediately above may be further augmented, wherein step (c) further comprises sliding the upper fence rail 12 sequentially along the upper ends 21 of the plurality of fence planks 18.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements.
This application is a continuation of U.S. patent application Ser. No. 11/187,637, filed Jul. 22, 2005, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 11/092,129, filed Mar. 28, 2005, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/996,178, filed Nov. 22, 2004, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/849,496, filed May 18, 2004, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/705,243, filed Nov. 10, 2003, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/447,678, filed May 28, 2003, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/320,343, filed Dec. 16, 2002, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/165,170, filed Jun. 6, 2002, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 10/032,812, filed Dec. 26, 2001, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 09/899,804, filed Jul. 3, 2001, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 09/761,379, filed Jan. 16, 2001, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 09/435,418, filed Nov. 8, 1999, now U.S. Pat. No. 6,202,987, entitled “Fence System,” which is a continuation of U.S. patent application Ser. No. 09/238,754, filed Jan. 28, 1999, now U.S. Pat. No. 6,041,486, entitled “Method of Assembling a Fence,” which is a divisional of U.S. patent application Ser. No. 08/808,981, filed Feb. 19, 1997, now U.S. Pat. No. 5,988,599, entitled “Fence System,” all of which are incorporated herein by reference in their entireties, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced applications is inconsistent with this application, this application supercedes said above-referenced applications.
Number | Date | Country | |
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Parent | 08808981 | Feb 1997 | US |
Child | 09238754 | Jan 1999 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 11187637 | Jul 2005 | US |
Child | 11271496 | Nov 2005 | US |
Parent | 11092129 | Mar 2005 | US |
Child | 11187637 | Jul 2005 | US |
Parent | 10996178 | Nov 2004 | US |
Child | 11092129 | Mar 2005 | US |
Parent | 10849496 | May 2004 | US |
Child | 10996178 | Nov 2004 | US |
Parent | 10705243 | Nov 2003 | US |
Child | 10849496 | May 2004 | US |
Parent | 10447678 | May 2003 | US |
Child | 10705243 | Nov 2003 | US |
Parent | 10320343 | Dec 2002 | US |
Child | 10447678 | May 2003 | US |
Parent | 10165170 | Jun 2002 | US |
Child | 10320343 | Dec 2002 | US |
Parent | 10032812 | Dec 2001 | US |
Child | 10165170 | Jun 2002 | US |
Parent | 09899804 | Jul 2001 | US |
Child | 10032812 | Dec 2001 | US |
Parent | 09761379 | Jan 2001 | US |
Child | 09899804 | Jul 2001 | US |
Parent | 09435418 | Nov 1999 | US |
Child | 09761379 | Jan 2001 | US |
Parent | 09238754 | Jan 1999 | US |
Child | 09435418 | Nov 1999 | US |