Not Applicable.
A. Field of the Invention
The field of the present invention relates generally to wood fence systems. More particularly, the present invention relates to metal fence posts utilized in wood fence systems to support one or more wood rails. Even more particularly, the present invention relates to such fence posts which are shaped and configured to beneficially mount one or more wood rails thereto and then be substantially covered by other wood components.
B. Background
As is well known, wood fence systems are commonly utilized to segregate one person's property from another person's property and to segregate a single property into separate sections. Despite the availability of many different materials, wood fences are often preferred by many property owners. The reasons for this preference include aesthetics, cost, blending with neighborhood fences and materials utilized in nearby structures and due to the contractor's familiarity with the materials.
Wood fences are typically, but not exclusively, configured in a post, rail and picket formation whereby a series of spaced apart posts have their lower ends mounted into the ground in a generally vertical, upright configuration, one or more of the rails are perpendicularly attached to the posts such that they are configured generally horizontal relative to the ground, and a series of pickets are attached in a substantially perpendicular, side-by-side configuration to the rails such that they are generally vertically disposed and parallel to the posts. The standard wood fence system has at least one rail positioned at or near the top of the posts and one rail positioned at or near the bottom of the posts. A center rail may be utilized midway between the top and bottom rails to better support the pickets. In the typical prior art fence, the materials for the posts, rails and pickets have all been wood, such as cedar, pine or the like. The bottom portion of the wood post that is mounted in the ground supports the fence system. To provide additional upright support for the posts and, therefore, for the entire fence system, the bottom portion of the fence post may be placed into a post hole that is then filled with cement, concrete or like materials. In some areas, the use of concrete or like material is mandated by city or county codes to prevent the fence from falling over due to high winds. Even where not mandated, many fence owners and fencing contractors prefer to mount the posts in concrete to prevent strong winds, unexpected contact or other events causing the fence, or portions thereof, to be knocked down.
Often, new wood fences are installed to replace a previous wood fence. A common reason for replacing a fence is because it no longer stands in the preferred upright position due to the posts being unable to adequately support the weight of the rails and pickets (i.e., after being blown over). Often this results from deterioration of the wooden posts, particularly at or near the interface with the ground or concrete in which the post is buried. Generally, this deterioration takes place over time, weakening the fence system as it gets older. Although the posts may be damaged and unable to support the fence, it is not unusual that the remaining components may still be in relatively good condition. Even if this is the case, the fence owner typically replaces the entire fence system. Although some of the fence post deterioration can be avoided or substantially slowed by the use of proper preventative materials and techniques, such as specially formulated coatings, most fence owners do not apply these materials or do not apply them on a frequent enough basis. As a result, there is a need for a new fence post that can be utilized with wood fence systems (i.e., the rails and pickets are still wood). Preferably, the new materials for fence posts should not detract from the beauty of the wooden fence system.
Several fence manufactures and material suppliers provide fence posts that substantially eliminate the deterioration problems associated with wood fence posts by utilizing fence posts made out of non-wood materials, such as galvanized steel and like materials (i.e., strong, non-corrosive, etc.). These posts are mounted into the ground or, often preferably, into a concrete filled hole and then the rails are mounted to the posts and the pickets to the rails, creating a fence system that is configured substantially the same as a typical wood fence system. Often the posts are no more than square or round tubular shaped members, which tend to visually stand out and detract from the overall wood fence system. To avoid detracting from the beauty of a wood fence system, at least one manufacturer has developed a galvanized steel post that is adaptable to being substantially hidden by the wood fence system components. The PostMaster™ fence post by Master-Halco comprises a generally U shaped member with a pair of opposing, outwardly extending side members at the open end of the U. The wood rail sections, such as two-by-fours, are mounted to the post on opposite sides of the U against the side members. A series of holes in the side members are utilized for inserting nails or screws into the rails to connect it to the post. A separate piece of wood material is used to cover the otherwise exposed closed end of the U. Master-Halco also has a SteelMate™ fence post that is shaped similar to the above-described post except that the “arms” of the U are pressed close together. Both of these posts are made from galvanized steel.
Although the Master-Halco fence posts provide some of the benefits desired from the present invention, they do have several drawbacks. Because these fence posts include a U member that is mounted in the ground or in concrete at the bottom of the post, a channel is formed that runs the full length of the post above the ground or concrete. To provide the illusion of a fully wooden fence, the U shaped member must be hidden. Manufacturing the fence post to properly make the desired shape and avoid potential corrosion problems within the channel results in a relatively expensive fence post.
Several fence posts have been the subject of issued patents. For instance, the U-shaped Master-Halco fence posts set forth above are described in U.S. Pat. No. 6,530,561 to Larsen, et al. and U.S. Pat. No. 6,173,945 to Lindsey, et al., both of which are assigned to Master-Halco, Inc. of La Habra, Calif. U.S. Pat. No. 4,542,885 to Rossiter describes a C-shaped metal fence post that has a plurality of openings in the side of the post configured to receive wooden fence rails therethrough. U.S. Pat. No. 670,042 to Vinson describes a generally Z-shaped fence post having wings which extend above the top of the mid-rib member of the fence post to receive the top rail therebetween to support the top rail on top of the mid-rib member. The patent describes only one of the side wings as having perforations for attaching a rail between the mid-ribs of adjacent fence posts. There is no indication that the mid-rib has a width equal to the width of a standard two-by-four or that the lengths of the wings are of any specific length. In addition, because the top rail is disposed between the wings above the top of the mid-rib, the fence post is not easily adaptable for turning a corner for the fence system.
What is needed, therefore, is an improved fence post for wood fence systems that can be made out of metal or other non-wood materials and which is less expensive to manufacture and more easily hidden than presently existing metal fence posts. The fence post must be of sufficient strength to provide the support needed for the typical wood fence system. The preferred fence post should be shaped and configured to be easily mounted in the ground or a concrete filled hole (preferred) and adaptable for mounting one or more wood rails thereto. To be effective, the fence post must be made to support the typical wood fence system without requiring an undo number of posts or extraordinary efforts to conceal the non-wood fence post.
The fence post for wood fence systems of the present invention solves the problems identified above. That is to say, the present invention discloses a new and improved metal fence post that can be relatively easily and inexpensively made out of galvanized steel and other non-corrosive materials. The metal fence post of the present invention is utilized in a wood fence system to support one or more wood rails connected thereto and a plurality of wood pickets attached to the rails. In a fence system utilizing the present fence post, the metal fence post can be easily hidden from sight by a wood picket or other wood member to provide the illusion of a solid wood fence.
In one embodiment of the present invention, the fence post has an elongated center panel, a first side flange and a second side flange. The center panel has a first side edge, a second side edge, a top edge and a bottom edge. The center panel of the fence post has a panel width that is approximately the same dimension as the width of a standard two-by-four, which is approximately 1.5 inches. The first side flange is disposed along the first side edge of the center panel in substantially perpendicular relation to the center panel. The first side flange has a first end disposed at the center panel, a second end extending outwardly in a first direction from the center panel and a top edge aligned with the top edge of the center panel. The second side flange is disposed along the second side edge of the center panel in substantially perpendicular relation to the center panel. The second side flange has a first end disposed at the center panel, a second end extending outwardly in a second direction from the center panel and a top edge aligned with the top edge of the center panel. The second direction is generally opposite the first direction such that the center panel, the first side flange and the second side flange define a generally Z-shaped cross-section for the fence post. Each of the first side panel and second side panel have a plurality of mounting apertures that are sized and configured to receive a connector therethrough to connect the first side flange to one side of a first rail and the second side flange to one side of a second rail. In the fence system utilized with the fence post, the rails are attached to the fence post with one or more connectors and the pickets are attached to the rails. A picket or other wood member can be utilized to cover the metal fence post to provide the illusion of a solid wood fence.
Accordingly, the primary objective of the present invention is to provide a fence post and a fence system utilizing such fence post that provides the benefits described above and solves the problems presently associated with presently available fence posts and fence systems.
More specifically, it is a primary objective of the present invention to provide a Z-shaped fence post that is suitable for being made out of galvanized steel and like materials to avoid the corrosion and deterioration problems associated with presently utilized wooden fence posts.
It is also an object of the present invention to provide a fence post that has a center panel with a width that is substantially the same width as that of a standard two-by-four member and a pair of side flanges that are perpendicularly disposed relative to the center panel and which extend in opposite directions away from opposite ends of the center panel to define a generally Z-shaped fence post.
It is also an object of the present invention to provide a fence system utilizing a Z-shaped fence post that supports a pair of opposite extending fence rails wherein the fence post can be substantially hidden utilizing one or more pickets placed over the fence post.
It is also an object of the present invention to provide a fence system that utilizes a non-wood fence post that is configured for attachment to a plurality of wooden rails used to support a plurality of wood pickets.
The above and other objectives of the present invention are explained in greater detail by reference to the attached figures and description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of parts presently described and understood by the claims.
In the drawings which illustrate the best modes presently contemplated for carrying out the present invention:
With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed text and drawings are merely illustrative of a preferred embodiment and represent one of several different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein. For instance, although the figures and description provided herein are directed primarily to an eight to ten foot high fence post that is made out of galvanized steel, those skilled in the art will readily understand that this is set forth merely for purposes of simplifying the present disclosure and that the present invention is not so limited.
A fence post that is manufactured out of the materials and configured pursuant to one embodiment of the present invention is shown generally as 10 in
As best shown in
Center panel 22 will have a panel width, shown as W in
Typically, fence post 10 will be manufactured from a single piece of elongated, non-wood material approximately eight to ten feet long with center panel 22, first side flange 24 and second side panel 26 being formed by bending or otherwise shaping the material at the appropriate locations. In the preferred embodiment, fence post 10 is manufactured from galvanized steel, such as ten or twelve gauge galvanized steel, due to its strength, corrosion resistant nature, cost and ability to shape. As will be readily appreciated by those skilled in the art, materials other than galvanized steel can be used for post 10. These materials, which may include aluminum, certain composites and the like, must be sufficiently strong to support the weight of the fence and be able to withstand wind and other loads. In addition, it is preferred that the materials either be selected as being generally corrosion resistant, for as least as long as the anticipated useful life of fence system 12, or be easily adaptable to being covered, such as being painted, powder coated or the like, or otherwise treated to reduce the likelihood of corrosion.
As best shown in
The fence system 12 of the present invention, shown in
Fence post 10 of the present invention can be manufactured by use of a bending machine, familiar to those skilled in the use of galvanized materials, that can bend a flat piece of galvanized steel into shape to form first side flange 24 and second side flange 26 on either side of center panel 22. In conjunction therewith, or before or after bending, the mounting apertures 62 can be placed into fence post 10. Typically, mounting apertures 62 will be formed in first 24 and second 26 side flanges before such bending. Due to the simplicity of the design, the cost of manufacturing fence post 10 is somewhat less expensive than the other configurations presently available.
In use, posthole 68 is dug into the ground 70 at the desired location for fence post 10 or, alternatively, fence post 10 can be driven directly into the ground 68. If posthole 68 is utilized, supporting material 72, preferably a material such as concrete, is placed into posthole 68 around the lower section 66 of fence post 10 to secure fence post 10 in place in an upright position. Once a plurality of fence posts 10 are installed in spaced apart relation to each other, first rails 14 are attached to first side flange 24 and second rails 16 are attached to second side flange 26 at the locations desired on fence post 10, typically at or near the top, bottom and middle thereof, by inserting one or more connectors 60 into one or more mounting apertures 62. First 24 and second 26 rails will extend between pairs of adjacent fence posts 10. Pickets 18 are attached to rails 14/16, using nails, screws or other attachment mechanisms, in a side-by-side configuration to form fence system 12. Additionally, due to the Z-shaped configuration of post 10, the first side flange 24 and second side flange 26 will be in abutting relation to the respective sides 56/58 of rails 14/16 and generally in-line, though not as thick, with the pickets 18. As shown in
Although post 10 will typically be utilized as a free standing member to which rails and pickets will be attached in the manner shown in
While there are shown and described herein a specific form of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to any dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention.
This application claims the benefit of U.S. Provisional Application No. 60/932,119 filed May 29, 2007.
Number | Date | Country | |
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60932119 | May 2007 | US |