U.S. patent application number 10/394406 was filed with the patent office on 2004-02-26 for extruded fence post and rail system.
Invention is credited to Dodson, Gordon, Kise, Kazuhiko, Roble, Marcus, Takagi, Kyozaburo.
Application Number | 20040036064 10/394406 |
Document ID | / |
Family ID | 28678168 |
Filed Date | 2004-02-26 |
United States Patent
Application |
20040036064 |
Kind Code |
A1 |
Takagi, Kyozaburo ; et
al. |
February 26, 2004 |
Extruded fence post and rail system
Abstract
A fence assembly including a post and interconnecting rails. The
post includes an interior chamber structure defined by numerous
compartments, an exterior wall structure and a plurality of
inwardly projecting rail-receiving channels. The rail-receiving
channels at least partially define the geometry of the interior
chamber structure. The assembly may be made of extruded plastic
material such that the post, rails and additional components, such
as channel inserts, are generally hollow along their respective
elongate dimensions. Each of the components within the assembly may
be cut to user-defined lengths. The purpose of the abstract is to
enable the United States Patent and Trademark Office and the public
generally to determine from a cursory inspection the nature and
gist of the technical disclosure, and is not to be used for
interpreting the scope of the claims.
Inventors: |
Takagi, Kyozaburo;
(Centerville, OH) ; Dodson, Gordon; (Lewis Center,
OH) ; Roble, Marcus; (Cottonwood, CA) ; Kise,
Kazuhiko; (Chiba, JP) |
Correspondence
Address: |
Killworth, Gottman, Hagan & Schaeff, L.L.P.
Suite 500
One Dayton Centre
Dayton
OH
45402-2023
US
|
Family ID: |
28678168 |
Appl. No.: |
10/394406 |
Filed: |
March 21, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60366382 |
Mar 21, 2002 |
|
|
|
60398062 |
Jul 24, 2002 |
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Current U.S.
Class: |
256/65.02 |
Current CPC
Class: |
E04H 17/168 20130101;
E04H 17/1456 20210101; E04H 17/20 20130101; E04H 17/1413
20130101 |
Class at
Publication: |
256/65.02 |
International
Class: |
E04H 017/24 |
Claims
What is claimed is:
1. A post defined by a generally hollow construction along an
elongate axis thereof, said post comprising: an interior chamber
structure defined by a plurality of elongate compartments at least
one of which defines a pole-receiving compartment configured to
engage a rigid support pole along a pole-engaging axis offset
relative to and substantially parallel with a post centerline
defined along said elongate axis; an exterior wall structure; and a
plurality of inwardly projecting elongate rail-receiving channels
formed into said exterior wall structure, each of said channels
comprising an interior surface which at least partially defines
said interior chamber structure.
2. A post according to claim 1, wherein said pole-receiving
compartment comprises a plurality of projections disposed
therein.
3. A post according to claim 1, wherein each of said plurality of
rail-receiving channels defines a connecting member therein such
that, upon placement of a rail defined by a surface complementary
to that of said connecting member into said rail-receiving channel,
translation of said rail along its longitudinal dimension is
substantially prohibited.
4. A post according to claim 3, wherein said connecting member
comprises a narrowed throat disposed in said channel.
5. A post according to claim 1, wherein said post is of unitary
construction.
6. A post according to claim 5, wherein said post is made of
plastic.
7. A post according to claim 6, wherein said post defines an
extrudable cross sectional profile.
8. A post according to claim 1, further comprising at least one
channel insert selectively disposable in one of said rail-receiving
channels to form a flush surface with said exterior wall
structure.
9. A post according to claim 1, further comprising a removable
channel cover integrally formed across at least one of said
rail-receiving channels to form a substantially flush surface with
said exterior wall structure, said channel cover substantially
circumscribed by at least one line of weakness to facilitate ease
of removal.
10. A post according to claim 8, wherein said removable channel
cover is substantially circumscribed by a pair of substantially
parallel lines of weakness.
11. A post according to claim 8, wherein said line of weakness
comprises a score line.
12. A reinforced post comprising: a post defined by a generally
hollow construction along an elongate axis thereof, said post
comprising: an interior chamber structure defined by a plurality of
elongate compartments at least one of which defines a
pole-receiving compartment configured to engage a rigid support
pole along a pole-engaging axis offset relative to and
substantially parallel with a post centerline defined along said
elongate axis; an exterior wall structure; and a plurality of
inwardly projecting elongate rail-receiving channels formed into
said exterior wall structure, each of said channels comprising an
interior surface which at least partially defines said interior
chamber structure; and a rigid support pole engaged with said
pole-receiving compartment along said pole-engaging axis, said
rigid support pole configured to be anchored to a mounting surface
such that said rigid support pole defines a reinforcing axis
substantially parallel to said elongate axis, thereby providing
increased resistance to rotation of said post about said elongate
axis when coupled to said mounting surface and said pole-receiving
compartment.
13. A reinforced post according to claim 12, wherein said rigid
support pole defines a non-axisymmetric cross section to facilitate
an interlocking fit with said pole-receiving compartment.
14. A reinforced post according to claim 13, wherein said
non-axisymmetric cross section defines at least one radial
detent.
15. A reinforced post according to claim 13, wherein said rigid
support pole defines a substantially T-shaped cross section.
16. A reinforced post according to claim 13, wherein: said
non-axisymmetric cross section of said rigid support pole defines a
plurality of anti-rotational engagement surfaces; at least a
portion of said pole-receiving compartment is configured to engage
one of said anti-rotational engagement surfaces upon rotation of
said post in a first direction; and at least a portion of said
pole-receiving compartment is configured to engage one of said
anti-rotational engagement surfaces upon rotation of said post in a
second direction opposite said first direction.
17. A reinforced post according to claim 16, wherein said pole
receiving compartment and said anti-rotational engagement surfaces
are configured such that a degree of rotation permitted prior to
engagement of said anti-rotational engagement surfaces with said
compartment is insubstantial.
18. A reinforced post according to claim 13, wherein: said
non-axisymmetric cross section of said rigid support pole further
defines a plurality of anti-translational engagement surfaces; at
least a portion of said pole receiving compartment is configured to
engage one of said anti-translational engagement surfaces upon
translation of said post in a first translational direction
perpendicular to said pole-engaging axis; and at least a portion of
said pole receiving compartment is configured to engage one of said
anti-translational engagement surfaces upon translation of said
post in a second direction perpendicular to said first
translational direction and said pole-engaging axis.
19. A reinforced post according to claim 13, wherein said
projections form a unitary structure with said interior chamber
structure.
20. A reinforced post according to claim 12, wherein said
pole-receiving compartment comprises a plurality of projections
disposed therein.
21. A reinforced post according to claim 20, wherein said rigid
support pole and said plurality of projections define an
interlocking fit.
22. A reinforced post according to claim 20, wherein said plurality
of projections are configured to engage said rigid support pole in
such a manner that substantial rotation of said post about said
rigid support pole is impeded.
23. A reinforced post according to claim 12, wherein said
interlocking fit is only possible over a substantially singular
angular orientation about said reinforcing axis between said rigid
support pole and said pole-receiving compartment.
24. A reinforced post according to claim 12, wherein the
longitudinal dimension of said rigid support pole extends along a
substantial length of said post plus a distance below sufficient to
ensure secure anchoring into a mounting surface.
25. A reinforced post according to claim 12, wherein said
projections are substantially triangle-shaped.
26. A reinforced post according to claim 12, wherein said
pole-receiving chamber structure defines a substantially
trapezoidal-shaped compartment.
27. A reinforced post according to claim 13, wherein at least a
portion of said projections are disposed against an outer wall of
said post.
28. A reinforced post according to claim 13, wherein said
pole-receiving compartment is at least partially defined by said
exterior wall surface.
29. A post defined by a generally hollow construction along an
elongate axis thereof, said post comprising: an interior chamber
structure defined by a plurality of elongate compartments at least
one of which defines a pole-receiving compartment; an exterior wall
structure; a plurality of inwardly projecting elongate
rail-receiving channels formed into said exterior wall structure,
each of said channels comprising an interior surface which at least
partially defines said interior chamber structure; and at least one
removable channel cover integrally formed across at least one of
said channels to form a substantially flush surface with said
exterior wall structure, said channel cover substantially
circumscribed by at least one line of weakness to facilitate ease
of removal.
30. A post according to claim 29, wherein said pole-receiving
compartment comprises a plurality of projections disposed therein,
said plurality of projections configured to engage a rigid support
pole along a pole-engaging axis of said pole-receiving
compartment.
31. A post according to claim 29, wherein said pole-receiving
compartment is offset relative to and substantially parallel with a
post centerline defined along said elongate axis.
32. A post according to claim 29, further comprising a rigid
support pole configured to be anchored to a mounting surface such
that said rigid support pole defines a reinforcing axis
substantially parallel to said elongate axis, thereby providing
increased resistance to rotation of said post about said elongate
axis when coupled to said mounting surface and said plurality of
projections.
33. A reinforced post comprising: a structure substantially hollow
along an elongate axis thereof, said structure configured to be
anchored to a mounting surface and comprising: an interior chamber
structure defined by a plurality of elongate compartments at least
one of which defines a pole-receiving compartment; an exterior wall
structure; and a plurality of inwardly projecting elongate
rail-receiving channels formed into said exterior wall structure,
each of said channels comprising an interior surface which at least
partially defines said interior chamber structure; a rigid support
pole defined by a non-axisymmetric cross section, said rigid
support pole configured to be anchored to a mounting surface such
that said rigid support pole defines a reinforcing axis
substantially parallel to said elongate axis, said rigid support
pole configured to impede rotation of said post about said elongate
axis when engaged with said pole-receiving compartment; and a
removable channel cover integrally formed across at least one of
said channels to form a substantially flush surface with said
exterior wall structure, said channel cover substantially
circumscribed by a line of weakness to facilitate ease of
removal.
34. A reinforced post according to claim 33, wherein said
pole-receiving compartment comprises a plurality of projections
disposed therein, said plurality of projections configured to
complement said non-axisymmetric cross section of said rigid
support pole.
35. A reinforced post according to claim 33, wherein said
pole-receiving compartment is offset relative to and substantially
parallel with a post centerline defined along said elongate
axis.
36. A fence assembly comprising: a reinforced post defined by a
generally hollow construction along an elongate axis thereof, said
post comprising: an interior chamber structure defined by a
plurality of elongate compartments at least one of which defines a
pole-receiving compartment configured to define a pole-engaging
axis offset relative to and substantially parallel with a post
centerline defined along said elongate axis; an exterior wall
structure; a plurality of inwardly projecting elongate
rail-receiving channels formed into said exterior wall structure,
each of said channels comprising an interior surface which at least
partially defines said interior chamber structure; and a rigid
support pole engaged with said pole-receiving compartment, said
rigid support pole configured to be anchored to a mounting surface
such that said rigid support pole defines a reinforcing axis
substantially parallel to said elongate axis, thereby providing
increased resistance to rotation of said post about said elongate
axis when coupled to said mounting surface and said pole-receiving
compartment; a plurality of rails, each of which includes ends
configured to be received within one of said rail-receiving
channels; and a channel insert configured to be selectively
disposed within one of said rail-receiving channels.
37. A post according to claim 36, wherein said pole-receiving
compartment comprises a plurality of projections disposed therein,
said plurality of projections configured to engage said rigid
support pole along said pole-engaging axis.
38. A fence assembly according to claim 36, further comprising at
least one pin disposed in each end of each of said rails, said pin
to effect a locking relationship between each of said rails and a
corresponding one of said channels.
39. A fence assembly according to claim 38, wherein said at least
one pin comprises a plurality of pins axially aligned with one
another in each said end of said rail.
40. A fence assembly according to claim 36, wherein the
cross-sectional shape of said rail-receiving channels defines a
narrowed throat.
41. A fence assembly according to claim 36, further comprising a
plurality of said channel inserts, each configured to stack within
said rail-receiving channel relative to said rails such that a
preferred height and spacing of said rails is effected.
42. A fence assembly according to claim 36, wherein said post and
said rail define an extrudable cross sectional profile.
43. A fence assembly according to claim 36, wherein an outer
surface of said channel insert is shaped to form a flush surface
with said exterior wall structure.
44. A fence assembly according to claim 36, further comprising a
removable channel cover integrally formed across at least one of
said rail-receiving channels to form a substantially flush surface
with said exterior wall structure, said channel cover substantially
circumscribed by at least one line of weakness to facilitate ease
of removal.
45. A fence assembly according to claim 36, further including a cap
releasably connected to a top of said post.
Description
CROSS-REFERENCE TO RELATED APPLCATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/366,382 filed Mar. 21, 2002, and No. 60/398,062
filed Jul. 24, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to fence structures,
and more particularly to extruded plastic fence rails and posts
that can form connections with one another that improve the ease
with which fence assemblies can be fabricated.
[0003] Fences have traditionally been constructed of wood, stone or
metal. The use of plastic componentry in fence structures, which
typically include posts, rails, pickets and related parts, has been
in its ascendancy in recent years due to the ability to manufacture
inexpensive, environmentally durable systems. Contributing to the
desirability of using plastic fence assemblies is that once
installed, they require comparatively little maintenance, such as
painting, rust and vermin protection.
[0004] Despite these advantages, plastic fence assemblies continue
to suffer from various shortcomings. For example, many of the
constructions are overly complex, requiring multiple pieces or
hybrid metal/plastic structures, as well as detailed steps to piece
together the myriad components. In addition, if all or portions of
the fence need to be disassembled for access, maintenance or
replacement of damaged parts, the cumbersome process has to be
repeated. Moreover, accommodations are often required at the time
of fence installation for various contingencies, such as topography
of the land and natural or artificial structures that could get in
the way of the installation. In such cases, the installer may have
to make minor adjustments to the dimensions of the post, rails and
inserts. For example, an installer, especially if working alone, is
faced with the difficult, if not impossible task of establishing a
neat, secure assembly unless there are features built into the
rails or posts to secure the two while determining placement of
other components, such as subsequent posts. This task is
exacerbated when additional component reinforcement, in the form of
metal structure surrounded by plastic sleeves or covering, is used,
as the additional weight makes the maneuvering of long parts (such
as rails) even more unwieldy. Furthermore, once installed, the
fence posts can be subject to rotational movements about its
vertical axis unless they are adequately secured into the
ground.
[0005] The present inventors have recognized a need for extruded
plastic fence assemblies that are made up of components that are
inexpensive to manufacture. They have further recognized a need for
features within the components of the fence assembly that
facilitate the rapid, secure anchoring of the components to one
another, as well as to a mounting surface, such as the ground.
SUMMARY OF THE INVENTION
[0006] According to an aspect of the present invention, a post
defined by a generally hollow construction along its elongate axis
is disclosed. The post includes an interior chamber structure, an
exterior wall structure and a plurality of inwardly projecting
elongate rail-receiving channels formed into the exterior wall
structure. Each of the channels include an interior surface which
at least partially defines the interior chamber structure. The
interior chamber structure is defined by numerous elongate
compartments at least one of which defines a pole-receiving
compartment that can engage a rigid support pole along a
pole-engaging axis. This pole-engaging axis is offset relative to
and substantially parallel with a post centerline defined along the
elongate axis. In the present context, the term "substantially"
refers to an arrangement of elements or features that, while in
theory would be expected to exhibit exact correspondence or
behavior, may, in practice embody something slightly less than
exact. As such, the term denotes the degree by which a quantitative
value, measurement or other related representation may vary from a
stated reference without resulting in a change in the basic
function of the subject matter at issue.
[0007] Optionally, the pole-receiving compartment includes
projections that facilitate secure connection between the pole and
the pole-receiving compartment. As another option, each of the
channels defines a locking mechanism, thus allowing a
complementary-shaped rail to cooperate therewith to substantially
prohibit movement and subsequent disengagement of the rail and
channel along the rail's longitudinal dimension. In the present
context, the term "movement" of a solid body includes both
rotational and translational range of motion. Thus, for example,
the limitation on translational movement does not necessarily imply
limitation on rotational movement. The locking mechanism can
further be defined by a narrowed throat in the form of opposing
projections that extend from the or outward opening of the channel.
Thus, the cross sectional area within any plane in the channel
parallel to and inward of the opposing detents is greater than that
between the opening throat defined by the detents. Preferably, the
post is of unitary construction and is made of plastic. More
preferably, the post defines an extrudable cross sectional profile.
In another option, a channel insert can be selectively disposable
in one of the rail-receiving channels, thus forming a flush surface
with the exterior wall structure. In yet another option, a
removable channel cover is integrally formed across at least one of
the rail-receiving channels to form a substantially flush surface
with the exterior wall structure, the channel cover substantially
circumscribed by one or more lines of weakness to facilitate ease
of removal, where the line (or lines) of weakness preferably
comprise a score line such that a user can easily remove the panels
(using, for example, a utility knife), thereby exposing the
channels.
[0008] According to another aspect of the invention, a reinforced
post is disclosed. The post includes an interior chamber structure,
exterior wall structure and plurality of inwardly projecting
elongate rail-receiving channels as previously described, plus a
rigid support pole engaged with the previously-discussed
pole-receiving compartment. The rigid support pole can be anchored
to a mounting surface such that the rigid support pole defines a
reinforcing axis substantially parallel to the elongate axis. When
the pole is coupled to the mounting surface and the pole-receiving
compartment, the post has an increased resistance to rotation about
its elongate axis.
[0009] Optionally, the pole-receiving compartment can include a
plurality of projections similar to that of the previous aspect. In
another option, the rigid support pole defines a non-axisymmetric
cross section to facilitate an interlocking fit with the
projections. In one form, the interlocking fit is only possible
over a substantially singular angular orientation about the
reinforcing axis between the rigid support pole and the plurality
of projections, thus precluding a relative loose fit between the
pole and projections. As such, the pole receiving compartment and
the surface of the pole are configured such that a degree of
rotation permitted prior to engagement of the pole surfaces with
the compartment is insubstantial. In one form, the non-axisymmetric
cross section defines at least one detent extending radially from
the surface of the pole normal to the pole's longitudinal
dimension, where a more particular configuration defines a
substantially T-shaped cross section. The length of the rigid
support pole is such that its longitudinal dimension preferably
extends along a substantial length of the fence post plus a
distance below the post that is sufficient to ensure secure
anchoring into a mounting surface. In one form, the projections are
substantially triangle-shaped, while in another the pole-receiving
compartment defines a substantially trapezoidal-shaped chamber.
Preferably, the projections form a unitary structure with the
interior chamber structure, and more particularly at least a
portion of the projections are disposed against an outer wall of
the post. Moreover, the pole-receiving compartment is at least
partially defined by the exterior wall surface. In another option,
at least one removable channel cover is integrally formed across at
least one of the channels to form a substantially flush surface
with the exterior wall structure. Furthermore, the non-axisymmetric
cross section of the rigid support pole defines a plurality of
anti-rotational engagement surfaces that are configured to engage
at least a portion of the pole-receiving compartment upon rotation
of the post in a first direction, and at least a portion of the
pole-receiving compartment is configured to engage one of the
anti-rotational engagement surfaces upon rotation of the post in a
second direction opposite the first direction. In addition, the
non-axisymmetric cross section of the rigid support pole further
defines a plurality of anti-translational engagement surfaces,
where at least a portion of the pole receiving compartment is
configured to engage one of the anti-translational engagement
surfaces upon translation of the post in a first translational
direction perpendicular to the pole-engaging axis, and at least a
portion of the pole receiving compartment is configured to engage
one of the anti-translational engagement surfaces upon translation
of the post in a second direction perpendicular to the first
translational direction and the pole-engaging axis.
[0010] According to another aspect of the invention, a post is
disclosed. The post includes an interior chamber structure defined
by a plurality of elongate compartments at least one of which
defines a pole-receiving compartment, an exterior wall structure, a
plurality of inwardly projecting elongate rail-receiving channels
formed into the exterior wall structure, and at least one removable
channel cover integrally formed across at least one of the channels
to form a substantially flush surface with the exterior wall
structure. The channel cover is substantially circumscribed by at
least one line of weakness to facilitate ease of removal of the
cover from the post. The pole-receiving compartment optionally
includes a plurality of projections disposed therein to engage a
rigid support pole along a pole-engaging axis.
[0011] According to another aspect of the invention, a reinforced
post is disclosed. The post includes an interior chamber structure
defined by a plurality of elongate compartments at least one of
which is offset relative to and substantially parallel with a post
centerline defined along the elongate axis and defines a
pole-receiving compartment, an exterior wall structure with a
plurality of inwardly projecting elongate rail-receiving channels
formed therein, a rigid support pole defined by a non-axisymmetric
cross section, and at least one removable channel cover integrally
formed across at least one of the channels to form a substantially
flush surface with the exterior wall structure. The rigid support
pole is configured to be anchored to a mounting surface such that
the pole defines a reinforcing axis substantially parallel to the
post's elongate axis.
[0012] According to another aspect of the invention, a fence
assembly is disclosed. The fence assembly includes a reinforced
post as previously discussed, a plurality of rails, each of which
includes ends configured to be received within one of the
rail-receiving channels; and a channel insert configured to be
selectively disposed within one of the rail-receiving channels. As
an option, the cross-sectional shape of the rail-receiving channels
defines a narrowed throat. In another option, each of the rails
include one or more pins disposed in its end such that the pin (or
pins) effect a locking relationship between the rail and its
corresponding channel. This pin (which could be a bolt, screw,
nail, rivet or the like) is sized such that it sticks out wider
than the channel throat to help the rail avoid slipping out of the
channel during fence assembly fabrication and subsequent use. The
pins can extend all the way through both opposing lateral rail
surfaces, or can be made up of a pair of smaller pins, each
protruding through one of the surfaces. In yet another option, a
plurality of the channel inserts can be used within each channel
and stacked within the channel relative to the rails such that a
preferred height and spacing of the rails is affected. As with the
previous embodiments, the post defines an extrudable cross
sectional profile, as can the rail. In another option, an outer
surface of the channel insert is shaped to form a flush surface
with the exterior wall structure. Furthermore, a removable channel
cover can be integrally formed across at least one of the
rail-receiving channels similar to that previously discussed. The
assembly may further include a cap releasably connected to a top of
the post. As with the previous embodiments, the rigid support pole
may define different cross-sectional shapes, including cylindrical,
elliptical or variations on a T-bar shape, the latter of which can
engage with a complementary surface of the pole-receiving
compartment in the interior chamber structure in such a way as to
resist rotation of the post about the elongate axis. The rails may
be configured such that they can include or accept one or more
exaggerated surfaces near their channel-engaging end to affect a
locking relationship with the channel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] The following detailed description of the preferred
embodiments of the present invention can be best understood when
read in conjunction with the following drawings, where like
structure is indicated with like reference numerals and in
which:
[0014] FIG. 1 illustrates a top view of a fence assembly according
to an aspect of the present invention;
[0015] FIG. 2 illustrates a perspective view of a fence post and
two channel insert variants;
[0016] FIG. 3 illustrates a perspective view of a section of fence
using the fence assembly of FIG. 1;
[0017] FIG. 4 illustrates the positioning of the rails, channel
inserts, a rigid support pole and end cap relative to the fence
post shown in FIG. 1;
[0018] FIG. 5 illustrates a top view of an alternate fence post
configuration, showing the addition of a rigid support pole
inserted therein;
[0019] FIG. 6 illustrates a top view of another alternate fence
post configuration;
[0020] FIG. 7 illustrates the fence post of FIG. 6, including a
rail, channel inserts and a rigid support pole offset-mounted along
the post's elongate axis; and
[0021] FIGS. 8A through 8C show the various channel inserts that
can be used with the fence post of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring first to FIG. 5, a top view of a post 10 according
to an embodiment of the present invention is shown. Post 10 may be
formed into a single, unitary construction from a plastic material
(such as polyvinyl chloride (PVC)) by known methods (such as
extrusion) and as such, defines an extrudable cross sectional
profile. In the present context, a structural member defines an
extrudable cross sectional profile if respective cross sections of
the member, taken along a length or width-wise axis of the member,
each define substantially identical dimensions. In such case, the
member defining the extrudable profile may be produced by an
extrusion process where a semi-soft plastic is forced through the
orifice of an extrusion die to produce a continuously formed piece
having a cross-sectional shape defined by the orifice or other
shaping members downstream of the orifice. It is contemplated that
a structural member having an extrudable cross-sectional profile
may also include portions along its axis that are subject to post
extrusion cutting, drilling, bending, deforming or related
operations. Post 10 includes an interior chamber structure 15 made
up of numerous hollow, elongate compartments 80, 82, 84 and 86 the
last three of which are offset from and substantially parallel with
a post centerline defined along a longitudinal (elongate) axis. By
having the pole-receiving compartment 86 offset from the post
centerline and at least partially against outer wall 12, it is
easier for an installer to place the post 10 directly on a property
line and without recourse to visual estimation, as the post side
adjacent the pole/compartment combination can be placed closest to
such property line. The post 10 is also made up of an exterior wall
structure 12 and numerous inwardly projecting elongate
rail-receiving channels 20 formed into exterior wall structure 12.
Interior wall structure 14 defines the boundary between the
rail-receiving channels 20 and the various compartments 80, 82, 84
and 86. This commonality allows each of the channels 20 to
partially define the interior chamber structure 15. An interface in
the form of a locking mechanism 60 is defined between the channel
20 and the exterior wall structure 12 such that channel 20 can
engage a complementary end surface of a rail (as shown and
described below) to substantially prohibit translation of the rail
along its longitudinal dimension once the rail and channel are
engaged. In the configuration shown, locking mechanism 60 includes
a pair of lateral detents that form a throat in channel 20 to
provide a narrowed contact region.
[0023] At least one compartment 86 is made up of a plurality of
projections 45 that can engage a rigid support pole 50. Together,
the projections and rigid support pole 50 define a pole-engaging
axis that is parallel to the longitudinal, or elongate, axis of
post 10, but radially offset relative to the post centerline. By
coupling the pole 50 to the post 10 and having both secured to a
mounting surface, such as the ground (not shown), a reinforced post
is formed that exhibits increased resistance to torsional forces
acting on it, thereby maintaining proper post orientation.
Resistance to rotation is important to maintaining the integrity of
a fence assembled with posts 10, as forces due to weather or
animal, human or related contact otherwise would have a tendency to
cause the rails and posts to shift relative to one another, causing
the assembly to come apart. The rigid support pole 50 is shaped to
include non-axisymmetric features to improve the tightness of the
fit between rigid support pole 50 and the projections 45 that are
formed in the offset compartment 86. In the configuration shown,
rigid support pole 50 is substantially T-shaped, such that its
various radial detents 51, 52, 53 and 54 fit in narrowly-defined
spaces 40 formed by substantially triangular-shaped projections 45.
It will be appreciated by those skilled in the art that while the
projections 45 are shown as being triangular-shaped, the invention
is not so limited, as other shapes configured to securely engage
the rigid support pole 50 would also suffice. The projections 45
can be integrally formed with the remainder of post 10 through the
aforementioned extrusion process. Moreover, the T-shape of the
rigid support pole 50 is such that the interlocking fit between the
detents 51, 52, 53 and 54 is only possible over a substantially
singular angular orientation about the reinforcing axis. This sort
of "keyed" connection ensures that the post 10 and rigid support
pole 50 are placed in proper angular orientation to one another,
subject only to the tolerance in the space 40 between the rigid
support pole 50 and the projections 45. The longitudinal dimension
of the rigid support pole 50 extends along a substantial length of
the post 10, plus an additional distance beyond the lowermost
portion of post 10 to ensure secure anchoring into the ground or
other mounting surface.
[0024] Referring next to FIGS. 2 and 3, details of connection
between the post 10 and rails 30 and channel inserts 70A, 70B are
shown. In the present figure, the post 10 is structurally similar
to that shown in FIG. 5, except for the lack of pole-engaging
features in compartment 86. It will be appreciated by those skilled
in the art that either variant can be employed, depending on
individual user needs, such as how much torsional resistance is
required. Referring with particularity to FIG. 2, two variants 70A,
70B of the inserts, as well as how they fit into channel 20 of post
10, are depicted. The first variant 70A, with its conventional box
shape, emphasizes simplicity of structure and manufacture, while
the second 70B, with its additional faceted surfaces to produce a
step structure complementary with that of the throat in channel 20
(as shown in FIG. 1 and discussed below), is used to provide a
smooth, flush finish with outer wall structure 12. Referring with
particularity to FIG. 3, in addition to providing an
aesthetically-pleasing finished surface to post 10, the inserts
70A, 70B (only the latter presently shown) maintain vertical
spacing between rails 30, providing both a neat finished product
and additional resistance to rail 30 movement. The construction of
post 10 is such that it can function equally well as an end post,
corner post or intermediate post, the last two being shown in the
figure. As with the post 10, the inserts 70A, 70B are extrudable,
and in situations where made of plastic, can be easily cut to any
desired length. Similarly, rails 30 can be made from plastic such
that they can be cut to desired lengths, and extrudable such that
they can be produced economically in large quantities. As with the
fit between the channel 20 and rails 30 described above, locking
mechanism 60 may also be used to engage a complementary surface on
the inserts 70A, 70B.
[0025] Referring next to FIG. 1, a top view showing connection
details of a fence assembly constructed using the post 10, rails 30
and channel insert 70B of FIGS. 2 and 3 is shown. Two of channels
20 of post 10 are shown engaged to rails 30, while a third has a
channel insert 70B disposed therein. In the present figure, the
post 10 is used as a corner post, such that inserts 70B provide
flush surface finish features for channel 20 not being used. The
faceted surfaces of insert 70B complement those the locking
mechanism 60 formed at the throat of channel 20 such that the
insert 70B cannot be removed other than by sliding it out along the
elongate axis of post 10. The gaps shown between inner wall 14 and
insert 70B are shown exaggerated for clarity; it will be
appreciated by those skilled in the art that tolerances can be made
much tighter to ensure a secure, relatively smooth surface finish.
Each of the rails 30 show a different protrusion extending
laterally from the ends of the rails 30. In the present context,
the "end" of the rail 30 includes not just the remote edge, but all
portions of rail 30 that are designed to fit into the channel 20.
These protrusions are sized to allow a locking interconnection
between the rails 30 and the locking mechanism 60 of channels 20.
In one variation, the rail 30 includes a pair of pins 37 that are
axially aligned with one another so that the lateral dimension of
rail 30 is greater than throat produced between locking mechanisms
60. Thus, once the rail 30 is disposed in channel 20 (such as by
aligning the rail end with channel 20 and dropping the rail 30 down
into the channel along the elongate axis of post 10), the
interference fit between pins 37 and locking mechanism 60 prohibits
movement between them, save the movement equal to the relatively
small gap G, which, like the gap earlier described between the
between channel 20 and insert 70B, is shown exaggerated for
clarity. In another variation, the rail 30 includes a pair of flaps
33 integrally formed in the opposing lateral walls. Flaps 33 are
shown as rectangular members defined by cut-outs on three sides
such that when the rail is ready to be placed in channel 20, the
flaps can be bent away from the rails 30 to provide an interference
fit similar to that described for the pins 37 above. In addition to
the protrusions in the form of flaps 33 and pins 37 to allow a
locking interconnection between the rails 30 and the locking
mechanism 60, rail 30 can include a securing pin 95 placed
vertically through apertures 35 in the end of the rails 30. Details
of the securing pin will be discussed in conjunction with FIG. 4
below.
[0026] Referring next to FIG. 4, a perspective view of the details
of the fence assembly of FIG. 3 is shown. The assembly highlights
how the inserts 70B act not only top establish a smooth surface
finish along the exterior wall structure of post 10, but also
vertical spacing between rails 30. In addition to the post 10,
rails 30 and channel inserts 70B, the above-mentioned securing pin
95 is shown. The hollow nature of the inserts 70B along the
longitudinal dimension of securing pin 95 improves the ease of pin
placement through apertures 35 in the ends of each rail 30. The
securing pin 95 can be configured to be long enough to extend
through all of the inserts 70B and the ends of rails 30 stacked
with the inserts, and can, like the rigid support pole 50 (shown in
FIG. 5), extend into a mounting surface, such as the ground. The
fence assembly also includes a cap 90 releasably connected to the
top of post 10. Not only does this improve post aesthetics, it
prevents debris and moisture from accumulating in the interior
chamber structure of post 10.
[0027] Referring next to FIGS. 6 and 7, a top view of an alternate
embodiment of the post and a reinforced fence assembly,
respectively, are shown. As with the previous embodiment, numerous
hollow, elongate compartments 180-190 define an interior chamber
structure, including a trapezoidal-shaped pole-receiving
compartment 186 with projections 145. In addition, as shown with
particularity in FIG. 6, post 110 includes a removable channel
cover 113 integrally formed across at least one of the
rail-receiving channels 120 to form a substantially flush surface
with exterior wall structure 112. One or more lines of weakness 115
are formed into exterior wall structure 112 such that cover 113 can
be easily removed. In one form, the lines of weakness are made up
of score lines. The cover 113 preserves the smooth appearance of
the exterior wall structure 112 until such time as access to the
channel 120 disposed below the cover 113 is required. The lines of
weakness 115 permit a user to easily remove the cover 113 with a
conventional utility knife or the like. In addition, insert
securement 160 shows a variation of locking mechanism 60 shown in
FIG. 5, where it now defines an interface between the exterior wall
structure 112 and channel 120 that includes two pair of lateral
detents such that not only does securement 160 define a throat in
channel 120, but also an additional slot 161 for receiving a
complementary surface on inserts 170A, 170B and 170C (shown and
described below). Referring with particularity to FIG. 7, rigid
support pole 150 (still possessive of a substantially T-shaped
construction similar to the one shown in FIG. 5) can fit in a
particular angular orientation relative to the projections 145 and
pole-receiving compartment. It will be appreciated by those skilled
in the art that other rigid support pole 150 configurations are
possible, including cylindrical and non-axisymmetric
configurations. For example, a plurality of cylindrical poles (not
shown) can be used, each disposed within each of the various
semi-autonomous spaces formed by the projections 145. An additional
pole (not shown) could be placed within pole-receiving compartment
186 adjacent the exterior wall structure 112 such that the
plurality of poles provide additional support. Also as with the
previous embodiment, the pole-receiving compartment 186 is disposed
offset relative to the centerline of post 110, disposed against the
exterior wall structure 112 so that the entire assembly can be
accurately placed along the property line. Tabs (shown and
described below) on the inserts 170B promote a secure fit with
securement 160. Also as shown in FIG. 7, the stacking of rail 130
on top of insert 170B in the same channel 120 is highlighted. It
will be appreciated by those skilled in the art that although the
present invention shows particular components depicted within two
separate embodiments, it can embody any combination of the
aforementioned interior chamber structure, pole-receiving
compartment structure, securement configuration, and rail end and
channel insert construction.
[0028] Referring next to FIGS. 8A-8C, details of various
embodiments of channel inserts 170A, 170B and 170C are shown. All
three include tabs 172A, 172B and 172C, respectively, that are
disposed adjacent an outermost face of the inserts and used to
engage the slot 161. As such, the slot 161 and any one of tabs
172A-172C together make up securement 160 (as shown previously in
FIG. 7). It will be appreciated by those skilled in the art that
while what is referred to herein as securement 160 is made up of
laterally-disposed slots 161 formed into the post 110 with
corresponding tabs 172A-172C that extend from the lateral ends of
the inserts 170A-170C, slot 161 could alternately be disposed in
the inserts 170A-170C, while the tabs 172A-172C could be disposed
on the throat 160. The nature of securement 160 is to be broadly
construed to include both variants. The tabs 172A-C, in conjunction
with the relatively thin depth-wise profile of the insert 170A-C,
allow manufacturing tolerances to be relaxed on the inserts. By
having the depth-wise distance from the outermost face to the tabs
172A-C kept to a minimum, precise dimensional tolerances for the
securement 160, the tabs 172A-C and transition zones 171A-C between
the insert outermost faces and the tabs is not required. The three
insert configurations shown highlight different transition zones
along the outermost face, including a transition zone 171A bevelled
inward (FIG. 8A), right angle transition zone 171B (FIG. 8B) and
transition zone 171C bevelled outward (FIG. 8C). The locking
between the tabs 172A-C and slots 161 (shown in FIGS. 6 and 7)
relieves the requirement of having large depth-wise insert
dimensions to ensure adequate coupling between the insert and
channel. Thus, unlike conventional inserts, where the relatively
large depth-wise dimension necessitates manufacturing to a
relatively tight tolerance to ensure a good fit between the insert
and the channel, the present inserts 170A-C are constructed to
allow for some dimensional variation.
[0029] Having described the invention in detail and by reference to
preferred embodiments thereof, it will be apparent that
modifications and variations are possible without departing from
the scope of the invention defined in the appended claims. More
specifically, although some aspects of the present invention are
identified herein as preferred or particularly advantageous, it is
contemplated that the present invention is not necessarily limited
to these preferred aspects of the invention.
* * * * *