U.S. patent application number 10/908099 was filed with the patent office on 2005-11-03 for composite fencing components.
Invention is credited to Giacchino, Keith.
Application Number | 20050242336 10/908099 |
Document ID | / |
Family ID | 46304441 |
Filed Date | 2005-11-03 |
United States Patent
Application |
20050242336 |
Kind Code |
A1 |
Giacchino, Keith |
November 3, 2005 |
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.
Inventors: |
Giacchino, Keith;
(Littleton, CO) |
Correspondence
Address: |
GLENN L. WEBB
P.O BOX 951
CONIFER
CO
80433
US
|
Family ID: |
46304441 |
Appl. No.: |
10/908099 |
Filed: |
April 27, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10908099 |
Apr 27, 2005 |
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10707472 |
Dec 16, 2003 |
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Current U.S.
Class: |
256/33 ;
256/19 |
Current CPC
Class: |
B29C 45/0013 20130101;
B29C 48/175 20190201; E04H 17/1447 20210101; E04H 17/143 20130101;
B29L 2031/766 20130101; B29C 48/12 20190201; B29C 48/001 20190201;
B29C 2045/1702 20130101; B29C 45/1701 20130101; B29L 2031/73
20130101; B29C 37/0053 20130101; E04H 17/146 20210101 |
Class at
Publication: |
256/033 ;
256/019 |
International
Class: |
E04H 017/14; E04H
017/02; B21F 027/00 |
Claims
What is claimed is:
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.
Description
FIELD OF THE INVENTION
[0001] 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
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] Thus a problem exists with the installation, replacement or
refurbishing of fence systems.
SUMMARY OF THE INVENTION
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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
[0019] FIG. 1 is a perspective illustration of a sleeve component
for a fence of a preferred embodiment of the present invention.
[0020] FIG. 2 is an end view of FIG. 1.
[0021] FIG. 3 is a perspective illustration of another sleeve
component of a preferred embodiment.
[0022] FIG. 4 is a perspective assembly drawing of the present
invention.
[0023] FIG. 5 building material component of a preferred embodiment
of the present invention.
[0024] FIG. 6 is a cross-sectional view of the component of FIG.
6.
[0025] FIG. 7 is a schematic of a typical molding process.
[0026] 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.
[0027] FIG. 9 is a perspective view of a fencing assembly section
of a preferred embodiment of the present invention.
[0028] FIG. 10 is a detail view of the post and rail assembly of
the embodiment of FIG. 8.
[0029] FIG. 11 is a detail view of the rail and post assembly of
the embodiment of FIG. 8.
[0030] FIG. 12 is a view of the fastener of post and rail assembly
of FIG. 10.
[0031] FIG. 13 is a view of the fastener of the rail and picket
assembly of FIG. 10.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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 3/4
inch or 7/8 inch thick and four to six inches wide and six feet
tall.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
* * * * *