U.S. patent application number 11/479384 was filed with the patent office on 2006-12-14 for thermoformed wall and fencing assemblies.
Invention is credited to Viken Ohanesian.
Application Number | 20060278862 11/479384 |
Document ID | / |
Family ID | 25455808 |
Filed Date | 2006-12-14 |
United States Patent
Application |
20060278862 |
Kind Code |
A1 |
Ohanesian; Viken |
December 14, 2006 |
Thermoformed wall and fencing assemblies
Abstract
Plastic panels are thermoformed to include a variety of
three-dimensional features resembling masonry patterns, various
types of walls, and fencing sections. The thermoformed panels are
incorporated into fencing and wall assemblies. A fencing assembly
includes plastic panels thermoformed to resemble a plurality of
stakes. Panels are disposed between a pair of posts with side
portions configured to overlap. Each stake includes a top return
projecting rearwardly. Horizontal reinforcements couple the panels
to the posts. A double-sided wall assembly employs plastic panels
thermoformed to resemble bricks and other wall patterns. Each
sub-assembly includes a pair of panels coupled to a frame in a
back-to-back arrangement. The sub-assemblies are disposed
side-by-side in between a pair of posts.
Inventors: |
Ohanesian; Viken; (Laguna
Niguel, CA) |
Correspondence
Address: |
MYERS DAWES ANDRAS & SHERMAN, LLP
19900 MACARTHUR BLVD.,
SUITE 1150
IRVINE
CA
92612
US
|
Family ID: |
25455808 |
Appl. No.: |
11/479384 |
Filed: |
June 30, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10609030 |
Jun 26, 2003 |
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11479384 |
Jun 30, 2006 |
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09928153 |
Aug 10, 2001 |
6719277 |
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10609030 |
Jun 26, 2003 |
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Current U.S.
Class: |
256/24 |
Current CPC
Class: |
E04H 17/16 20130101;
E04H 17/168 20130101 |
Class at
Publication: |
256/024 |
International
Class: |
E04H 17/16 20060101
E04H017/16 |
Claims
1-52. (canceled)
53. A method of manufacturing a double-sided wall assembly,
comprising: thermoforming a first panel to form a first
three-dimensional front surface and a first rear surface;
thermoforming a second panel to form a second three-dimensional
front surface and a second rear surface; forming a first panel
sub-assembly by facing the first rear surface of the first panel
towards the second rear surface of the second panel; thermoforming
a third panel to form a third three-dimensional front surface and a
third rear surface; thermoforming a fourth panel to form a fourth
three-dimensional front surface and a fourth rear surface; forming
a second panel sub-assembly by facing the third rear surface of the
third panel towards the fourth rear surface of the fourth panel;
and coupling the first panel sub-assembly to the second panel
sub-assembly in a side-by side arrangement.
54. The method of claim 53, wherein coupling the first panel
sub-assembly to the second panel sub-assembly in the side-by side
arrangement comprises: coupling the first panel sub-assembly and
the second panel sub-assembly to a post.
55. The method of claim 53, wherein: thermoforming the first panel
to form the first three-dimensional front surface and the first
rear surface comprises forming the first three-dimensional front
surface to resemble a first brick pattern; thermoforming the second
panel to form the second three-dimensional front surface and the
second rear surface comprises forming the second three-dimensional
front surface to resemble a second brick pattern; thermoforming the
third panel to form the third three-dimensional front surface and
the third rear surface comprises forming the third
three-dimensional front surface to resemble a third brick pattern;
and thermoforming the fourth panel to form the fourth
three-dimensional front surface and the fourth rear surface
comprises forming the fourth three-dimensional front surface to
resemble a fourth brick pattern.
56. The method of claim 53, wherein forming the first panel
sub-assembly by facing the first rear surface of the first panel
towards the second rear surface of the second panel comprises:
coupling the first panel and the second panel to a first frame.
57. The method of claim 56, wherein forming the second panel
sub-assembly by facing the third rear surface of the third panel
towards the fourth rear surface of the fourth panel comprises:
coupling the third panel and the fourth panel to a second
frame.
58. A method of manufacturing a double-sided wall assembly,
comprising: thermoforming a first panel to form a first
three-dimensional front surface and a first rear surface;
thermoforming a second panel to form a second three-dimensional
front surface and a second rear surface; forming a first panel
sub-assembly by coupling the first panel to the second panel such
that first rear surface faces the second rear surface;
thermoforming a third panel to form a third three-dimensional front
surface and a third rear surface; thermoforming a fourth panel to
form a fourth three-dimensional front surface and a fourth rear
surface; forming a second panel sub-assembly by coupling the third
panel to the fourth panel such that third rear surface faces the
fourth rear surface; and coupling the first panel sub-assembly to
the second panel sub-assembly in a side-by side arrangement.
59. The method of claim 58, wherein coupling the first panel
sub-assembly to the second panel sub-assembly in the side-by side
arrangement comprises: coupling the first panel sub-assembly and
the second panel sub-assembly to a post.
60. The method of claim 58, wherein: thermoforming the first panel
to form the first three-dimensional front surface and the first
rear surface comprises forming the first three-dimensional front
surface to resemble a first brick pattern; thermoforming the second
panel to form the second three-dimensional front surface and the
second rear surface comprises forming the second three-dimensional
front surface to resemble a second brick pattern; thermoforming the
third panel to form the third three-dimensional front surface and
the third rear surface comprises forming the third
three-dimensional front surface to resemble a third brick pattern;
and thermoforming the fourth panel to form the fourth
three-dimensional front surface and the fourth rear surface
comprises forming the fourth three-dimensional front surface to
resemble a fourth brick pattern.
61. The method of claim 58, wherein forming the first panel
sub-assembly by facing the first rear surface of the first panel
towards the second rear surface of the second panel comprises:
coupling the first panel and the second panel to a first frame.
62. The method of claim 61, wherein forming the second panel
sub-assembly by facing the third rear surface of the third panel
towards the fourth rear surface of the fourth panel comprises:
coupling the third panel and the fourth panel to a second
frame.
63. A method of manufacturing a double-sided wall assembly,
comprising: providing a first panel sub-assembly having a first
pair of panels coupled in a back-to-back arrangement; forming each
front surface of the first pair of panels with a first
three-dimensional brick pattern; providing a second panel
sub-assembly having a second pair of panels coupled in a
back-to-back arrangement; forming each front surface of the second
pair of panels with a second three-dimensional brick pattern;
coupling the first panel sub-assembly to the second panel
sub-assembly in a side-by-side arrangement.
64. The method of claim 63, wherein coupling the first panel
sub-assembly to the second panel sub-assembly in a side-by-side
arrangement comprises: coupling the first panel sub-assembly and
the second panel sub-assembly to a post.
65. The method of claim 63, wherein providing the first panel
sub-assembly having the first pair of panels coupled in the
back-to-back arrangement comprises: coupling the first pair of
panels to a first frame.
66. The method of claim 65, wherein providing the second panel
sub-assembly having the second pair of panels coupled in the
back-to-back arrangement comprises: coupling the second pair of
panels to a second frame.
Description
[0001] This is a divisional application of application Ser. No.
10/609,030 filed on Jun. 26, 2003, which is a divisional
application of application Ser. No. 09/928,153 filed on Aug. 10,
2001, now U.S. Pat. No. 6,719,277.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to thermoplastic
fencing, wall and building structures.
[0004] 2. Description of Prior Art and Related Information
[0005] Until recently, fences have typically been composed of wood
or metal. Wooden fences include several drawbacks. Such fences are
susceptible to a great deal of wear and tear caused by natural
elements, such as heat, wind and rain. The cost of the wood itself
can be quite high, especially if a fence needs to be replaced.
Corrugated metallic fences include several drawbacks as well. Not
only is the metal subject to corrosion, but metallic fence sheets
lack rigidity and dent easily. In addition to the susceptibility to
deterioration, metallic fences tend to present a flimsy and cheap
appearance.
[0006] As an alternative to wood fences, thermoplastic fencing
assemblies have been provided with components formed to resemble
wood fencing structures. Such thermoplastic assemblies include
extruded, hollow tubes shaped to resemble planks. The "planks" are
joined by horizontal "rails" and coupled to posts, all of which
also consist of plastic, extruded tubes. Though such thermoplastic
assemblies do not deteriorate in the same manner as does wood, the
plastic fences of the prior art have their own disadvantages.
[0007] With respect to cost, the prior art assemblies include
"planks" that are individually extruded. In particular, each plank
consists of a separately extruded tube. As extruded tubes with
hollow cores and open ends, caps are required to cover at least the
tops of each tube in order to preserve aesthetics. Having to
extrude each plank separately, however, leads to high costs. Each
plank must then be secured to one or more horizontal rails, which
increases costs and complexities related to assembly.
[0008] A further disadvantage of existing plastic fences includes
the inability to withstand heat. Fences are generally provided for
the outdoors where they are subject to the sun. In prior art
plastic fences, each individual plank is extruded as a hollow tube,
with a thin layer of plastic material. If the tubes are dark
colored, a greater amount of heat from the sun is absorbed and
captured within their hollow cores. The heat absorption exacerbated
by dark colored tubes causes the thin tubes to deform.
SUMMARY OF THE INVENTION
[0009] The present invention provides structures and methods which
overcome the deficiencies in the prior art.
[0010] In one aspect, a fence assembly is provided. The fence
assembly comprises a thermoformed panel, a reinforcement coupled to
the panel, and a post coupled to the panel. The thermoformed panel
comprises a top, a bottom, a first axis defined between the top and
the bottom, a plurality of stakes, with each stake extending
parallel to the first axis and having a top return extending
perpendicular to the first axis, and a nestable side portion. Each
rearwardly projecting top return comprises a rounded curved shape.
Each stake comprises a major portion and a minor portion that meet
at a forwardly protruding ridge.
[0011] The assembly further comprises a side cover coupled to a
side portion of the panel and a bottom flange. The reinforcement
comprises a hollow bar and a solid insert disposed within the bar.
The assembly further comprises a flat vertical portion disposed
between each stake, wherein the reinforcement is welded to the flat
vertical portions.
[0012] In another aspect, a fence assembly comprises a first post,
a second post, a first thermoformed panel having a first plurality
of vertically extending stakes with top returns, and a first side
portion, and a second thermoformed panel having a second plurality
of vertically extending stakes with top returns, and a second side
portion configured to overlap the first side portion of the first
thermoformed panel. The first thermoformed panel is disposed
side-by-side with the second thermoformed panel such that the
second side portion overlaps the first side portion. The first
thermoformed panel and the second thermoformed panel are disposed
in between the posts. The first thermoformed panel is coupled to
the first post, and the second thermoformed panel is coupled to the
second post. The assembly further comprises horizontal
reinforcements coupled to the panels. The first side portion
comprises a first laterally extending flange. The second side
portion comprises a forwardly extending flange connected to a
second laterally extending flange.
[0013] A double-sided wall structure is also provided. The
structure comprises a frame having a first side and an opposite
second side, a first thermoformed panel coupled to the first side
of the frame, and a second thermoformed panel coupled to the second
side of the frame. The first thermoformed panel comprises a first
three-dimensional, non-extrudable front surface and a first rear
surface substantially parallel to the first front surface. The
second thermoformed panel comprises a second three-dimensional,
non-extrudable front surface and a second rear surface
substantially parallel to the second front surface. The frame
comprises at least a top horizontal beam, a bottom horizontal beam,
a first vertical beam and a second vertical beam.
[0014] The structure further comprises a support bar coupled to the
top horizontal beam of the frame and a support bar coupled to the
bottom horizontal beam of the frame. Side covers are coupled to at
least a portion of the structure perimeter, namely to first and
second sides of the structure. A post is coupled to the frame. The
first rear surface comprises a first plurality of flat sections.
The second rear surface comprises a second plurality of flat
sections. The frame is coupled to the first and second plurality of
flat sections.
[0015] In a further aspect, a double-sided wall assembly comprises
a first sub-assembly, a second sub-assembly, a first post, and a
second post. The first sub-assembly comprises a first frame, and a
first pair of thermoformed panels coupled to opposite sides of the
first frame. Each of the first pair of thermoformed panels has a
front surface and a rear surface. The panels of the first pair are
coupled to the first frame in a back-to-back configuration. The
second sub-assembly comprises a second frame, and a second pair of
thermoformed panels coupled to opposite sides of the second frame.
Each of the second pair of thermoformed panels has a front surface
and a rear surface. The panels of the second pair are coupled to
the second frame in a back-to-back configuration. The first
sub-assembly and the second sub-assembly are disposed side-by-side
and in between the posts.
[0016] The assembly further comprises a first pair of brackets
coupling the first sub-assembly to the first post, and a second
pair of brackets coupling the second sub-assembly to the second
post. The assembly further comprises a first, upper support bar and
a second, lower support bar juxtaposed in an overlapping
relationship with the first frame and second frame. A top cover and
a bottom cover are disposed over the first sub-assembly and the
second sub-assembly.
[0017] A method for manufacturing a fencing assembly is provided.
The method comprises the steps of thermoforming a panel to form a
three-dimensional front surface and a rear surface substantially
parallel to the front surface, providing a thermoplastic post, and
coupling a reinforcement to a rear surface of the panel. The step
of thermoforming a panel comprises the step of forming a plurality
of stakes and returns. The step of providing a thermoplastic post
comprises the steps of extruding a hollow tube and injection
molding a cap. The step of coupling a reinforcement to a rear
surface of the panel comprises the step of adhering the
reinforcement to the rear surface of the panel.
[0018] A method for assembling a plastic fence comprises the steps
of coupling a first thermoformed panel to a first post, disposing a
second thermoformed panel adjacent to the first thermoformed panel,
overlapping a first side portion of the first thermoformed panel
with a second side portion of the second thermoformed panel,
removing a portion of the second thermoformed panel to leave a
cut-off edge, covering the cut-off edge of the second thermoformed
panel with a side cover, and coupling the second thermoformed panel
to a second post.
[0019] A method for manufacturing a double-sided wall assembly
comprising the steps of thermoforming a first panel to form a first
three-dimension front surface and a substantially parallel first
rear surface, thermoforming a second panel to form a second
three-dimension front surface and a substantially parallel second
rear surface, and forming a frame with a first side and a second
side. The step of thermoforming the first panel comprises the step
of forming the first panel with a first plurality of flat portions.
The step of thermoforming the second panel comprises the step of
forming the second panel with a second plurality of flat portions.
The step of forming the frame comprises the step of providing
horizontal bars and vertical bars configured to abut the first
plurality of flat portions and the second plurality of flat
portions. The step of thermoforming the first panel comprises the
step of forming the first panel with a first plurality of flat
portions. The step of thermoforming the second panel comprises the
step of forming the second panel with a second plurality of flat
portions.
[0020] A method for assembling a double-sided wall assembly is
provided as well. The method comprises the steps of coupling a
first pair of thermoformed panels to a first frame in a
back-to-back configuration to form a first sub-assembly, coupling a
second pair of thermoformed panels to a second frame in a
back-to-back configuration to form a second sub-assembly, placing
the first sub-assembly side-by-side with the second sub-assembly,
coupling the first sub-assembly to a first post, and coupling the
second sub-assembly to a second post. The method further comprises
the steps of removing a portion of the second sub-assembly to
expose a cut-off edge, and covering the cut-off edge with a side
cover. A vertical support may be coupled to the cut-off edge of the
second sub-assembly. The step of covering the cut-off edge of the
second sub-assembly with a side cover comprises the step of
covering the vertical support.
[0021] In summary, plastic panels are thermoformed to include a
variety of three-dimensional features resembling masonry patterns,
various types of walls, and fencing sections. The thermoformed
panels are incorporated into fencing and wall assemblies. A fencing
assembly includes plastic panels thermoformed to resemble a
plurality of stakes. Panels are disposed between a pair of posts
with side portions configured to overlap. Each stake includes a top
return projecting rearwardly. Horizontal reinforcements couple the
panels to the posts. A double-sided wall assembly employs plastic
panels thermoformed to resemble bricks and other wall patterns.
Each sub-assembly includes a pair of panels coupled to a frame in a
back-to-back arrangement. The sub-assemblies are disposed
side-by-side in between a pair of posts.
[0022] The invention, now having been briefly summarized, may be
better appreciated by the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a front elevation view of a preferred embodiment
of a fence panel according to the invention;
[0024] FIG. 2 is a rear perspective view of the preferred
embodiment of the fence panel;
[0025] FIG. 3 is a cross-sectional view of the preferred fence
panel taken along lines 3-3 of FIG. 1;
[0026] FIG. 4 is a cross-sectional view of the preferred fence
panel taken along lines 4-4 of FIG. 1;
[0027] FIG. 5 is a cross-sectional view of the preferred fence
panel taken along lines 5-5 of FIG. 1;
[0028] FIG. 6 is a cross-sectional view of the preferred fence
panel taken along lines 6-6 of FIG. 1;
[0029] FIG. 7 is a front elevation view of a further preferred
embodiment of a fence panel according to the invention;
[0030] FIG. 8 is a rear exploded, perspective view of a preferred
embodiment of a fencing assembly;
[0031] FIG. 9 is a front elevation view of the preferred embodiment
of the fencing assembly;
[0032] FIG. 10 is a top plan view of the preferred embodiment of
the fencing assembly;
[0033] FIG. 11 is a top plan view, in part, of a further preferred
embodiment of a fencing assembly;
[0034] FIG. 12 is an exploded perspective view of a preferred
embodiment of a double-sided wall sub-assembly according to the
invention;
[0035] FIG. 13 is a partially exploded front view of the preferred
embodiment of the wall structure;
[0036] FIG. 14 is a top plan view of the preferred embodiment of
the wall structure in part; and
[0037] FIG. 15 is a top plan view, in part, of the preferred
embodiment of the wall structure incorporating a side cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The invention and its various embodiments can now be better
understood by turning to the following detailed description wherein
illustrated embodiments are described. It is to be expressly
understood that the illustrated embodiments are set forth as
examples and not by way of limitations on the invention as
ultimately defined in the claims.
[0039] In a first preferred embodiment shown in FIGS. 1 and 2, a
wall panel 10 is thermoformed into an integral, thermoplastic fence
section resembling a plurality of stakes, or planks, 30 grouped
together. A Y axis is defined between a top 25 and a bottom 27 of
the panel 10. The stakes 30 thus extend vertically and
substantially parallel to the Y-axis. Since the fence section 10 is
preferably composed of a thermoplastic material, such as polyvinyl
chloride (PVC), the thickness of the wall of the section 10 is
roughly 0.05 inch to 0.15 inch. The panel 10 comprises an external,
or front, surface 21 and an opposite internal, or rear, surface 23.
Each "stake" 30 comprises a majority section 32 and a minority
section 34 that meet at an outward ridge 36 and extend rearwardly
therefrom to creases 38. The sections 32, 34, ridges 36, and
creases 38 are preferably vertically extending. The stakes 30 are
preferably identical with one another to allow for nesting as will
be described further below.
[0040] Since the panel 10 is thermoformed and relatively thin, the
front surface 21 is substantially parallel to the rear surface 23.
Thus, each front ridge 36 on the front surface 21 shown in FIG. 1
corresponds to a rear crease 61 defined in the opposite rear
surface 23 while a front crease 38 corresponds to a rear ridge 63.
Each stake 30 includes a rearwardly projecting flange, or top
return, 41. In the preferred embodiment, each top return 41 is
rounded to form a "dog ear" design which may be perceived as a more
desirable design. The returns 41 not only give the appearance of
three-dimensional depth, but also provide extra rigidity.
Similarly, the wall panel 10 includes a rearwardly projecting
bottom flange 43 that provides additional strength. In particular,
the top returns 41 and bottom flange 43 prevent the panel 10 from
buckling along the vertical ridges 36 and creases 38. Each stake 30
includes a rear recess 65 defined by the vertical sections 32, 34,
top return 41 and bottom flange 43.
[0041] It will be appreciated that the thermoforming process
enables a panel to be formed with structural features, such as
flanges and returns, which extend in a direction that is
discontinuous with the remainder of the panel, such as the vertical
sections. In the conventional extrusion process, an extruded body
maintains a constant cross-section, or profile, throughout the
axial length of the body. An extruded panel, therefore, may only be
formed with linear, continuous sections that extend parallel to the
axis defined by an extrusion die. Thermoforming, on the other hand,
enables a panel to have "non-extrudable" structural features,
including three-dimensional discontinuous texture, that is simply
impossible to accomplish with extrusion. Thus, a thermoformed panel
may have an irregular or variable profile along any axis of the
panel.
[0042] For example, FIGS. 3 and 4 are vertical cross-sectional
views taken along different points of the X-axis of the panel 10
shown in FIG. 1. It will be noted that the profiles are dissimilar.
Likewise, FIGS. 5 and 6, which are horizontal cross-sectional views
taken along different points along the Y-axis of the panel 10 shown
in FIG. 1, also illustrate different profiles. In FIGS. 5 and 6, it
will be noted that a relatively narrow flat section 45 is provided
between each stake 30.
[0043] A laminate or other finishing layer 67 may be disposed on
both the front surface 21 and rear surface 23 for aesthetics.
Alternatively, it may be preferable and cost efficient to provide
the finishing layer on the front surface 21 only. The finishing
layer 67 may include three-dimensional texture for a more
aesthetically pleasing appearance.
[0044] The panel 10 further comprises side portions 70, 72 adapted
to overlap with each other, as best shown in FIGS. 5 and 6. A first
side portion 70 preferably comprises a flat, vertical flange. The
opposite, second side portion 72 includes a forwardly extending
flange 74 that connects to a laterally extending flange 76. The
laterally extending flange 76 is therefore configured to overlap
and cover the front surface of a side portion of an adjacent panel,
as will be described below in connection with a preferred fencing
assembly.
[0045] FIG. 7 illustrates a further preferred embodiment of a
fencing panel 10a wherein structural elements similar to those
previously discussed are designated by the same reference numeral
followed by the letter "a". The panel 10a is thermoformed to
include an integral rail 80. It is to be understood that more rails
may be provided. Each rail 80 comprises an outward rectangular flat
portion 82 coupled to the rest of the panel 10a by a pair of
outwardly extending flanges 84. Along with the top returns 41 and
the bottom flanges 43a, the forwardly projecting rail 80 reinforces
the rigidity of the panel 10 by preventing buckling along the
vertical ridges 36a and creases 38a. Likewise, the vertical ridges
36a and creases 38a prevent buckling along the horizontal creases
86 of the rail 80.
[0046] In FIGS. 8-10, a preferred embodiment of a fencing assembly
100 incorporates a plurality of the preferred fence panels 10 as
described above. As an example and not by way of limitation, two
panels 10 are disposed between a pair of posts 112 although more or
less panels 10 may be provided between a pair of posts 112. The
posts 112 preferably comprise a hollow tube 114 topped with an
ornamental cap 116. The tube 114 preferably comprises a rectangular
cross-section and thus includes four sides 118. The tube 114 is
preferably extruded while the cap 116 is preferably injection
molded.
[0047] To give the appearance of a unitary, continuous fence, the
two fence panels 10 are placed side-by-side and disposed in a
slightly overlapping relationship. In particular, a side portion 72
of the first panel 10 overlaps and covers the front surface of an
adjacent side portion 70 of the second panel 10. As best shown in
the top plan view of FIG. 10, the covering side portion 72 includes
the forwardly extending flange 74 and laterally extending flange 76
as described above. The covered side portion 70 comprises a flat
vertical section that is nested in the area defined by the adjacent
flanges 74, 76. It will be noted that the forwardly extending
flange and laterally extending flange (not shown) has been removed
from the panel 10 comprising the covered side portion 70.
[0048] One or more horizontal reinforcements 120 may be provided.
In the preferred embodiment, top and bottom reinforcements 120 are
provided. Each reinforcement 120 preferably comprises a pair of
thermoplastic hollow bars 122, each bar 122 being coupled to its
corresponding fence panel 10 on the rear surface 23 preferably by
adhesion. In the preferred embodiment, the bars 122 are preferably
rectangular so as to provide a flat surface that abuts the flat
sections 45 of the panels 10. The bars 122 are preferably composed
of a thermoplastic material and may be adhered to the panels 10
with adhesive material, such as polyvinyl chloride cement. The bars
122 are aligned to receive an insert 124 which is then fastened to
the pair of bars 122. Outer end portions 126 of the bars are
coupled to the posts 112, preferably by brackets 130. Vertical
supports (not shown) may be optionally disposed in the stake
recesses 65 adjacent to the rear creases 61. In the preferred
embodiment, the posts 112 and reinforcement bars 122 are composed
of a thermoplastic material, such as polyvinyl chloride.
[0049] To allow for adjustability in the width of the fence
assembly 100, a side cover 132 is provided and configured to
resemble a stake. The side cover 132, which is preferably composed
of the same thermoplastic material as the panels 10, comprises a
first flat portion 134 adapted to be coupled to the post 112 and
disposed between the post 112 and the narrowed panel 10. A second,
slanted portion 136 extends from the first flat portion 134.
[0050] In a preferred method of assembly, an unwanted portion of a
fence panel 10 may be removed prior to being joined to a post 112,
thereby yielding a side edge 138 which may be unsightly.
Accordingly, the corresponding reinforcement bars 122 of the
narrowed panel 10 must be shortened. The side cover 132 is coupled
to the post 112. The narrowed panel 10 is then coupled to the post
112. As a result, the slanted portion 136 overlaps a side portion
of the narrowed panel 10 and gives the continuous appearance of
another stake while covering the rough side edge 138 from frontal
view.
[0051] FIG. 11 is a top plan view, in part, of another preferred
embodiment of a fence assembly 100b wherein structural elements
similar to those previously discussed are designated by the same
reference numeral followed by the letter "b". The fence assembly
100b incorporates a further preferred embodiment of a fence panel
10b wherein the flat side flanges 70, 74, 76 shown in FIGS. 1, 3
and 4 have been omitted. As a result, two panels 10b may be placed
side-by-side and disposed in an overlapping relationship by having
an outer stake 30b, or a portion thereof, of one panel 10b nest
within the outer stake 30b of the other, adjacent panel 10b.
[0052] In the above illustrated embodiments, the fence assembly is
shown as having two panels 10 disposed in between a pair or posts
112. An expanded fence assembly may be provided by coupling
additional panels to any of the unattached sides of the posts 112
and adding further posts. Since the posts 112 preferably comprise a
tube with a rectangular profile having four sides, it will be
appreciated that additional panels may be coupled to any of the
unused sides to form perpendicular fence sections which may be
preferable in fencing off areas of land. The tube 114, however, may
be formed in a variety of polygonal profiles, thereby varying the
number of sides available for coupling to additional panels. For
example, a post may comprise a hexagonal tube 114 which would then
provide six surfaces to which fence panels may be coupled. This may
give a user greater flexibility, for example, in bordering corners
of land that are not right angles. The tubes 114 of the posts 112
according to the invention are formed with a thickness preferably
about 0.125 inch.
[0053] It will be appreciated that an elongated fencing assembly
may be formed with a plurality of the fence sections 10 according
to the invention. With increasing needs for environmental
preservation, an inexpensive alternative is provided for wood
fencing which is just as aesthetically pleasing and even longer
lasting. Furthermore, unlike conventional plastic fences in which
each individual stake is extruded, the fencing section 10 according
to the invention is much less expensive since a plurality of stakes
may be formed in a single, integral panel. Since the panel 10 is
thermoformed, three-dimensional features, such as the top flanges
43, bottom flange 45, and the corrugation of the stakes 30,
collectively give the panel 10 an impression of depth and volume
when, in fact, the thickness of the panel is, for example, only
0.06 inch in the preferred embodiment.
[0054] In the preferred embodiments, the wall panels comprise solid
sheets without holes or openings. As fencing assemblies, this
feature of the wall panel provides greater privacy than
conventional fences. It is to be expressly understood, however,
that apertures may be formed in the panels if desired. In the fence
panel 10 shown in FIGS. 1-6, apertures may be formed, for example,
by removing portions of the minority portion 34 of the stakes
30.
[0055] In another aspect, a double-sided wall assembly according to
the invention may be provided with wall panels thermoformed to
resemble a variety of different wall structures. In FIGS. 12-15, a
preferred embodiment of a double-sided wall assembly incorporating
thermoformed panels is illustrated and designated generally by the
reference numeral 200. As described above, thermoforming enables
panels to be formed with discontinuous structural features that are
impossible to achieve by extrusion. In FIGS. 12-15, the wall
assembly 200 includes panels 210 thermoformed to resemble a brick
wall section. It is to be understood that a variety of masonry
patterns may be formed.
[0056] Each panel 210 comprises a front surface 212 and a rear
surface 214. A plurality of forwardly protruding "bricks" 216 are
formed with recessed "grout lines" 218 horizontally and vertically
dividing the bricks 216. The rearwardly protruding grout lines 218
correspond to flat rear surfaces which provide surface area for
abutting a frame as described further below. A border 230 of the
panel 210 comprises flat side flanges 232 and flat top and bottom
flanges 234. The outwardly raised front surface 212 may include
finer three-dimensional texture, such as asymmetrical bumps and
grooves, to give a more realistic and aesthetically pleasing
appearance of bricks. For example, the preferred embodiment
includes a Slumpstone texture. Other textures may be employed.
[0057] For ease of manufacturability, the wall panel 210 may simply
comprise two alternating rows 240a, 240b of differing structure.
More or less rows of differing structure may be provided. In the
embodiment illustrated in FIG. 12, a Running Bond pattern of bricks
is configured. It is to be expressly that a variety of different
patterns may be thermoformed into the panel, such as basket weave,
herringbone, stack bond, stone, rock, and more.
[0058] In the preferred embodiment shown in FIG. 13, the wall
assembly 200 includes two panel sub-assemblies, or double-sided
wall structures, 250 disposed side-by-side in between a pair of
posts 252. More or less panel sub-assemblies may be provided
between a pair of posts 252. Each panel assembly 250 includes a
frame, or skeleton, 254 which comprises a plurality of vertical
bars 256 and horizontal bars 258. The frame defines opposite sides
260, 261. A pair of panels 210 are coupled to the opposite sides
260, 261 of the frame 254, such as with fasteners, in a
back-to-back arrangement with the rear surfaces 214 facing each
other. Accordingly, the front surfaces 212 of the pair of panels
210 face outwardly and away from each other.
[0059] Side covers 262, each defining a U-channel, are coupled to
the sides 262 of each panel sub-assembly 250. The panel
sub-assemblies 250 are coupled to each in a side-by-side
arrangement. In the preferred embodiment, a top horizontal bar 258
of the frame 254 is offset from and disposed beneath top edges 266
of the panels 210. A bottom horizontal bar 258 is also offset from
and disposed above the bottom edges 270 of the panels 210.
Accordingly, top and bottom spaces 272, 274, respectively, are
provided for receiving reinforcing members, or support bars, 276
which may be composed of metal, for example. In the preferred
embodiment, a top reinforcing member 276 is disposed in the top
space 272 bridging the two panel assemblies 250. Similarly, a
bottom reinforcing member 276 is disposed in the bottom space 274.
The reinforcing members 276 are coupled to the frame 254. Thus,
each reinforcing member 276 is juxtaposed in an overlapping
relationship with both frames 254. A dowel, or pin, 277 couples the
two sub-assemblies 250 together. The pin 277 is inserted through
the side covers 262 and the vertical bars 256 of the frames 254. A
clip 299 fixed over the pin 277 keeps the pin 277 stationary by
preventing any lateral movement between the sub-assemblies 250.
[0060] A single top end cover and bottom end cover 280, 282,
respectively, are preferably disposed across both panel
sub-assemblies 250. The top and bottom end covers 280, 282 define
U-channels. With the spaces 272, 274 provided by the offset
horizontal frame bars 264, 268, respectively, it will be
appreciated that the reinforcement members 276 received therein may
be substantially flush with the top edges 266 and bottom edges 270
of the panels 210.
[0061] In the preferred embodiment, a pair of L-flanges, or
brackets, 284 are coupled to each post 252 so as to define a slot
286 for receiving the panel sub-assemblies 250. A variety of
mechanisms may be employed to couple the panel sub-assemblies 250
to the posts 252. The posts 252 preferably comprise a hollow tube
286 topped with an ornamental cap 288.
[0062] It will be appreciated that an elongated wall structure may
be formed by providing additional panel sub-assemblies and posts
and coupling such additional structures to the wall structure
200.
[0063] The wall assembly 200 also provides adjustability in width
as shown in FIG. 15. For example, a user may desire a specific
width between the pair of posts 252 that is different from the
width provided by pre-manufactured panels 210. In such a case, an
unwanted portion (not shown) of a panel sub-assembly 250 may be
removed so as to provide the desired width. For example, by making
a vertical cut, an unwanted side portion of a panel sub-assembly
250, including portions of the frame and opposing side panels, may
be removed to leave the remainder of the panel assembly 250 with
the desired width. A vertical frame bar, or vertical support, 290
may be coupled to the edge 292 from which the unwanted portion has
been removed. To maintain a continuous and aesthetically pleasing
appearance, a side cover 294 according to the invention is coupled
to the panel assembly 250. The side cover 294 includes a central
recess, or central U-channel, 296 defined by a pair of central
flanges 298 joined by a middle flange 302. The U-channel is
configured to receive and cover the projecting vertical frame bar
290 that has been added. Outer flanges 304 are configured to cover
the unsightly edges 292 of the cut panels 210. The outer flanges
304 are joined by connecting flanges 306 to the central flanges
298. The side cover 294 is also configured to fit within the slot
286 defined by the L-flanges 284.
[0064] With the side cover 294 coupled to the reduced panel
sub-assembly 250, the sub-assembly 250 may then be coupled to the
post 252 by inserting the side cover 294, namely the central
U-channel, into the slot 286. In the preferred embodiment of the
wall assembly 200, the panels 210, posts 252, covers 262, 280, 282,
294 are composed of a thermoplastic material, such as polyvinyl
chloride.
[0065] It will be appreciated that the double-sided wall assembly
200 according to the invention may incorporate wall panels
thermoformed in a variety of designs. For example, a wall panel may
be thermoformed to resemble a brick wall with an uneven array of
bricks. In particular, each brick may be configured to be outwardly
or inwardly disposed relative to adjacent bricks so as to form an
uneven pattern. As further examples, the wall panel may be
thermoformed to resemble other masonry patterns.
[0066] The above embodiments may be erected in open space to serve
as a fence around an open piece of property. The unique heat
dissipation characteristic of the thermoformed panels according to
the invention also enable a variety of dark colors to be applied.
The panels according to the invention comprise unitary sheets
without cavities. Since no pockets exist in which absorbed heat can
build up, the heat absorbed by the panels simply dissipates into
the ambient environment. With the excellent heat dissipating
qualities of the panels due to the lack of cavities, it will be
appreciated that the fencing and wall assemblies according to the
invention may be painted a variety of dark colors, such as redwood
brown, to resemble a natural wood fence or siding. Furthermore, the
posts may optionally include solid inserts, such as wood studs,
disposed in the cavity in order to prevent the tube from
warping.
[0067] Many alterations and modifications may be made by those
having ordinary skill in the art without departing from the spirit
and scope of the invention. Therefore, it must be understood that
the illustrated embodiments have been set forth only for the
purposes of examples and that they should not be taken as limiting
the invention as defined by the following claims. For example,
notwithstanding the fact that the elements of a claim are set forth
below in a certain combination, it must be expressly understood
that the invention includes other combinations of fewer, more or
different elements, which are disclosed in above even when not
initially claimed in such combinations.
[0068] The words used in this specification to describe the
invention and its various embodiments are to be understood not only
in the sense of their commonly defined meanings, but to include by
special definition in this specification the generic structure,
material or acts of which they represent a single species.
[0069] The definitions of the words or elements of the following
claims are, therefore, defined in this specification to not only
include the combination of elements which are literally set forth.
In this sense it is therefore contemplated that an equivalent
substitution of two or more elements may be made for any one of the
elements in the claims below or that a single element may be
substituted for two or more elements in a claim. Although elements
may be described above as acting in certain combinations and even
initially claimed as such, it is to be expressly understood that
one or more elements from a claimed combination can in some cases
be excised from the combination and that the claimed combination
may be directed to a subcombination or variation of a
subcombination.
[0070] Insubstantial changes from the claimed subject matter as
viewed by a person with ordinary skill in the art, now known or
later devised, are expressly contemplated as being equivalently
within the scope of the claims. Therefore, obvious substitutions
now or later known to one with ordinary skill in the art are
defined to be within the scope of the defined elements.
[0071] The claims are thus to be understood to include what is
specifically illustrated and described above, what is
conceptionally equivalent, what can be obviously substituted and
also what incorporates the essential idea of the invention.
* * * * *