Modular fence system

Abstract

A modular fence system (10) is provided. The modular fence system 10 generally includes a plurality of spaced post assemblies (100) for securement to a support surface, and at least one cross member (200) coupled to respective support portions of at least a pair of such post assemblies (100) to extend transversely therebetween. Each post assembly (100) includes first and second molded post members (110, 120) joined one to the other in opposed manner to define therebetween at least one transverse eyelet (105a, 105b, 105c). Each of the first and second post members (110, 120) is formed with a base section (114, 124) and a support section (112, 122) extending longitudinally therefrom. The support section (112) of the first post member (110) includes at least one slotted recess (115a, 115b, 115c) for defining against the second post member support section (122) at least a portion of one transverse eyelet (105a, 105b, 105c). At least one of the first and second post members (110, 120) includes a protuberant portion (111a, 111b) for engaging a cavity (121a, 121b) formed in the other of the first and second post members (110, 120). The cross member (200) engages respective ones of the transverse eyelets (105a, 105b, 105c) of the pair of post assemblies (100).

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The subject modular fence system is generally directed to a fence structure for partitioning or peripherally bounding areas of property. More specifically, the subject modular fence system is one which includes cross members supported by a plurality of post assemblies, wherein one or more of at least the post assemblies is formed with a modular, molded construction.

[0003] A type of fence system often used, particularly where it is to be of considerable length, is the board type where a plurality of rail-like board members are horizontally passed through transverse eyelet openings formed in a plurality of spaced vertical support posts. Depending on such factors as the peripheral contour of the area being fenced, dimensional constraints on the board members, and the spacing requirements for neighboring posts, individual board members may be supported by two, three, or even more neighboring support posts. A plurality of sections having boards thus supported by spaced support posts are extended in series to collectively define a given fence system. Such fence systems in many outdoor applications extend over great distances.

[0004] A number of practical considerations typically bear on the manufacture and use of such board type fence systems. First, costs escalate to considerable levels because the fence system is often the fence type of choice where the application calls for great fence lengths. Material and fabrication costs may mount to prohibitively significant levels in those applications. Additionally, most applications of such fence systems occur outdoors; hence, the fence's structural members are continually exposed to the elements. It is important for these reasons to form such fences from materials which afford not only minimal manufacturing costs but provide great durability, so as to withstand the constant environmental exposure encountered in typical applications.

[0005] Other points of considerable practical concern are the cost and convenience of adequately maintaining the fence system over the many years of service normally required of such fence systems. Because they are typically intended to serve at least in some degree a containment function, these fence systems tend to extend in substantially contiguous manner about the given area of containment. Even where containment is not a primary function, a substantially contiguous configuration is desirable to preserve the visual continuity of the partition structure established by the fence system. Most fence systems, therefore, are formed with few if any intermediate breaks in their structure.

[0006] Where a repair is to be made at an intermediate portion of the fence system, then, it may become difficult to remove or replace an individual board or support post member without removing or otherwise disturbing the surrounding members. Replacing a damaged support post member, for instance, would require disassembly of the given fence section, at least to the extent that the section's board members would first need to be disengaged not only from the particular support post member in question, but also from the other neighboring support post member(s) by which the board members is also supported.

[0007] Consequently, there remains a need for a board type fence system whose structural members are inexpensive to manufacture yet durable enough to withstand continual environmental exposure and maintain structural soundness. There remains a need, moreover, for such a fence system whose structural members, even at its intermediate sections, may be accessed for repair or replacement with simplicity and ease.

[0008] 2. Prior Art

[0009] Fence systems of various type are known in the art. The most relevant art known to Applicant includes U.S. Pat. Nos. 6,131,885; 4,324,388; 4,702,459; 4,240,615; 5,803,438; 4,858,891; 5,931,450; 4,540,160; 3,698,692; 4,735,397; 5,601,278; 4,060,222; 4,357,001; 6,299,142; 6,173,944; 5,613,664; 6,311,956; 3,955,801; 4,722,514; 6,284,336; 5,599,599; 5,255,897; 4,553,741; and, 5,149,060. While these references disclose fence systems of various structure and material composition, there is no fence system heretofore known which provides the combination of low cost manufacturability, durability, and simplicity of maintenance to the degree that the subject modular fence system provides.

SUMMARY OF THE INVENTION

[0010] A primary object of the present invention is to provide a modular fence system whose structural members are inexpensive to manufacture.

[0011] It is another object of the present invention to provide a modular fence system that is both durable and structurally sound.

[0012] It is yet another object of the present invention to provide a modular fence system that may be easily and conveniently repaired.

[0013] These and other objects are attained by the subject modular fence system comprising, generally, a plurality of spaced post assemblies for securement to a support surface, and at least one cross member coupled to support portions of two or more such post assemblies to extend transversely therebetween. Each post assembly includes first and second molded post members joined one to the other in opposed manner to define therebetween at least one transverse eyelet. Each of the first and second post members is formed with a base section and a support section extending longitudinally therefrom. The support section of the first post member includes at least one slotted recess for defining against the second post member support section at least a portion of one transverse eyelet. At least one of the first and second post members includes a protuberant portion for engaging a cavity formed in the other of the first and second post members. The cross member engages respective transverse eyelets of the pair of post assemblies.

[0014] In a preferred embodiment, the first and second post members are integrally molded from a thermoplastic composition, as are each of the cross members. Preferably, the thermoplastic composition includes a recycled plastic resin material that is impact modified and includes a pigmentation component. Each cross member is in that embodiment reinforced by a core having a predetermined sectional contour.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a perspective view of a portion of one embodiment of the present invention;

[0016] FIG. 2 is an exploded perspective view of the portion of the embodiment of the present invention shown in FIG. 1;

[0017] FIG. 3 is an elevational view, partially cut away, of one embodiment of the present invention as assembled in an exemplary application;

[0018] FIG. 3A is an elevational view, partially cut away, of an alternate configuration for a portion of the embodiment shown in FIG. 3;

[0019] FIG. 4A is a sectional view in one embodiment of a first portion of the system shown in FIG. 3;

[0020] FIG. 4B is a sectional view in an alternate embodiment of a first portion of the system shown in FIG. 3;

[0021] FIG. 5 is a sectional view in one embodiment of another portion of the system shown in FIG. 3; and,

[0022] FIG. 6 is an elevational view, partially cut away, of various portions of the embodiment of the present invention shown in FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Referring now to FIGS. 1-3, there is shown one exemplary embodiment of the subject modular fence system 10. Fence system 10 includes in this embodiment a plurality of spaced post assemblies 100 secured to a support surface 1. Each post assembly 100 is formed by opposing first and second modular post members 110, 120 that adjoin as shown to define a plurality of transverse eyelet openings 105a, 105b, 105c therebetween. Fence system 10 further includes in this embodiment a plurality of cross members 200, each of which transversely extends to engage for support corresponding eyelets 105a, 105b, 105c of a plurality of neighboring post assemblies 100.

[0024] In the embodiment shown, a contiguous series of fence sections 10′, 10″ is thus defined (two inner ones of which are illustrated in FIG. 3). Each fence section 10′, 10″ includes multiple transverse rows of board-like cross members 200 supported by a pair of outer post assemblies 100a and an intermediate post assembly 100b. Where the given fence section adjoins another fence section as shown, the outer post assembly 100a closest to the other adjoining fence section serves concurrently as an outer post assembly for that adjoining fence section as well.

[0025] FIG. 3 illustrates but one exemplary configuration for the embodiment of system 10 shown, and numerous other suitable configurations may be employed. For example, each section 10′, 10″ may include different numbers of post assemblies 400 and/or cross members 200 arranged with uniform or nonuniform relative spacing. As a further example, neighboring fence sections 10′, 10″ may be arranged with an overlapping delineation. That is, the rows of cross members 200 may be lengthwise staggered in arrangement such that cross members 200 in different rows terminate at different post assemblies 100 rather than at the same post assemblies 100a as shown. The present invention is not limited to any particular configuration or arrangement of fence sections, as the requirements of various intended applications may render certain configurations/arrangements more suitable than others.

[0026] Preferably, the erected fence structure is reinforced by intermittently connecting terminal ends of adjacent cross members 200 disposed in the same row using a plurality of fasteners 210. Such fasteners 210 may be of any suitable type known in the art capable of securely coupling the two opposing cross member ends. At other points along a given row of cross members 200, transversely opposing terminal ends of adjacent cross members 200 are preferably left free and uncoupled to permit their relative displacement for accommodating such things as vibration, shock, and thermal expansion/contraction.

[0027] An exemplary embodiment is illustrated for inner fence sections 10′ and 10″ in FIG. 3, wherein terminal ends of two cross members 200 are disposed within post assembly 100a opposing one another in substantially abutting manner. In alternate configurations, such as shown in FIG. 3A, the terminal ends of cross members 200′ may be disposed within post assembly 100a′ overlapped at respective regions 205′. The transverse eyelet opening and/or the terminal end portions of the cross members 200′ may be suitably configured in contour and dimension to enable such overlap in this configuration. The overlapping of terminal ends, of course, permits extended lengths in the cross members 200′, affording the fence system greater tolerance to contraction/expansion and displacement of cross members 200′ than in the configuration shown in FIG. 3.

[0028] An exemplary embodiment for fence sections 10a, 10b disposed at ends or corners of the given fence system is illustrated in FIG. 6. In fence sections 10a, 10b, cross members 200 are anchored to post assemblies 100 disposed at or near an end/corner by suitable fasteners 220. Fasteners 220 are preferably of the self-tapping type and suitably configured to securely affix and retain cross members 200 relative to the given post assemblies 100.

[0029] Referring back to FIGS. 1-2, each of the first and second molded post members 110, 120 of post assembly 100 is integrally molded preferably from a thermoplastic composition. Post members 110, 120 may be formed with various shapes, dimensional proportions, and such other configurational features than those shown, to the extent permitted by the requirements of the intended application. In accordance with the present invention, however, each of the first and second post members 110, 120 is formed with a base section 114, 124 sufficiently adapted for stable securement to the ground or other supporting surface, and a support section 112, 122 extending longitudinally therefrom. The support sections 112, 122 are suitably configured such that when post members 110, 120 are joined in opposed manner, they cooperatively define the transverse eyelet(s) 105a, 105b, 105c for supportingly receiving the cross member(s) 200 employed in the given application. Accordingly, at least the first post member 110 is formed with one or more slotted recesses, each of which defines all or part of a transverse eyelet 105a, 105b, 105c against a corresponding portion of the second post member 120.

[0030] In the exemplary application shown, a plurality of eyelets 105a, 105b, 105c are thus defined by a plurality of slotted recesses 115a, 115b, 115c formed in longitudinally spaced manner in the first post member 110. These slotted recesses 115a, 115b, 115c respectively oppose and communicate with corresponding slotted recesses 125a, 125b, 125c similarly formed into the second post member 120 when the two post members 110, 120 are brought together.

[0031] Note that in certain alternate embodiments, the second post member 120 may, for instance, define simply a flat, unrecessed planar surface, with the slotted recesses formed (dimensioned accordingly) only into the first post member 110. In the embodiment shown, the slotted recesses 115a, 115b, 115c and 125a, 125b, 125c separate a plurality of respective coupling bodies 117, 127 defined on the two post members 110, 120. These coupling bodies 117, 127 form opposing faces which make substantially flush contact one with the other in the embodiment shown, as do the opposed longitudinal base surfaces 119, 129 (defined at the respective base sections 114, 124) when the first and second post members 110, 120 are joined for fence assembly.

[0032] At least one of the first and second post members 110, 120 includes one or more protuberances 111a, 111b preferably protruding from a corresponding coupling body 117, 127. Each protuberance 11a, 11b engages a cavity 121a, 121b preferably formed in an opposing coupling body 117, 127 on the other of the first and second post members 110, 120. The protuberances 111a, 111b and their receiving cavities 121a, 121b may be formed on opposing first and second post members 110, 120 in any suitable combination and number necessary to ensure reliably guided alignment of the opposed first and second post assemblies 110, 120 when they are brought together for assembly.

[0033] As mentioned in preceding paragraphs, each of the first and second post members 110, 120 is molded to a predetermined form using preferably a thermoplastic composition. This thermoplastic composition includes in the embodiment shown a recycled plastic resin that is preferably impact modified and pigmented with one or more pigmentation components. The recycled plastic resin employed is preferably of an olefinic recycled type which typically exhibits a dark, blackish color. By incorporating a series of iron oxides as pigmentation components, a range of naturally occurring earth colors such as varying shades of brown, blue, gray, and the like may be derived for the molded post assemblies 110, 120. Any suitable molding technique known in the art may be employed using these and other such components to yield structural members which in texture and general appearance simulate a particular type of lumber or other fencing material typically employed in the intended application.

[0034] Tremendous savings in material and recurring labor costs may be realized by forming the structural members in this manner. The plastic resin component may be derived from a multiplicity of scrap or virgin sources. If necessary, fillers such as talc, minerals, glass, bamboo, kenaf grasses, and the like may also be incorporated to obtain a desired combination of material properties.

[0035] Moreover, each of the first and second post members 110, 120 may in accordance with the present invention be formed with either a solid or non-solid structure. Where formed with a non-solid structure, each member 110, 120 may at its various portions include a hollow, honeycomb, or other internal configuration suitable for the given application. Each of the coupling bodies 117, 127 as well as the base sections 114, 124 of the two post members 110, 120 are hollowed to the extent that they define respective cavities 117′, 127′, 119′, 129′, so as to minimize the weight of each post member 110, 120 without significantly compromising the strength and structural integrity thereof. The actual choice of structural configurations and material properties employed will depend upon such factors as the required service life, the load to be borne, and the environmental extremes to be encountered in the intended application.

[0036] Once they are assembled to form a post assembly 100, the first and second post members 110, 120 may be fastened together by any suitable means known in the art. Preferably, though, the post members 110, 120 are ultrasonically, heat or friction welded together, so as to realize a firm coupling while minimizing the number of extraneous components required and avoiding conspicuous structural alterations.

[0037] While the coupling bodies 117, 127 and longitudinal base surfaces 119, 129 of the two post members 110, 120 are configured in the embodiment shown to define opposing faces for flush abutting engagement, they may be formed with other suitable configurations to effect various other types of engagement. For instance, the opposed coupling bodies 117, 127 and base sections 114, 124 may be suitably configured in contour and dimension such that one telescopically engages the other. In such embodiments, the need to separately provide protuberances 111a, 11b and receiving cavities 121a, 121b may be obviated, as the coupling bodies 117, 127 and base sections 114, 124 themselves provide the reinforcing and self-guiding engagement of protuberant and receiving cavity portions.

[0038] The modular structure prevailing for each post assembly 100 formed in accordance with the present invention not only facilitates convenient initial assembly of fence system 10, it facilitates the convenient repair of fence sections 10′, 10″, 10a, 10b even after the fence system has been fully assembled and erected. Where a particular post assembly 100 is to be repaired or replaced, that post assembly 100 may be conveniently removed—without disturbing the surrounding post assemblies 100 and supported cross members 200— by decoupling the post assembly's post members 110, 120, then drawing apart and away from the cross members 200. The repaired or replaced post members 110, 120 may be re-coupled thereafter, at the appropriate position about the cross members 200. Similarly, where a particular cross member 200 is to be removed for repair or replacement, the post assembly 100a to which, or within which, a terminal end of the cross member 200 is fastened, is disassembled to expose the cross member's fastened terminal end. Once the fastening is released, the cross member 200 may simply be slid out of engagement with the eyelets 105a, 105b, or 105c of the given fence section's other post assemblies 100. The repaired or replaced cross member 200 may thereafter be slid back into engagement with the other post assemblies 100, then refastened to the adjacent cross member 200, with the post members 110, 120 of the previously-disassembled post assembly 100a being re-coupled one to the other.

[0039] Preferably, each cross member 200 is molded from a thermoplastic composition in much the same manner as described in preceding paragraphs for post members 110, 120. Like post members 110, 120, each cross member 200 may be formed with either a solid or non-solid structure, with any suitable internal configuration permitted by the requirements of the intended application. Where cross members 200 of sufficiently extended length are employed, however, an internal reinforcing core 230, 232 is incorporated into each such cross member 200, as shown in the exemplary embodiments of FIGS. 4A-4B. This reinforcing core 230, 232 may be formed of ferrous metals, non-ferrous metals, or any other suitable material of comparable reinforcing strength and rigidity. Each reinforcing core is preferably formed with a rigidity-enhancing sectional contour, such as the I-beam contour shown in FIG. 4A, or the C-channel contour shown in FIG. 4B, such that the cross members 200 will not sag or bow between supporting post assemblies 100, even after an extended period of use has occurred.

[0040] In other alternate embodiments, more than one reinforcing core 230, 232 may be incorporated into a cross member 200 to further reinforce its strength and rigidity. Two or more reinforcing cores 230, 232 sectionally contoured such as shown in FIGS. 4A, 4B may in those embodiments be disposed in nested manner within one cross member 200, for instance, to multiply the reinforcement provided.

[0041] Although this invention has been described in connection with specific forms and embodiments thereof, it will be appreciated that various modifications other than those discussed above may be resorted to without departing from the spirit or scope of the invention. For example, equivalent elements may be substituted for those specifically shown and described, certain features may be used independently of other features, and in certain cases, certain arrangements of features may be reversed or interposed, all without departing from the spirit or scope of the invention as defined in the appended claims.

Claims

1. A fence system comprising:

(a) a plurality of spaced post assemblies for securement to a support surface, each said post assembly including:

first and second molded post members joined one to the other in opposed manner to define therebetween at least one transverse eyelet, each of said first and second post members having a base section and a support section extending longitudinally therefrom, said support section of said first post member including at least one slotted recess for defining against said second post member support section at least a portion of one said transverse eyelet;

at least one of said first and second post members including a protuberant portion for engaging a cavity formed in the other of said first and second post members; and,

(b) at least one cross member coupled to said support portions of a pair of said post assemblies to extend transversely therebetween, said cross member engaging respective ones of said transverse eyelets of said pair of post assemblies.

2. The fence system as recited in claim 1 wherein each of said first and second post members has formed therein at least one slotted recess, each said slotted recess of said first post member being in open communication with one said slotted recess of said second post member to define one said transverse eyelet therewith.

3. The fence system as recited in claim 2 wherein said first and second post members each include a plurality of said slotted recesses to define a plurality of said transverse eyelets.

4. The fence system as recited in claim 1 comprising a plurality of said cross members extending substantially in parallel one with the other, each said cross member passing substantially through corresponding ones of said transverse eyelets respectively of at least a pair of said post assemblies.

5. The fence system as recited in claim 1 wherein said cross member includes a reinforcing core embedded therein.

6. The fence system as recited in claim 5 wherein said reinforcing core of said cross member is formed with a sectional contour selected from the group consisting of: a C-channel, and I-beam.

7. The fence system as recited in claim 1 wherein each of said first and second post members is integrally molded from a thermoplastic composition.

8. The fence system as recited in claim 1 wherein said thermoplastic composition includes a recycled plastic resin material, said recycled plastic resin material being impact modified and including a pigmentation component.

9. The fence system as recited in claim 1 wherein each said cross member is integrally molded from a thermoplastic composition.

10. The fence system as recited in claim 1 wherein:

said base sections of said joined first and second post members define respective longitudinal base surfaces disposed in substantially flush contact one with the other; and,

said support sections of said first and second post members each include a plurality of coupling bodies separated one from the other by one said slotted recess, said coupling body of said joined first and second post members being disposed in substantially flush contact respectively one with the other.

11. The fence system as recited in claim 10 wherein each said coupling body has formed therein a hollowing cavity.

12. The fence system as recited in claim 11 wherein said base section of each said first and second post member has formed therein a hollowing cavity.

13. A fence system comprising:

(a) a plurality of spaced post assemblies for securement to a support surface, each said post assembly including:

first and second molded post members detachably coupled one to the other in opposed manner to define therebetween at least one transverse eyelet, each of said first and second post members being integrally formed in structure, said first and second post members each having a base section and a support section extending longitudinally therefrom, said support sections of said detachably coupled first and second post members including slotted recesses respectively formed therein for cooperatively defining said transverse eyelet;

at least one of said first and second post members including a protuberant portion for engaging a cavity formed in the other of said first and second post members;

(b) at least one cross member coupled to said support portions of a pair of said post assemblies to extend transversely therebetween, said cross member engaging respective ones of said transverse eyelets of said pair of post assemblies.

14. The fence system as recited in claim 13 wherein said first and second post members each include a plurality of said slotted recesses to define a plurality of said transverse eyelets, said first post member includes a plurality of said protuberant portions, and said second post member includes a plurality of said cavities.

15. The fence system as recited in claim 13 wherein said base sections of said detachably coupled first and second post members define respective longitudinal base surfaces disposed in substantially flush contact one with the other.

16. The fence system as recited in claim 14 wherein said support sections of said first and second post members each include a plurality of coupling bodies separated one from the other by one said slotted recess, said coupling bodies of said detachably coupled first and second post members being disposed in substantially flush contact respectively one with the other, each said coupling body having formed therein a hollowing cavity.

17. The fence system as recited in claim 13 wherein each of said first and second post members is integrally molded from a thermoplastic composition including a recycled plastic resin material, said recycled plastic resin material being impact modified and including a pigmentation component.

18. A fence system having a plurality of spaced post assemblies for securement to a support surface, each said post assembly comprising:

first and second opposed post members detachably coupled one to the other to define therebetween a plurality of transverse eyelets for the insert of a plurality of cross members respectively therein;

said first and second post members and said cross members each being integrally molded from a thermoplastic composition, and having a base section and a support section extending longitudinally therefrom, said support section of each said first post member and said second post member including a plurality of slotted recesses, said slotted recesses of said first post member being aligned in open communication with one of said slotted recess of said second post member to define one said transverse eyelet;

at least one of said first and second post members including a transversely protuberant portion for engaging a cavity formed in the other of said first and second post members, the engagement of said transversely protuberant portions and cavity guiding the detachable coupling of said first and second post members in substantially aligned manner.

19. The fence system as recited in claim 18 wherein said thermoplastic composition includes a recycled plastic resin material, said recycled plastic resin material being impact modified and including a pigmentation component.

20. The fence system as recited in claim 19 wherein said recycled plastic resin material includes an olefinic recycled material, said pigmentation component including an iron oxide constituent.

21. The fence system as recited in claim 18 wherein said support sections of said first and second post members each include a plurality of coupling bodies separated one from the other by one said slotted recess, said coupling bodies of said detachably coupled first and second post members being disposed in substantially flush contact respectively one with the other, each said coupling body having formed therein a hollowing cavity.

22. The fence system as recited in claim 21 wherein said first post member includes a plurality of said transversely protuberant portions, and said second post member includes a plurality of said cavities, mutually engaging ones of said transversely protuberant portions and cavities being formed respectively on opposed ones of said coupling bodies.