Fence post, fence assembly, and method of fabricating the same

Abstract

The present invention relates to a fence post, a fence assembly (e.g., corral panel) including such a fence post, and methods of making the same. This fence post may generally be characterized as having first and second distinct post portions that each have a length substantially similar to that of the fence post. Rails, beams, or other appropriate fencing is at least partially interposed or “sandwiched” between these first and second fence post portions to make up a fence assembly of the invention. Moreover, adhesive (e.g., fast-set acrylic), rather than welding, is utilized to interconnect the first and second fence posts, as well as to interconnect the rails, beams, or other fencing with the first and/or second post portions of the fence post.

Description

STATEMENT REGARDING RESEARCH/DEVELOPMENT FUNDING

Partial funding for this invention was received under an award from the Kentucky Science & Technology Corporation under Contract #146-403-32.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention generally relates to corral panels and gates that are used by horse trainers, breeders and riders for at least temporarily corralling, confining, housing, watering, feeding, and/or isolating horses. In addition, such corral panels have been shown useful for other types of livestock breeders and handlers as well.

2. General Background of the Invention

Fence assemblies (e.g., corral panels) are available from a variety of suppliers and are conventionally fabricated from tubular stock such as steel. In a typical fabrication process of such a fence assembly, components such as vertical posts and horizontal rails are welded together. Further, it is customary that these welded fence assemblies or panels are fabricated from first quality (typically expensive), continuous lengths of steel tubing, pipe or bar stock. When galvanized steel is used, the weld areas are preferably “touched up” with silver paint to hide the burned coating and welds. These areas tend to rust very quickly, due to the inferior coating. When plain steel is used, entire assemblies are typically either painted (dip or spray) or powder coated after welding. Powder coating is an application of a least one of several polymeric powder materials, such as epoxy urethanes or polyester to an article (e.g. generally as a spray), which is then cured (e.g., in an oven). It is not practical to coat the pieces before welding due to coating damage and spatter from the welds. Also a shot blasting process is required to remove weld spatter if a high quality finish is desired. Therefore, a continuous production coating line tends to be very long in duration (and expensive) to incorporate blasting, cleaning, and coating of entire assemblies.

Additionally, some conventional welding processes employed in typical fence assembly fabrication frequently leave remains of the weld filler wire on the panel in the form of sharp and/or pointed projections. This generally results in an increased likelihood of cuts and/or laceration of animals that rub or come into contact with the fence assembly(ies).

As another detriment to conventional fence assembly fabrication methods, labor cost s associated with the welding process tend to be very expensive. For instance, experienced production welders may command wages in the range of $20/hour or more, and tend to be hard to retain long term. Moreover, employing a large number of production welders at one location can be difficult and expensive.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides an alternative construction of fence assemblies (e.g., corral panels), as well as fence posts thereof, which at least generally reduces (or even eliminates) marring of a finish (e.g., powder coating) during fabrication and/or additionally provides significantly lower manufacturing costs. One economic benefit of the present invention comes from the potential use of inexpensive “scrap” bar and channel stock in fence assembly fabrication, which is achieved through a unique configuration of posts and rails making up a fence assembly of the invention, such as a corral panel. Because of a beneficial configuration of the bar and channel stock used, a fence assembly of the invention can be fabricated through the use of commercially available adhesives. This use of adhesive in the fence assembly fabrication process of the invention tends to reduce a need for skilled (and generally costly) production welders in favor of lesser skilled (and generally less costly) assembly workers. As another benefit, the use of low cost channel and bar stock allows for new post and rail configurations that provides for a more attractive and more easily assembled finished product. Indeed, the present invention may be said to at least generally provide a beneficial “fabricated lumber” and/or a “lumber substitute” for use as a fence post (e.g., in a fence assembly). These benefits, as well as others, may be achieved by the present invention herein described.

In a first aspect, the present invention is directed to a fence post having a longitudinal reference axis that extends at least between first and second ends of the fence post. This fence post also includes first and second post portions that both extend at least generally along the reference axis, and adhesive interconnecting the first and second post portions.

Various refinements exist of the features noted in relation to the subject first aspect of the present invention. Further features may also be incorporated in the subject first aspect as well. These refinements and additional features may exist individually or in any combination. For instance, in one embodiment, the first and second post portions of the fence post may be substantially symmetrical. Stated another way, the first and second post portions may be substantially identical, and/or may even be characterized as being mirror images of one another. In another embodiment, the first and second post portions may exhibit a male-female relationship. In other words, part of one of the first and second post portions maybe positionable within a channel, groove, recess, or the like of the other post portion. In yet another embodiment, the first and second post portions maybe said to exhibit an interlocking tongue and groove configuration. Moreover, the adhesive utilized to interconnect the first and second post portions may be found at least generally between a tongue and a groove of this tongue and groove configuration.

In the case of the first aspect of the present invention, at least one of the first and second post portions may include (or be made up of) a sheet material, and preferably a sheet metal such as steel, for example. This sheet material (especially in the case of the sheet material being a sheet metal) may have some type of coating such as a powder coating, paint, epoxy, and galvanization. Since adhesive is generally utilized to interconnect the first and second post portions associated with this first aspect, some embodiments may be characterized as being free of welds. As welds tend to sacrifice the integrity (e.g., lessen the quality) of any coatings on the sheet material, the use of adhesive to interconnect the first and second post portions generally provides a benefit of avoiding the cost and negative structural effects associated with welds. Moreover, since welding may increase a propensity for spur or sharp edge formation, the use of adhesive may be said to reduce the tendency for formation of such spurs/sharp edges. Numerous adhesives may be appropriate for use with regard to this first aspect. By way of example, appropriate adhesives may include, but are not limited to, acrylics (e.g., fast-set acrylics), epoxies, urethanes, and appropriate combinations thereof.

Still with regard to this first aspect of the present invention, each of the first and second post portions preferably includes a bonding surface. This bonding surface generally refers to part of the corresponding post portion that adhesive may be applied to and/or in contact with to at least generally facilitate adhesive interconnection of the first and second post portions to each other. While these bonding surfaces associated with the first and second post portions may be oriented in a variety of appropriate manners relative to each other, they are preferably substantially parallel with one another.

In a second aspect, the present invention is embodied in a fence post that has a longitudinal reference axis extending at least generally between first and second ends of the fence post. This fence post also includes a first post portion having a first length that is substantially aligned with the reference axis, and a separate and distinct second post portion having a second length that is substantially aligned with (e.g., substantially parallel to) the reference axis. Moreover, these first and second lengths associated with the fence post of the second aspect are substantially equal.

Various refinements exist of the features noted in relation to the subject second aspect of the present invention. Further features may also be incorporated in the second aspect as well. These refinements and additional features may exist individually or in any combination. For instance, the first and second post portions may at least generally define corresponding first and second channels (e.g., what may be referred to as C-channels or box channels) that extend along the reference axis. These channels are preferably found on the “inside” of the fence post. In other words, the fence post of the second aspect, at least in one embodiment, may be characterized as being substantially hollow or having a cavity defined therein. In one embodiment, at least part of the first post portion extends into the second channel defined by the second post portion. Adhesive may be disposed at least generally between and in contact with the second post portion and the part of the first post portion that extends into the second channel associated with the second post portion.

Still referring to the second aspect of the present invention, the first post portion of the fence post may include what may be characterized as a first (e.g., front) side of the fence post, and the second post portion of the fence post may include an opposing second (e.g., back) side of the fence post. In one embodiment, these first and second sides are substantially parallel relative to each other. Further, portions of both of the first and second post portions may be said to make up third and fourth sides of the fence post. So, at least portions of the first, third, and fourth sides of the fence post may be defined by the first post portion. Similarly, at least portions of the second, third, and fourth sides of the fence post may be defined by the second post portion. In one embodiment, the first and second post portions may be equipped with corresponding first and second attachment projections. This first attachment projection associated with the first post portion may be oriented in any appropriate manner, but is preferably substantially parallel to the first side of the fence post. Likewise, the second attachment projection may be oriented in a number of appropriate ways, but is preferably substantially parallel to the second side of the fence post.

Further, at least one embodiment exhibits at least a first segment of the first attachment projection that is substantially parallel with at least a second segment of the second attachment projection. Regardless of the particular embodiment of the second aspect having these first and second attachment projections, adhesive is preferably interposed between and in contact with both of the first and second segments of the first and second attachment projections. In other words, adhesive may be utilized to interconnect appropriate attachment projections of the respective post portions with one another.

Yet a third aspect of the invention is embodied in a fence assembly that includes a fence post having an elongate (e.g., having a notably more length than width) first post portion, and a separate and distinct elongate second post portion. Moreover, this fence assembly of the third aspect includes a fence rail, and at least a portion of this fence rail is interposed between the first and second post portions of the fence post. That is, at least some of the fence rail is at least generally situated between the first and second post portions.

Various refinements exist of the features noted in relation to the subject third aspect of the present invention. Further features may also be incorporated in the third aspect as well. These refinements and additional features may exist individually or in any combination. The fence post may be characterized as having first and second opposing sides, and a rail aperture may be defined in at least a third side of the fence post. As mentioned above with respect to the second aspect of the present invention, the third side of the fence post may be made up of parts of both the first and second post portions. Accordingly, this rail aperture maybe said to be defined by both the first and second post portions of the fence post. Herein, the term “rail aperture” may refer to a depression or receptacle that spans only partially through a width of the fence post, as well as a hole that extends through the entire width of the fence post (e.g., from the third side to an opposing fourth side of the fence post). In one characterization, an outer perimeter of this rail aperture may spaced from each of the first and second sides of the fence post by a distance of between about 0.100 inch and about 0.380 inch. However, other distances of separation maybe appropriate, for example, to allow for a sufficient adhesive interconnection of the fence rail with at least one (and preferably both) of the first and second post portions.

Still with regard to the case of the third aspect of the present invention, the fence assembly may also include adhesive disposed between and in contact with both of the first post portion and the fence rail. Likewise, adhesive may be disposed between and in contact with both of the second post portion and the fence rail. In other words, the adhesive may be utilized to interconnect the fence rail with one (or preferably both) of the first and second post portions of the fence post. Moreover, the adhesive is preferably in contact with a substantially flat surface of each of the first and second post portions of the fence post. This may be said to at least generally enhance the bond strength of the adhesive. However, other bonding surfaces (e.g., textured, roughened, irregular, etc.) maybe appropriate for employment with regard to this third aspect of the invention.

Still a fourth aspect of the invention is directed to a fence assembly that has a fence post, which includes a longitudinal reference axis extending at least between first and second ends of the fence post, and first and second post portions that each extend at least generally along the reference axis. Further, this fence assembly includes a fence rail, at least a portion of which is generally found between the first and second post portions of the fence post. Yet further, this fence assembly of the fourth aspect includes adhesive that is interposed between and in contact with the first post portion and at least a portion of the fence rail. Moreover, this adhesive is generally interposed between and in contact with the second post portion and at least a portion of the fence rail.

Various refinements exist of the features noted in relation to the subject fourth aspect of the present invention. Further features may also be incorporated in the fourth aspect as well. These refinements and additional features may exist individually or in any combination. The fence post may be characterized as having first (e.g., front) and second (e.g., back) opposing sides, as well as third and fourth opposing sides. In such an embodiment, a rail aperture maybe defined in the third side of the fence post, so that the fence rail (when positioned within the rail aperture) may be spaced from both of the first and second sides of the fence post by a distance of preferably no more than about 0.100 inch. Other distances may still allow for sufficient adhesive interconnection of the fence rail with one or both of the first and second sides of the fence post. With regard to the composition of the fence rail associated with this fourth aspect, it should be noted that any appropriate material may be utilized including, but not limited to, plastics, metals, polyvinyl chloride (PVC), wood, and the like.

With regard to either of the third and fourth aspects of the invention relating to fence assemblies, it should be understood that a particular fence assembly of the invention may include a plurality of the fence posts and/or the fence rails described herein. Moreover, the fence assemblies of the third and/or fourth aspects of the invention may include one or more gates including the fence post(s) and/or fence rail(s) described herein.

In yet a fifth aspect, the present invention is embodied in a method of fabricating a fence assembly. In this method, first and second fence post portions are formed, and a fence rail is adhesively interconnected to the first fence post portion. In addition, the second fence post portion is adhered to both of the fence rail and the first fence post portion so that at least part of the fence rail is disposed between the first and second fence post portions.

Various refinements exist of the features noted in relation to the subject fifth aspect of the present invention. Further features may also be incorporated in the fifth aspect as well. These refinements and additional features may exist individually or in any combination. Cutouts may be removed from a sheet material (e.g., sheet metal) during formation of the first and second fence post portions. The removal of these cutouts may be characterized as defining at least a portion of a rail aperture in the sheet material. This rail aperture is generally configured to accommodate at least part of the fence rail. In the case that the first and second fence post portions are made from a sheet material, a channel may be shaped (e.g., via bending) along a length of the sheet material. Segments of this sheet material are preferably cut to at least a first predetermined length substantially corresponding to a desired length of a resultant fence post. In other words, once dimensions (or at least a length) of the desired fence post have been determined, the sheet material may be cut to about that particular length. This length of the segments of sheet material may, at least in one embodiment, be said to at least roughly correspond to the length of the resultant fence post. However, various contours and/or bends in the sheet material may result in the finished fence post having a finished length that is shorter (or less) than the first predetermined length. While the various steps in the method of this fifth aspect may occur in a variety of orders, the formation of the first and second fence post portions preferably occurs prior to adhesively interconnecting the fence rail and/or adhering the second fence post portion.

Still referring to the fifth aspect of the present invention, at least one of the first and second fence post portions may be said to be biased at least generally toward the fence rail. Moreover, at least one of the first and second fence post portions may be characterized as being biased toward the other of the first and second fence post portions. This biasing of (e.g., imposition of pressure or force on) one or both the first and second fence post portions may be said to at least generally facilitate formation of a sufficient adhesion/bond between the respective components of the fence assembly. So, for example, once there is adhesive disposed between the first and second fence post portions, the two fence post portions maybe pressed together to foster sufficient bonding.

In yet a sixth aspect, the present invention is embodied in a method of fabricating a fence assembly. In this method, first and second sections of sheet metal are formed into channeled first and second post portions, respectively. Further, a fence rail is adhesively interconnected with a first substantially flat surface of the first fence post portion. Yet further, a second substantially flat surface of the second fence post portion is adhered to the fence rail. As a result, the first and second substantially flat surfaces are substantially parallel with one another, and at least part of the fence rail is disposed between the first and second fence post portions.

Various refinements exist of the features noted in relation to the subject sixth aspect of the present invention. Further features may also be incorporated in the sixth aspect as well. These refinements and additional features may exist individually or in any combination. For instance, formation of the channeled first and second fence post portions may include bending the sheet metal and/or defining at least a portion (e.g., substantially half) of a rail aperture in the sheet metal. With regard to the particular order of the steps associated with this sixth aspect, it is preferred that the formation of the first and second fence post portions occurs prior to the adhesive interconnection of the fence rail to the first fence post portion and/or the adhering of the second fence post portion to the fence rail.

One or more of the various features discussed herein in relation to one or more of the described aspects of the present invention may be utilized by any other appropriate aspect(s) of the present invention as well, alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side view of a fence assembly.

FIG. 1B is a perspective view of first and second fence post portions of a fence post.

FIG. 2A is a cross-sectional view of one embodiment of the fence post of FIG. 1A along cut-line 2-2.

FIG. 2B is a cross-sectional view of another embodiment of the fence post of FIG. 1A along cut-line 2-2.

FIG. 2C is a cross-sectional view of yet another embodiment of the fence post of FIG. 1A along cut-line 2-2.

FIG. 2D is a cross-sectional view of still yet another embodiment of a fence post taken along a plane like that of cut-line 2-2 associated with FIG. 1A.

FIG. 3A is a cross-sectional view of the fence post of FIG. 2A taken along a plane like that of cut-line 3-3 associated with FIG. 1A.

FIG. 3B is a cross-sectional view of the fence posts of FIG. 2B taken along a plane like that of cut-line 3-3 associated with FIG. 1A.

FIG. 3C is a cross-sectional view of another embodiment of the fence post of FIG. 2D taken along a plane like that of cut-line 3-3 associated with FIG. 1A.

FIG. 4 is a cross-sectional view of the fence post of FIG. 3B having an associated end cap.

FIG. 5 is flow chart illustrating a fence assembly fabrication protocol.

FIG. 6 is flow chart illustrating another fence assembly fabrication protocol.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described in relation to the accompanying drawings, which at least assist in illustrating the various pertinent features thereof. FIG. 1A shows a fence assembly 10 having a plurality of fence posts 12a, 12b and fence rails 14. While the fence rails 14 are illustrated as being oriented in a substantially perpendicular fashion relative to the fence posts 12a, 12b, other arrangements and/or orientations of the fence posts 14 relative to the fence posts 12a, 12b may be appropriate. The fence posts 12a differ the from the fence posts 12b in that a length 16a of the fence post 12a is substantially greater than a length 16b of the fence post 12b. As illustrated, the length (e.g., 16a) of a particular fence post (e.g., 12a) is preferably determined along or in alignment with a longitudinal reference axis 18 (e.g., 18a) associated with each post 12. This reference axis 18 may generally be characterized as extending or spanning at least between first and second ends 20, 22 of each corresponding fence post 12. While the fence assembly 10 of FIG. 1A includes two longer fence posts 12a, two shorter fence posts 12b, and three fence rails 14, other embodiments may include different numbers (e.g., quantities or amounts) of posts 12a, 12b and/or rails 14. While the various features of the fence posts 12a, 12b are indicated with corresponding “a” and “b” designations, these features may be referred to generically (e.g., without the “a” and “b” designation) herein when such features are preferably common to both fence posts 12a, 12b. So, for example, the “reference axis 18″ may refer to both reference axis 18a and 18b of the corresponding fence posts 12a and 12b.

This fence assembly 10 of FIG. 1A may be characterized as a corral panel, a plurality of which may be appropriately interconnected (e.g., via chains, mechanical fasteners, adhesives, and the like) to define, for example, at least a portion of a boundary of a livestock corral. Moreover, the fence assembly 10 may be configured to function as a corral gate, for example, that is at least generally swingable/pivotable to enable access to the corral. In otherwords, the gate maybe said to be designed/configured to both open and close, thus both facilitating and preventing access to the corral as desired. By contrast, instead of an individual corral panel, the fence assembly 10 may be characterized as a continuous fencing to confine a particular area. In this characterization, the rails 14 of the fence assembly may span any desired distance (as indicated by the dashed rails 14′). Further, the rails 14 of the fence assembly 10 may exhibit any appropriate shape such as a round cross-section as indicated by 14a′ and/or a rectangular cross-section as indicated by 14b′. However, numerous other cross-sectioned rail geometries may be appropriate. While these rails 14a′, 14b′ are illustrated as being substantially solid, other appropriate fence rails of the invention may be hollow (e.g., like a pipe or conduit of sorts). Indeed, the rails 14 of the fence assembly 10 may exhibit a configuration similar to that of the fence post 12 described herein. Yet further, the fence assembly 10 may have rails 14a′ and/or 14b′ that extend out from a particular post (e.g., 12a) at various angles relative to the rails 14. So, for example, one of the fence posts 12a may be considered a “corner post” where one or more rails 14a′ and/or 14b′ may extend out therefrom at an approximately right angle relative to the fence rails 14.

Still with regard to the fence assembly 10 of FIG. 1A, the longer fence posts 12a, at least in one embodiment, may be utilized to interface with a support structure (e.g., the ground). More particularly, one or more of the second ends 22a of the longer fence posts 12a may contact and/or be submerged (e.g., buried) in the ground or other appropriate support structure (e.g., concrete). Each of the fence posts 12a, 12b is illustrated as having an end cap 24 disposed at each end 20, 22 thereof. These end caps will be discussed in more detail below in relation to FIG. 4.

FIG. 1B shows first and second fence post portions 26a, 26b that are separated (as indicated by the dashed lines 3) to show the features thereof, and that may be adhesively interconnected to make up the fence post 12b of the fence assembly 10. Incidentally, “interconnecting,” “interconnected,” “interconnectable,” or the like generally refers herein to something being (or capable of being) either directly or indirectly connected (or caused to be connected) with something else. While the following discussion is in regard to the fence post 12b of FIG. 1A, it will be understood, that this description will also apply to the design of the fence posts 12a of FIG. 1A. The first and second post portions 26a, 26b of the fence post 12b are substantially symmetrical (e.g., substantially identical and/or mirror images of one another). While the various features of the first and second post portions 26a, 26b are indicated with corresponding “a” and “b” designations, these features may be referred to generically (e.g., without the “a” and “b” designation) herein when such features are generally common to both the first and second post portions 26a, 26b. So, each post portion 26 is shown having an outer surface 28 and an inner surface 30 that is generally configured as a channel 32 (e.g., what maybe referred to as a “C-channel” or “box channel”) or elongate trough of sorts. These channels 32 generally extend along the longitudinal reference axis 18b. Accordingly, a length 36 of each of the first and second post portions 26a, 26b may be said to be substantially aligned with the longitudinal reference axis 18b. Further, it may be said that the corresponding lengths 36a, 36b of the respective first and second post portions 26a, 26b may be defined at least generally between the first and second ends 20, 22 of the fence post 12b. Preferably, these lengths 36a, 36b associated with the corresponding first and second post portions 26a, 26b of the fence post 12b are substantially equal.

Still referring to the fence post 12b of FIG. 1B, each post portion 26 includes an elongate flange (e.g., rim or lip) 34 that may be characterized as having a bonding surface to which adhesive may be applied and/or associated to at least generally facilitate adhesive interconnection of the first and second post portions 26a, 26b to each other. Moreover, these flanges 34 are substantially parallel with one another relative to the same post portion. Accordingly, the flanges 34a of the first post portion 26a are generally alignable and effectively interfacable with the flanges 34b of the second post portion 26b to at least generally facilitate in the adhesive interconnection of the first and second post portions 26a, 26b. Incidentally, the first and second post portions 26a, 26b are shown as being separated from each (as indicated by dashed lines 31) to illustrate the various features thereof.

Referring to FIGS. 1A-B and 2A, and as previously stated, the first and second post portions 26a, 26b at least generally define corresponding first and second channels 32a, 32b that extend along the reference axis 18b. FIG. 2A illustrates that adhesive 40 is applied to the flanges 34 of the first and/or second post portions 26a, 26b to enable the same to be adhesively interconnected with each other. The adhesive 40 of FIGS. 2A and 3A is illustrated as having a defined geometric (e.g., obloid) shape merely for ease of illustration. It will be understood that the adhesive 40 is preferably at least generally flowable (prior to any curing). So, the adhesive 40 may be any of a number of appropriate adhesives (e.g., glues) including, but not limited to, acrylics (e.g., fast-set acrylics), epoxies, urethanes, and appropriate combinations thereof. Since the adhesive 40 is generally utilized to interconnect the first and second post portions 26a, 26b the fence post 12b (and preferably the fence assembly 10) may be said to be preferably free of welds. When the first and second post portions 26a, 26b are adhesively interconnected, the channels 32a, 32b are preferably found on the “inside” of the fence post 12b. Accordingly, the fence post 12b may be characterized as having a cavity 38 of sorts defined therein by what may be said to be a “combination” of the channels 32a, 32b.

Still referring to FIG. 2A, the first post portion 26a of the fence post 12b defines a first side 54 of the fence post 12b, and the second post portion 26b of the fence post 12b defines an opposing second side 56 of the fence post 12b. These first and second sides 54, 56 are substantially parallel relative to each other. Further, portions of both of the first and second post portions 26a, 26b make up opposing third and fourth sides 58, 60, respectively, of the fence post 12b. In other words, the first side 54 and portions of the third, and fourth sides 58, 60 of the fence post 12b are defined by the first post portion 26a. Similarly, the second side 56 and portions of the third and fourth sides 58, 60 of the fence post 12b are defined by the second post portion 26b. In one characterization, the cross section of the fence post 12b illustrated in FIG. 2A may be said to be substantially rectangular, where this cross-section is defined along a plane substantially perpendicular to the reference axis 18b. However, other appropriate cross-sectional geometries may be appropriate (e.g., substantially round, or having curvatures, indentations, contours and/or the like).

FIG. 3A shows another view of the fence assembly 10, and more particularly, the fence post 12b and the rail 14. A rail aperture 62 is shown as being defined in the third side 58 of the fence post 12b. Accordingly, this rail aperture 62 maybe characterized as being defined by both the first and second post portions 26a, 26b of the fence post 12b. Since the rail aperture 62 enables the rail 14 to at least generally extend into the cavity 38 of the fence post 12b, it may be said that at least a portion of this fence rail 14 is at least generally interposed between the first and second post portions 26a, 26b (more particularly, at least the first and second sides 54, 56) of the fence post 12b. Further, this rail aperture 62 may be characterized as a hole of sorts to accommodate the rail 14. While this rail aperture 62 is defined by both the first and second post portions 26a, 26b, in other embodiments one or more rail apertures may be defined solely by one of the first and second post portions 26a, 26b. In other words, it is contemplated that a rail aperture may extend into one of the first and second sides 54, 56 of the fence post 12b (and even entirely through the fence post 12b from the first side 54 to the second side 56). While the rail aperture 62 extends through an entirety of the fence post 12b (e.g., from the third side 58 to the opposing fourth side 60), other appropriate rail apertures maybe characterized as rail receptacles or recesses that extend only partially into the fence post 12b to accommodate the rail 14.

Still referring to FIG. 3A, the fence assembly 10 includes adhesive 42 disposed between and in contact with both of the first post portion 26a (and more particularly, the inner surface 30a associated with the first side 54) and the fence rail 14. Likewise, adhesive 42 is disposed between and in contact with both of the second post portion 26b (and more particularly, the inner surface 30b associated with the second side 56) and the fence rail 14. Thus, the adhesive 42 may be said to provide, allow, and/or facilitate an adhesive interconnection of the fence rail 14 with both of the first and second post portions 26a, 26b of the fence post 12b. In addition, the adhesive 42 is preferably in contact with a substantially planar portion of the respective inner surfaces 30a, 30b of the first and second post portions 26a, 26b of the fence post 12b to at least generally enhance the bond strength of the adhesive 42 (e.g., by providing a significant contact or adhesive bonding surface). Incidentally, the adhesive 42 utilized to affix the rail 14 to the fence post 12b may be any appropriate adhesive, including those described in relation to the adhesive 40 utilized to interconnect the first and second post portions 26a, 26b. Thus, the adhesive 42 may or may not be the same composition as adhesive 40.

FIG. 3A also illustrates that the fence rail 14 is spaced from both of the first and second sides 54, 56 of the fence post 12b by a distance 64. This distance 64 is preferably no more than about 0.10 inch, more preferably between a range of about 0.010 inch and about 0.050 inch, and even more preferably about 0.010 inch. As previously mentioned herein, other distances (e.g., depending on the desired dimensions of the fence posts/rails) may still allow for sufficient adhesive interconnection of the fence rail 14 with the first and second sides 54, 56 of the fence post 12b.

FIGS. 2B and 3B illustrate a variation of the fence post 12b shown in FIG. 2A, and as such, a “single prime” designation is used to identify the fence post 12b′. Generally, the difference between the FIGS. 2A and 3A embodiment and the FIGS. 2B and 3B embodiment includes the fence post 12b′ of FIGS. 2B and 3B having first and second post portions 26a′, 26b′ that exhibit a male-female relationship. More particularly, the first post portion 26a′ includes first and second parts 44, 46 of the first post portion 26a′ that are positioned within a channel 32b′ defined by the second post portion 26b′. So, an effective width 48a of the first post portion 26a′ defined between the first and second parts 44, 46 thereof, is less than an effective width 48b of the second post portion 26b′ between first and second side walls 50, 52 thereof. In a preferred embodiment, the difference between these effective widths 48a, 48b is between about 0.010 inch and about 0.050 inch, and even more preferably is about 0.010 inch. So, at least part of an outer surface 28a′ of the first post portion 26a′ at least generally faces at least part of an inner surface 30b′ of the second post portion 26b′. Moreover, the adhesive 40 utilized to interconnect the first and second post portions 26a′, 26b′ is at least generally disposed between and physically contacts the outer surface 28a′ (at the first and second parts 44, 46) of the first post portion 26a′ and the inner surface 30b′ (at the first and second side walls 50, 52) of the second post portion 26b′. Accordingly, it may be said that the first and second post portions 26a′, 26b′ of the fence post 12b′ at least generally exhibit portions that “overlap”. As another characterization, portions of the first post portion 26a′ that are associated with opposing third and fourth sides 58′, 60′ may at least generally “taper in” to at least generally define the first and second parts 44, 46.

FIG. 2C illustrates yet another variation of the fence post 12b shown in FIG. 2A, and as such, a “double prime” designation is used to identify the fence post 12b″. Generally, the difference between the FIG. 2A embodiment and the FIG. 2C embodiment includes the fence post 12b″ of FIG. 2C having first and second post portions 26a″, 26b″ that exhibit an interlocking tongue and groove configuration. More particularly, the first and second post portions 26a″, 26b″ each include a hook-like lip 55a, 55b, respectively. With regard to this fabrication of this fence post 12b″, the first and second post portions 26a″, 26b″ may be “snapped” together by imposing a force on the first post portion 26a″ in a general direction 66a toward the second post portion 26b″ and/or by imposing a force on the second post portion 26b″ in a general direction 66b toward the first post portion 26a″. So, the first and second post portions 26a″, 26b″ can be urged together, or one can be substantially immobilized while the other is biased toward it. As another alternative, the one of the first and second post portions 26a″, 26b″ may be slid into engagement with the other in a direction substantially perpendicular to the page illustrating FIG. 2C and at least generally aligned with the reference axis 18b. The adhesive 40 utilized to interconnect the first and second post portions 26a″, 26b″ of the fence post 12b″ of FIG. 2C is disposed at least generally in contact with the lips 55a, 55b of each of the first and second post portions 26a″, 26b″. Moreover, this adhesive 40 interposed between the lips 55a, 55b of the respective post portions 26a″, 26b″ is preferably applied to one or both the lips 55a, 55b, prior to any engagement (e.g., sliding or snap-in) of the first post portion 26a″ and the second post portion 26b″. Further, the rail 14 is preferably inserted into an appropriate aperture (e.g., 62) defined by the post 12b″ after the first and second post portions 26a″, 26b″ have been engaged and adhesively interconnected.

FIGS. 2D and 3C illustrate still yet another variation of the fence post 12b shown in FIG. 2A, and as such, a “triple prime” designation is used to identify the fence post 12b′″. This fence post 12b′″ is characterized by having a plurality of indentations (or impressions) 74. More particularly, a first indentation 74a is disposed on a first side 54 of the fence post 12b′″, and a second indentation 74b is disposed on an opposing second side 56 of the fence post 12b′″. Moreover, both of these indentations 74a, 74b are associated with outer surfaces 28a′″, 28b′″ of the corresponding first and second post portions 26a′″, 26b′″. To characterize the embodiment of FIGS. 2D and 3C in another light, inner surfaces 30a′″, 30b′″ associated with the first and second post portions 26a′″, 26b′″ may be said to have outcroppings (or bulges) 76a, 76b relative to remainders of the respective first and second sides 54, 56 of the fence post 12b′″. Regardless of the characterization, these indentations 74 and/or outcroppings 76 maybe disposed at portions of the fence post 12 to which the rails 14 are to be interconnected, or they may span up to an entire length (e.g., 16b of FIG. 1) of the fence post 12b′″. These indentations 74 or outcroppings 76 are included in this embodiment to provide for a desired magnitude of clearance 78 between the rail 14 and the inner surfaces 30a′″, 30b′″ of the fence post 12b′″ This clearance 78 is preferably no more than about 0.10 inch, more preferably between a range of about 0.010 inch and about 0.050 inch, and even more preferably about 0.010 inch. However, other magnitudes of clearance may be appropriate. Accordingly, these indentations 74 or outcroppings 76 can be included to beneficially provide, inter alia, appropriate spacing to allow for sufficient adhesive bonding of the rail 14 to the first and second post portions 26a′″, 26b′″ via employment of the adhesive 42 at the outcroppings 76 associated with the inner surfaces 30a′″, 30b′″ of the fence post 12b″ to adhesively interconnect the fence post 12b′″ with the rail 14. These indentations 74 or outcroppings 76 may be appropriately incorporated into any fence posts herein described including, but not limited to, the fence posts 12b, 12b′, and/or 12b″.

Still referring to FIGS. 2D and 3C, another feature of the fence post 12b′″ is “rounded corners” 80. These rounded corners 80 maybe provided by any appropriate bending or forming of the sheet metal that makes up the fence post 12b′″. As one particular benefit, these rounded corners 80 at least generally reduce the tendency for animals confined by the fence assembly 10 from incurring injuries (e.g., scratches, soars, abrasions, lacerations, cuts, and the like) as a result of rubbing up against or coming into contact with sharp edges of a fence post. While these rounded corners 80 are illustrated in relation to the fence post 12b′″, it should be noted that these rounded corners 80 may be appropriately incorporated into any fence posts herein described including, but not limited to, the fence posts 12b, 12b′, and/or 12b”.

With regard to any of the variations of the fence post 12b shown in FIGS. 2A-D, the first and second post portions 26a, 26b are preferably made up of a sheet metal (preferably 16-gauge or 18-gauge steel). As stated above, this sheet metal may have some type of coating such a powder coating, paint, epoxy, and galvanization.

FIG. 4 shows the end cap 24 disposed at a first end 20b′ of the fence post 12b′. This end cap 24 may be interconnected with one and preferably both of the first and second post portions 26a′, 26b′ (e.g., via adhesive bonding). Here, adhesive 41 is utilized to interconnect the end cap 24 with both the first and second post portions 26a′, 26b′ of the fence post 12b′. As mentioned with regard to FIG. 1A, these end caps 24 may be disposed at one or both ends of a particular fence post. Use of these end caps 24 may provide a number of benefits. For example, the end cap 24 shown in FIG. 4 may hinder or substantially prevent the entry of dust, debris, and/or precipitation into the cavity 38 of the fence post 12b′. As another example, the end cap 24 may be configured to provide a minimal amount of clearance 70 between the same and the fence post 12b′. This not necessarily, but preferably enables the end cap 24 to provide at least some force on the first and second post portions 26a′, 26b′ in the directions 66a, 66b respectively. In other words, this end cap 24 may be utilized to keep the first and second post portions 26a′, 26b′ in close association (e.g., at least until the adhesive 40 that is utilized to interconnect the two has time to dry/cure). In the embodiment shown in FIG. 4, this end cap 24 is interconnected with the fence post 12b′ via use of adhesive 41. This adhesive 41 may be any appropriate adhesive including that described in relation to the adhesive 40 above. As for the composition of the end cap 24, it is preferably constructed of plastic; however, various other materials including, but not limited to, steel, aluminum, rubber may also be appropriate for construction of the same. Moreover, while the end cap 24 is illustrated as being associated with the fence post 12b′, the end cap 24 may be associated with any of the various embodiments discussed herein.

FIG. 5 illustrates one protocol 99 for fabricating the fence assembly 10. While various steps in this protocol 99 are illustrated and described in a preferred order, other embodiments may exhibit other arrangements of the disclosed steps. Moreover, while the protocol 99 is described in regard to the fence assembly 10 having the fence post 12b described in relation to FIGS. 2A and 3A, the protocol 99 may also apply to one or more of the variations of the fence post 12b described herein (e.g., 12b′, 12b″, and/or 12b′″). In any event, in a first step 100 of this protocol 99, the first and second fence post portions 26a, 26b are formed. As shown in step 102, this step 100 may include a step 102 of removing “cutouts” from the sheet metal that makes up the first and second portions 26a, 26b of the fence post 12b. The removal of these cutouts is preferably synonymous with formation of at least a portion of the rail aperture 62 in the sheet material, as shown in step 104. As shown in FIG. 3A, this rail aperture 62 is generally configured to accommodate at least part of the fence rail 14. In another step 106 associated with the formation of the first and second post portions 26a, 26b, the channels 32a, 32b may be shaped (e.g., via bending) along the length 36 (FIG. 1B) of the sheet metal. Referring to step 108, segments of this sheet metal may be cut to at least a first predetermined length substantially corresponding to a desired length 16b of the resultant fence post 12b. As previously mentioned, various contours and/or bends in the sheet metal may result in the finished fence post 12b having a finished length 16b that is shorter (or less) than the first predetermined length.

Subsequent to the formation of the first and second post portions 26a, 26b, the protocol 99 includes a step 110 of adhesively interconnecting the fence rail 14 to the first fence post portion 26a. As discussed with regard to FIG. 3A, this is generally accomplished utilizing an appropriate adhesive 42. In another step 112, the second fence post portion 26b is adhered (using an adhesive as describe herein) to both of the fence rail 14 and the first fence post portion 26a, so that at least part of the fence rail 14 is disposed between the first and second fence post portions 26a, 26b. As illustrated with regard to step 114, this may include at least one of the first and second fence post portions 26a, 26b being biased at least generally toward the fence rail 14. Likewise, at least one of the first and second fence post portions 26a, 26b may be biased toward the other of the first and second fence post portions 26a, 26b as shown in step 116. As mentioned above, this biasing of (e.g., imposition of pressure on) one or both the first and second fence post portions 26a, 26b may at least generally facilitate formation of a sufficient adhesion/bond between the respective components of the fence assembly 10. So, once the adhesive 40 is disposed between the first and second fence post portions 26a, 26b, the two fence post portions 26a, 26b maybe pressed together to foster sufficient bonding (e.g., at least during a portion of an appropriate curing process).

FIG. 6 illustrates yet another protocol 118 for fabricating the fence assembly 10. Again, while various steps in this protocol 118 are illustrated and described in a preferred order, other embodiments exhibit other arrangements of the disclosed steps. Moreover, while the protocol 118 is described in regard to the fence assembly 10 having the fence post 12b described in relation to FIGS. 2A and 3A, the protocol 118 may also apply to one or more of the variations of the fence post 12b described herein (e.g., 12b′, 12b″, and/or 12b′″). In this protocol 118, first and second sections of sheet metal are formed into channeled first and second post portions 26a, 26b, respectively, as shown in step 120. This may include a bending of the sheet metal (step 122) and/or defining at least a portion of the rail aperture 62 in the sheet metal (step 124), for example, as described above.

In a subsequent step 126 of the protocol 118, the fence rail 14 is adhesively interconnected with a first substantially planar surface 30a (associated with the first side 54) of the first fence post portion 26a. Likewise, another step 128 in the protocol 118 includes adhering a second substantially flat surface 30b (associated with the second side 56) of the second fence post portion 26b to the fence rail 14 employing the adhesive 42. As a result, the first and second substantially planar surfaces 30a, 30b are substantially parallel with one another, and at least part of the fence rail 14 is interposed (e.g., “sandwiched”) between the first and second fence post portions 26a, 26b. This may include adhesively joining the first fence post portion 26a with the second fence post portion 26b using the adhesive 40, as in step 130. Additionally or alternatively, this may also include a step 132 of biasing at least one of the first and second fence post portions toward the other of the first and second fence post portions 26a, 26b.

As disclosed above, fabrication of the fence assembly 10 of FIG. 1A may be accomplished by positioning the desired number of rails 14 in appropriate rail accommodating areas (e.g., a portion of the rail aperture 62) of the first post portion 26a. In addition, the second post portion 26b may be disposed over the top of the rails 14 so that at least portions of the rails 14 are at least generally sandwiched between the first and second post portions 26a, 26b upon completion of assembly. Moreover, these rails 14 are preferably interconnected with the first and second post portions 26a, 26b using a chemical adhesive (as opposed to welds). Accordingly, it may be said that the fence assembly 10 includes “hidden” interconnections of the rails 14 with the posts 12, as the adhesive 42 facilitating this interconnection is found at least generally within the fence post 12 (e.g., the cavity 38).

Those skilled in the art will now see that certain modifications can be made to the fence post, fence assembly, and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the present invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims.

Claims

1. A fence post, comprising:

a longitudinal reference axis extending at least between first and second ends of said fence post;

a first post portion that extends at least generally along said reference axis;

a second post portion that extends at least generally along said reference axis; and

adhesive interconnecting said first post portion and said second post portion.

2. A fence post, as claimed in claim 1, wherein:

said first and second post portions are substantially symmetrical.

3. A fence post, as claimed in claim 1, wherein:

said first and second post portions exhibit a male-female relationship.

4. A fence post, as claimed in claim 1, wherein:

said first and second post portions exhibit an interlocking tongue and groove configuration.

5. A fence post, as claimed in claim 1, wherein:

at least one of said first and second post portions comprises a sheet material.

6. A fence post, as claimed in claim 5, wherein:

said sheet material is a metal.

7. A fence post, as claimed in claim 5, wherein:

said sheet material is powder coated.

8. A fence post, as claimed in claim 1, wherein:

each of said first and second post portions comprises bonding surfaces that are substantially parallel with one another.

9. A fence post, as claimed in claim 8, wherein:

said adhesive is interposed between and in contact with said bonding surfaces.

10. A fence post, as claimed in claim 1, wherein:

said adhesive is selected from the group consisting of epoxy adhesives, acrylic adhesives, and urethane adhesives.

11. A fence post, comprising:

a longitudinal reference axis extending at least between first and second ends of said fence post;

a first post portion comprising a first length that is substantially aligned with said reference axis; and

a separate and distinct second post portion comprising a second length that is substantially aligned with said reference axis, wherein said first and second lengths are substantially equal.

12. A fence post, as claimed in claim 11, wherein:

said first and second post portions define corresponding first and second channels that extend along said reference axis.

13. A fence post, as claimed in claim 12, wherein:

at least part of said first post portion extends into said second channel defined by said second post portion.

14. A fence post, as claimed in claim 13, further comprising:

adhesive interposed between and in contact with both of said at least part of said first post portion and said second post portion.

15. A fence post, as claimed in claim 11, wherein:

said first and second post portions exhibit an interlocking tongue and groove configuration.

16. A fence post, as claimed in claim 15, further comprising:

adhesive disposed between a tongue and a groove of said tongue and groove configuration.

17. A fence post, as claimed in claim 11, wherein:

a cross section of said fence post is substantially rectangular, wherein said cross-section is defined along a plane substantially perpendicular to said reference axis.

18. A fence post, as claimed in claim 11, wherein:

said first post portion comprises a first side of said fence post, and wherein said second post portion comprises a second side of said fence post substantially parallel to said first side.

19. A fence post, as claimed in claim 18, wherein:

portions of both of said first and second post portions comprise third and fourth sides of said fence post.

20. A fence post, as claimed in claim 18, wherein:

said first and second post portions comprise corresponding first and second attachment projections.

21. A fence post, as claimed in claim 20, wherein:

said first attachment projection associated with said first post portion is substantially parallel to said first side of said fence post, and said second attachment projection is substantially parallel to said second side of said fence post.

22. A fence post, as claimed in claim 20, further comprising:

adhesive interposed between and in contact with both of said first and second attachment projections of said first and second post portions.

23. A fence post, as claimed in claim 20, wherein:

at least a first segment of said first attachment projection is substantially parallel with at least a second segment of said second attachment projection.

24. A fence post, as claimed in claim 23, further comprising:

adhesive interposed between and in contact with both of said first and second segments of said first and second attachment projections.

25. A fence assembly, comprising:

a fence post comprising an elongate first post portion, and a separate and distinct elongate second post portion; and

a fence rail, wherein at least a portion of said fence rail is interposed between said first and second post portions of said fence post.

26. A fence assembly, as claimed in claim 25, wherein:

said fence post comprises first and second opposing sides, and wherein a rail aperture is defined at least in a third side of said fence post, said third side comprising parts of said first and second post portions.

27. A fence assembly, as claimed in claim 26, wherein:

an outer perimeter of said rail aperture is spaced from each of said first and second sides of said fence post by a distance of between about 0.100 inch and about 0.380 inch.

28. A fence assembly, as claimed in claim 26, wherein:

said rail aperture extends from said third side to an opposing fourth side of said fence post.

29. A fence assembly, as claimed in claim 25, further comprising:

adhesive disposed between and in contact with both of said first post portion and said fence rail.

30. A fence assembly, as claimed in claim 29, wherein:

said adhesive is in contact with a substantially flat surface of said first post portion.

31. A fence assembly, as claimed in claim 29, wherein:

said adhesive is disposed between and in contact with both of said second post portion and said fence rail.

32. A fence assembly, as claimed in claim 31, wherein:

said adhesive is in contact with substantially flat surfaces of both of said first and second post portions.

33. A fence assembly, comprising:

a fence post comprising: a longitudinal reference axis extending at least between first and second ends of said fence post; a first post portion that extends at least generally along said reference axis; and a second post portion that extends at least generally along said reference axis;

a fence rail, wherein at least a portion of said fence rail is disposed between said first and second post portions of said fence post; and

adhesive interposed between and in contact with: said first post portion and said at least a portion of said fence rail; and said second post portion and said at least a portion of said fence rail.

34. A fence assembly, as claimed in claim 33, wherein:

said fence post comprises first and second opposing sides, and wherein a rail aperture is defined in a third side of said fence post, said third side comprising parts of said first and second post portions.

35. A fence assembly, as claimed in claim 34, wherein:

an outer perimeter of said rail aperture is spaced from each of said first and second sides of said fence post by a distance of between about 0.100 inch and about 0.380 inch.

36. A fence assembly, as claimed in claim 34, wherein:

said fence rail is spaced from both of said first and second sides of said fence post by a distance of no more than about 0.100 inch.

37. A fence assembly, as claimed in claim 33, wherein:

said adhesive is in contact with a substantially flat surface of at least one of said first and second post portions.

38. A fence assembly, as claimed in claim 33, wherein:

said adhesive is in contact with a substantially flat surface of each of said first and second post portions.

39. A fence assembly, as claimed in claim 33, wherein:

said fence assembly comprises a plurality of said fence posts and said fence rails.

40. A fence assembly, as claimed in claim 33, wherein:

said fence assembly comprises a gate.

41. A method of fabricating a fence assembly, the method comprising the steps of:

forming first and second fence post portions;

adhesively interconnecting a fence rail to said first fence post portion; and

adhering said second fence post portion to both of said fence rail and said first fence post portion, wherein at least part of said fence rail is disposed between said first and second fence post portions.

42. A method, as claimed in claim 41, wherein:

said forming step comprises removing cutouts from a sheet material.

43. A method, as claimed in claim 42, wherein:

said removing step comprises defining at least a portion of a rail aperture in said sheet material, said rail aperture being configured to accommodate said at least part of said fence rail.

44. A method, as claimed in claim 41, wherein:

said first and second fence post portions are made from a sheet material, and wherein said forming step comprises shaping a channel along a length of said sheet material.

45. A method, as claimed in claim 44, wherein

said forming step comprises cutting segments of said sheet material to at least a first predetermined length substantially corresponding to a desired length of a resultant fence post.

46. A method, as claimed in claim 41, wherein:

said forming step occur prior to at least one of said adhesively interconnecting step and said adhering step.

47. A method, as claimed in claim 41, wherein:

said adhering step comprises biasing at least one of said first and second fence post portions toward said fence rail.

48. A method, as claimed in claim 41, wherein:

said adhering step comprises biasing at least one of said first and second fence post portions toward another of said first and second fence post portions.

49. A method, as claimed in claim 41, wherein:

said adhesively interconnecting step and said adhering step comprise using at least one adhesive selected from the group consisting epoxies, acrylics, and urethanes.

50. A method of fabricating a fence assembly, the method comprising the steps of:

forming a first and second sections of sheet metal into channeled first and second post portions, respectively;

adhesively interconnecting a fence rail with a first substantially flat surface of said first fence post portion; and

adhering a second substantially flat surface of said second fence post portion to said fence rail, wherein said first and second substantially flat surfaces are substantially parallel with one another, and wherein at least part of said fence rail is disposed between said first and second fence post portions.

51. A method, as claimed in claim 50, wherein:

said forming step comprises bending said sheet metal.

52. A method, as claimed in claim 50, wherein:

said forming step comprises defining at least a portion of a rail aperture in said sheet metal.

53. A method, as claimed in claim 50, wherein:

said forming steps occur prior to said adhesively interconnecting step and said adhering step.

54. A method, as claimed in claim 50, wherein:

said adhering step comprises adhesively joining said first fence post portion with said second fence post portion.

55. A method, as claimed in claim 54, wherein:

at least one of said adhesively interconnecting step, said adhering step and said adhesively joining step comprise curing an adhesive.

56. A method, as claimed in claim 54, wherein:

said adhering step comprises biasing at least one of said first and second post portions toward another of said first and second post portions.

57. A method, as claimed in claim 50, wherein:

at least one of said adhesively interconnecting step and said adhering step comprise employing at least one adhesive selected from the group consisting of epoxies, acrylics, urethanes.

58. A method, as claimed in claim 50, wherein:

both of said adhesively interconnecting step and said adhering step comprise employing at least one adhesive selected from the group consisting of epoxies, acrylics, urethanes.