METHOD AND APPARATUS FOR REPAIRING THE RAIL OF A SPLIT RAIL FENCE
An apparatus for repairing the rail of a split-rail fence having a broken tapered end portion. The apparatus has elongate, hollow sleeve with a base portion and a tapered end portion. The base portion and end portion have a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and have interior cross-sectional dimensions that are larger than the exterior cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively. The sleeve can slide over and encase the tapered end and at least a portion of the central base portion of the rail. The apparatus preferably includes means for fastening the base portion of the sleeve to the base portion of the rail.
The present application claims priority to U.S. provisional application No. 61/516,690 entitled Rail Saver, filed Apr. 6, 2011, which is incorporated herein by reference.
FIELD OF THE INVENTIONThe present invention relates to fence repair and, more particularly, repair of the horizontal rails of a split-rail fence.
BACKGROUND OF THE INVENTIONTraditionally, agricultural and residential split-rail fencing has been constructed from wood. Such fencing typically comprises a plurality of vertical fence posts installed in the ground at standard intervals, and a plurality of horizontal rails connecting each post. The horizontal rails have roundish central portions and tapered ends. The rails are connected to the posts by inserting the tapered ends through bore holes in the post.
Over time, the entire fence is subjected to prolonged exposure to moisture, weather, dry rot, insects, and external forces placed on it by animals, people, and falling objects. Since the entire wooden fence is subject to the same adverse environmental conditions, the fence typically breaks at its structurally-weakest point, namely, its tapered ends. When this occurs, the posts and other rails of the fence may still be structurally sound. In such case, only one particular rail needs repair or replacement.
In the past when a fence rail broke or become weakened, it was necessary to replace the rail with a new rail, which can be costly as multiple rails of a long fence require repair. Furthermore, because the length of the rails is greater than the distance between posts, replacing a rail can be difficult if the fence posts are firmly set in the ground and have no leeway to sway back and forth.
One proposed solution to rail replacement is to use an alternative wood variety, such as redwood, that has greater durability. However, such woods are typically much more expensive. Instead, some land owners attempt to splice or mend broken fence rails with varying degrees of success. However, rail repair is beyond the skill level of may agricultural land owners and most residential land owners. Therefore, it would be desirable to provide an apparatus and method for repairing the broken ends of split-rail fencing rails that is inexpensive and easy to install.
SUMMARY OF THE INVENTIONThe invention provides an apparatus and method of repairing the horizontal rail of a split-rail fence that has broken at its tapered end. The apparatus restores the length of a broken rail to its original length in minutes and can be installed without the use of tools of any kind The apparatus eliminates the need to purchase an entirely new rail.
The apparatus generally comprises an elongate, hollow sleeve having a base portion and a tapered end portion. The base portion and end portion have a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively. The base portion and end portion have interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail. In preferred embodiments, the apparatus also has means for fastening the base portion of the sleeve to the base portion of the rail.
The tapered end of the sleeve is constructed and arranged to replace the broken tapered end portion of the rail and allow the rail to be re-installed on a split-rail fence post. The elongate sleeve has a uniform cross section along the central base portion and a cross-section that preferably tapers in two dimensions along the length of the sleeve. The elongate sleeve has open proximal and distal ends.
In one embodiment, the fastening means comprises at least one aperture extending through the base portion of the sleeve and a fastener extending through the aperture. In another embodiment, the fastening means comprises a threaded aperture extending through the base portion of the sleeve, and a hand-tightenable, threaded fastener engaging the aperture. In this embodiment, the threaded fastener may comprise a thumb screw.
In a further embodiment, the fastening means comprises an aperture extending through the base portion of the sleeve, a threaded anchor coaxial with the aperture, and a threaded fastener engaging the anchor. The anchor may be fixed in or adjacent the aperture. Preferably, the threaded fastener has an enlarged head at one end for hand tightening the fastener and a foot at the other end having a cross section larger than the cross section of the shank of the fastener.
In yet an additional embodiment, the fastening means may comprise a plurality of shims.
A method is also provided for repairing a split-rail fence rail having a first end and a second broken tapered end on a fence having immovable posts using the novel repair sleeve. Initially, the broken tapered end portion is completely removed from the rail if the rail was only fractured. The sleeve is then installed by axially sliding the repair sleeve over the broken end of the rail toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve. The unbroken end of the rail is then inserted into an aperture of a first post. The second end of the rail bearing the repair sleeve is then located adjacent an aperture in a second post. The sleeve is axially slid away from the center of the rail until the tapered end engages the post aperture. The repair sleeve is then fixed to the central portion of the rail using one of the fixing means.
The repair apparatus of the present invention is described below with reference to
A repair apparatus in accordance with a first preferred embodiment of the present invention is designated generally by reference numeral 9. The apparatus 9 is designed for repairing the rail 8 of a split-rail fence 5 having a plurality of vertical support posts 6. The rails 8 have a central base portion 8a and opposed, tapered end portions 8b, which are inserted through apertures 7 in each post. The apparatus 9 is designed for the common scenario wherein the rail has broken along one of the tapered end portions 8b, thereby forming a jagged broken end 8c as seen in
In a first preferred embodiment shown in
The tapered end portion 14 of the sleeve 10 has a top wall 14a, bottom wall 14b, side walls 14c,14d, and an open distal end 14e. The cross section of the tapered end portion 14 approximates and compliments the shape of the tapered end portion of an unbroken fence rail 8b. The cross section of the tapered end portion 14 gradually reduces in two dimensions extending from the base portion-tapered portion interface to the distal open end 14e.
In a preferred embodiment, the interior cross-sectional dimensions of the sleeve are slightly larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail. For example, the length of the base portion 12 may be about 12 in. while the length of the tapered portion 14 may be about 10 in. The base portion 12 may be about 4 in. high and about 2.5 in. wide. The tapered portion 14 tapers to a height of about 3 in. and a width of about 1 in. or less so that the tapered end can fit into the preexisting apertures 7 in the fence posts 6. These dimensions allow for a generous tolerance in the outer dimensions of the fence rail 8 over which the sleeve will be installed. The wall thickness will vary depending on the material from which the sleeve is formed. If the material is made from a high density UV resistant plastic, the wall thickness may be in the range of 0.060-0.070 in.
In one preferred embodiment, the sleeve 10 is dimensioned to snugly fit over the tapered end portion 8b of the rail and be held in place by friction created by an interference fit and/or friction created by the weight of the rail 8 on the interior of the sleeve 10 once the rail is re-installed on the fence. Alternatively, the sleeve 10 could be adhered to the post 8 after it is installed.
In another preferred embodiment, the sleeve 10 includes mechanical means for fastening the base portion 12 of the sleeve 10 to the base portion 8a of the rail 8. Referring to
In the embodiment shown in
In another embodiment shown in
In an additional embodiment shown in
In a further embodiment shown in
In yet a further embodiment shown in
The sleeve may be made of a variety of materials, including polymers and metals, having sufficient strength to support the rail and its intended design load. Preferably, the sleeve is also made of a material that is corrosion resistant. In a preferred embodiment, the sleeve is made from UV plastic that is blow molded.
A method of repairing a split-rail fence rail using the above-described repair sleeve is described with reference to
Initially, the user should remove, i.e., completely sever, the distal tip of the broken end if fractured but still intact. Then, the repair sleeve is installed by axially sliding the sleeve 10 over the broken end 8c of the rail 8 toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve as best seen in
The above-described method is especially useful when the posts 6 are firmly set in the ground and provide no leeway to move laterally along the fence line. If the posts 6 are loosely set in the ground, the repair sleeve 10 may be installed in the extended position shown in
The apparatus 9 and method of the present invention provide a less expensive alternative to replacing an entire fence rail. Furthermore, since the apparatus 9 is small and compact, one or more can be conveniently stored in a shed, barn or garage using much less space than a full replacement rail. The apparatus can be installed quickly and easily without tools and with minimal effort on the part of the user.
While the principles of the invention have been described above in connection with specific embodiments, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention. For example, it is conceived within the scope of the present invention that the repair sleeve could be applied to the ends of a fence rail that is not broken to reinforce the fence rail at those locations. This application of the invention has particular use along areas of the fence that experience frequent, excess loads, wear, or deterioration due to external forces. The apparatus may also be used to repair fence rails made of concrete, plastic or metal.
Claims
1. An apparatus for repairing a split-rail fence rail having a broken tapered end portion, comprising:
- a) an elongate, hollow sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail; and
- b) means for fastening the base portion of the sleeve to the base portion of the rail.
2. The apparatus recited in claim 1, wherein the tapered end of the sleeve is constructed and arranged to replace the broken tapered end portion of the rail and allow the rail to be re-installed on a split-rail fence post.
3. The apparatus recited in claim 1, wherein the elongate sleeve has a uniform cross section along the central base portion and a cross-section that tapers in at least two dimensions along the length of the sleeve.
4. The apparatus recited in claim 3, wherein the elongate sleeve has an open proximal and distal ends.
5. The apparatus recited in claim 1, wherein said fastening means comprises at least one aperture extending through the base portion of said sleeve and a fastener extending through said aperture.
6. The apparatus recited in claim 1, wherein said fastening means comprises a threaded aperture extending through the base portion of said sleeve, and a hand-tightenable, threaded fastener engaging said aperture.
7. The apparatus recited in claim 6, wherein said threaded fastener comprises a thumb screw.
8. The apparatus recited in claim 1, wherein said fastening means comprises an aperture extending through the base portion of said sleeve, a threaded anchor coaxial with said aperture, and a threaded fastener engaging said anchor.
9. The apparatus recited in claim 8, wherein said anchor is fixed in said aperture.
10. The apparatus recited in claim 9, wherein said anchor is fixed adjacent to said aperture.
11. The apparatus recited in claim 8, wherein said threaded fastener has an enlarged head at one end for hand tightening the fastener and a foot at the other end having a cross section larger than the cross section of the shank of the fastener.
12. The apparatus recited in claim 1, wherein said fastening means comprises a plurality of shims.
13. A method of repairing a split-rail fence rail having a first end and a second broken tapered end portion on a fence having immovable posts, comprising the steps of:
- a) providing an elongate, hollow repair sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail;
- b) removing the broken tapered end portion from the rail;
- c) axially sliding the repair sleeve over the broken end of the rail toward the center of the rail until the end of the rail abuts the interior of the tapered end portion of the sleeve;
- d) inserting the first end of the rail into an aperture of a first post;
- e) locating the second end of the rail bearing the repair sleeve adjacent an aperture in a second post;
- f) axially sliding the repair sleeve away from the center of the rail until the tapered end engages the post aperture; and
- g) fixing the base portion of the repair sleeve to the central portion of the rail.
14. An apparatus for repairing a split-rail fence rail having a broken tapered end portion, comprising and an elongate, hollow sleeve having a base portion and a tapered end portion, said base portion and end portion having a shape that compliments the shape of the central base portion and tapered end portion of the rail, respectively, and having interior cross-sectional dimensions that are larger than the cross-sectional dimensions of the central base portion and tapered end portion of the rail, respectively, which enable the sleeve to slide over and encase the tapered end and at least a portion of the central base portion of the rail.
Type: Application
Filed: Apr 6, 2012
Publication Date: Oct 11, 2012
Inventor: JAMES D. SHUTE (MALVERN, PA)
Application Number: 13/441,087
International Classification: E04G 23/02 (20060101); E04C 3/00 (20060101);