Quasi-wall composite panel fencing system

Abstract

This invention relates to a modular fencing system composed of panels affixed to modular composite columns mounted onto base footings and encased with preformed laminate façades with custom designs. The panels consist of opposing pairs of composite sandwich core laminate sheets separated and affixed to a polymer filament truss matrix. Each of the panel's two laminate sheets is constructed from fiber reinforced polymer layers laminating segmented sandwich core discs. Modular composite columns consists of two parallel vertically standing fiber reinforced polymer laminate flange plates oriented perpendicular to the panel, linked with two horizontal winged web plates between, forming what resembles an double I-beam. Decorative column façades constructed using the same sandwich core laminate material used in the panels are installed to veil and cover the modular composite column, corner posts, support brackets, and an associated hardware and allow for custom decorative finishes.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a nonprovisional application which claims the benefit of Provisional Application No. 61/742,915 filed Aug. 23, 2012.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT—Not Applicable

BACKGROUND

This invention relates generally to a modular fencing system with composite support columns, composite fence panels, and decorative column façades.

Since the beginning of civilization, people have used basic materials to construct walls and fencing for security and mark boundaries. Wood cut and configured in a post, picket, and/or rail was one of the earliest and simplest fencing. Two thousand years ago the Romans introduced brick and mortar walls with stucco covering. This method required the arduous task of stacking blocks on one another but proved more durable, secure, and decorative. Today, these materials and methods are still used in the construction of fencing.

More recently, a number of modular panel fencing systems have tried to reduce the time and cost associated with construction. These panel systems incorporate a number of designs to reduce installation time. Some systems use cast concrete panels which are then delivered to the intended installation site. Other existing “wall” fencing systems are made from some type of coated foam panel or an opposing pair of polymer sheets held apart with a variety of ties and spacers. Composite board and vinyl fence systems using posts, rails, and pickets have replaced some traditional wood fencing and provide greater durability. Examples of these systems include U.S. Pat. Nos. 5,353,562, 6,355,193, 5,218,797, 7,090,201 and 5,887,404. However, each of these references involve significant compromises and disadvantages with regard to cost, ease of installation, durability and rigidity, or aesthetics. Systems routinely sacrifice durability and aesthetics for costs and accessibility. Creating a fencing solution that is durable, rigid, cost-effective, easy to install, decorative, and accessible, has proven elusive.

SUMMARY

The primary objective of the present invention is to provide a cost-competitive fencing system with the strength, longevity, and aesthetic choices of a masonry wall but with the ease of installation of a fence.

The Quasi-wall fencing system is a modular fencing product utilizing rigid panels made from a pair of recycled sandwich core laminate sheets separated by a polymer filament truss matrix, modular composite columns, simple mounting hardware, and custom column façade options of various architectural cultured stone veneer designs. The primary objective of the present invention is to provide a fencing system that provides strength, rigidity, and longevity; serves as an effective sound barrier; allows for simple installation; allows for a cost-effective means of component fabrication; and is aesthetically pleasing with multiple façade designs.

The panels are easily manufactured to varying heights and lengths to function as a privacy wall, court yard wall, garden wall, or other type of fence or wall. The panels offer superior rigidity without the density and mass of traditional fencing system allows for increased panel length and column spacing, reduced transportation and labor cost associated with installation, and greater design flexibility to accommodate diverse property boundaries. Finishes can be applied independently to both sides of the panels allowing neighbors on opposite sides of the fence system to select their own column façade and panel color scheme. The elastic nature of the synthetic finish coupled with sound deadening characteristics exhibited by the sandwich core laminate panels significantly reduce sound transmission and provide privacy. The panels are light enough to be carried by an installation team and can be cut to length on the job site for a precise fit.

The modular composite column design also reduces weight and consumes less space during transportation as the components can be assembled on site. The area in the center of the assembled modular composite column is large enough to interface easily with an existing fence post or footings without the need to remove them. A spacing algorithm, factoring available panel lengths and the topography, is used to determine column location and visual aesthetics of the set. The system components allow for stepped or inclined panel installation between columns on gradient sites. In the event the fence line requires a change in direction, the support brackets can be adjusted and angled to allow for up to a 30 degree course deviation. If an embankment is encountered on the fence line, a modular composite column is set at the base and the peak, a panel is set along the modular composite column. In situations where space is limited and column façades will not aesthetically fit, a panel can be attached directly to an existing wall and/or a gate post without exposed bracketing.

DRAWINGS

These and other features of the present invention are better understood with regard to the following description, claims, and accompanying drawings where:

FIG. 1 shows the preferred embodiment perspective view depicting the main components of the fencing system;

FIG. 1a shows a close up of modular composite column, support brackets, and the panel;

FIG. 2 shows a system view of the panel;

FIG. 2a shows a close up of the panel;

FIG. 2b shows a side view of the panel;

FIG. 3 shows the modular composite column components;

FIG. 4 shows column façade choices.

DESCRIPTION

The Quasi-wall fencing system is a modular fencing product as shown in FIG. 1 composed of panels 2 made from a pair of sandwich core laminate sheets 23 24 separated by a polymer filament truss matrix 26, modular composite columns 4, simple mounting hardware, and custom column façade options 12. The primary objective of the present invention is to provide a fencing system that provides the strength, rigidity, and longevity; serves as an effective sound barrier; allows for easy installation; uses a cost-effective means of component fabrication; and is aesthetically pleasing with multiple designer façade options.

The panel 2, as illustrated in FIG. 2 and FIG. 2A, consists of a pair of composite sandwich core laminate sheets separated and affixed to a polymer filament truss matrix 26. Each of the composite sandwich core laminate sheets is constructed from two fiber reinforced polymer layers, an inner layer 23 and an outer layer 24, encapsulating a layer of discs in the sandwich core 28. The preferred sandwich core disc 28 material utilizes reclaimed wood boards, which are chipped, dried, combined with a flame retardant agent and other fillers, mixed with adhesive, and compressed into discs. This disc core laminating technique improves panel surface rigidity, reduces laminate cost, and prevents moisture propagation across the core. During the laminate lay-up process a depression is formed at areas devoid of sandwich core discs. These depressions further strengthen the panel surface and serve to align the truss matrix peaks during panel assembly.

The filament truss matrix 26, as illustrated in FIG. 2B, is an array of composite filaments 29 oriented in a zig-zag pattern repeating pyramid-like joints between the truss matrix and the laminate panels 25. A truss strand array, also referred to as a spar 29, is composed of three separate continuous polymer infused filament strands joined at the ends and separated evenly at the center by a filament separator ring 27. The continuous filament truss strand is formed through the duplication of the spar segment in opposing direction but includes a horizontal area at the point where the filaments of the truss matrix form a joint with the composite sandwich core laminate sheets 25. In place, the truss matrix acts as a stiffening filler between the composite sandwich core laminates improving overall rigidity of the panel 2. At the panel top and bottom edges, bonded between and bridging the laminates, is a retaining channel 15 made of fiber-reinforced laminate that serves to strengthen the panel and also provide retention for a decorative wall cap 14.

An assembled panel 2 is then coated on both exterior surfaces with durable stain and abrasion resistant synthetic finish, not limited to but mimicking stucco 21, in a texture and color of consumer preference. Panels 2 are to be manufactured in lengths and heights accommodating consumer needs.

Modular composite columns 4, shown in both FIG. 1A and FIG. 3, attached to grounded footings support the panel 2. The modular composite column 4 consists of two vertical, parallel-standing, fiber-reinforced, laminate flange plates 18 linked with horizontal winged web plates 20 forming what resembles a double I-beam. Each flange plate's outer edges along its length are broadened by sandwich core material and reinforced by continuous filament roving and include a series of holes for the attachment of various brackets used to mount the modular composite column 4 on the footing and to attach the panel 2. Base brackets 6 are bolted to the modular composite column 4 at the bottom four corners and also connected to the bottom corners of the panel 2. A decorative column cap is placed on top of each modular composite column 16.

The L brackets 8 bolt the panel 2 to the modular composite column 4 in predrilled locations. End blocks are inserted into the open panel ends where the L brackets 8 are bolted for firm retention of the panel 2 and to prevent panel compression. The panel 2 is placed between the modular composite columns 4 and bolted on the base brackets 6. The L brackets 8 supporting the panel 2 are then installed using bolts at predrilled holes along the edges of modular composite column flange plate 18. Separate V brackets 10 are also attached to modular composite column flange plates 18. The V brackets 10 are shaped to accept the V support blocks 22 attached inside the shell of the decorative column façade 12.

Decorative column façades 12 are installed to cover the modular composite columns 4, support brackets 6 8 10, and an associated hardware while providing decorative style. The column façades 12 consist of a façade shell constructed using the same sandwich core lamination process as the panel. The column façade shell protrudes out to create both visual depth of the column but also to allow for clearance behind the shell for the brackets and the modular composite column. Attached to the inner edge of the column shell 12 are tapered V-shaped blocks 22 coinciding column façade support brackets 10 mounted on the modular composite column 4. The V support block 22 inside the shell of the façade 12 attaches to the large flange of the V brackets 10 by hooking over the V brackets 10 with carriage bolts and nuts. A broad range of materials are available to adorn the outer surface of the column façade including synthetic materials fashioned to imitate stone, brick, block, architectural molding, wood, and other materials as shown in FIG. 4.

Claims

1. A modular support column and panel fence system, which comprises

Two or more footings;

A modular composite column placed atop each footing and joined at the base corners to the footing;

Two or more support brackets attached to the composite modular support column spaced from top to bottom;

A panel that is attached on the one end to the support brackets on a modular composite column placed on one footing and the other end to the support brackets on a modular composite column placed on a second footing; and

Two or more decorative column façades attached to the support brackets on each modular composite column fully wrapping the column, support brackets, and the attached panels.

2. A panel, which comprises

Fiber-reinforced polymer laminate sheets encapsulating thin segmented sandwich core discs;

Two separate laminate sheets spaced apart and joined together with a polymer impregnated fiber roving truss matrix;

3. A modular composite column as recited in claim 1, further comprising

A pair of polymer fiber-reinforced long, rigid flange plates separated and joined together with two or more fiber-reinforced polymer channel shaped web plates forming a double I-beam configuration; and

Two or more metal support brackets attached from top to bottom of the modular composite column that provide fastening points for one or more laminate fence panels and two or more decorative column façades.

4. A decorative column façade as recited in claim 1, further comprising

Molded laminate made of a thin segmented sandwich core board encapsulated with fiber-reinforced polymer; and

A customized exterior textured finish with polymer finish or cultured stone veneer.