SIMULATED ROCK MODULAR FENCE APPARATUS AND SYSTEM
A modular system of fencing components that can simulate the appearance and texture of traditional fencing materials is provided having novel connection and support components and systems to accommodate for thermal expansion while remaining strong, lightweight, easy to install and repair, and cost effective.
This application claims the benefit of, and claims priority to, U.S. Provisional Patent Application No. 62/647,171 entitled “SIMULATED ROCK MODULAR FENCE APPARATUS AND SYSTEM” and filed on Mar. 23, 2018 for Ted W. Nelson and David J. Black, the entire contents of which are incorporated herein by reference for all purposes. See MPEP § 213.
FIELD OF THE INVENTIONThe present invention relates to modular fencing components. More specifically, the present invention relates to rotationally molded modular fencing structures for simulating the appearance and texture of stone or other traditional fencing materials.
BACKGROUNDFencing structures may be constructed from wood, concrete, vinyl or other polymeric materials, chain link, brick and mortar, or stone. These fences may be used to surround both commercial and residential properties, and, for aesthetic and structural reasons, fencing materials like stone may be preferred.
SUMMARY OF THE INVENTIONThe present invention extends to improved modular fencing components and a modular fencing system designed to simulate the appearance and texture of traditional fencing materials, such as stone. It has been recognized that it would be advantageous to develop a fence constructed from pre-constructed modular components that can simulate the appearance and texture of stone or other traditional fencing material. Additionally, it has been recognized that it would be advantageous to develop construction of the panels used within the fence that would be lightweight and have the structural strength and rigidity to resist forces from high winds or dirt placed against the fencing structure. It has also been recognized that it would be advantageous to create a means of connecting the panels and the supporting posts that allows for connection with increased angular displacement of the panel. It has also been recognized that it would be advantageous to develop a means of connecting the fencing panels to the supporting posts that allows for increased tolerances in the length between the supporting columns and that can help to mitigate the effects of thermal expansion on the connection of the fencing panel to the post.
According to one aspect of the invention, the fence is constructed from pre-made component pieces such as supporting posts, fencing panels that connect the posts, external molded covers for the supporting posts, decorative capstone pieces for the supporting posts, and components for placing a gate within the fencing structure.
According to one aspect of the invention, the fencing panels have an outer surface made from a polymeric material that may be rotationally molded to simulate the appearance and texture of stone or brick. There is a hollow within the shell created by the molded external surface.
According to one aspect of the invention, two or more U-shaped supporting beams placed longitudinally within the hollow inside the fencing panels are provided that increase the structural strength and rigidity of the panel. The U-shaped beams may increase the ability of the fencing panel to resist forces applied to the panel by wind and allow for the fence to be used as a retaining wall.
According to another aspect of the invention, the U-shaped supporting beams may be surrounded by an injected or a poured polymeric foam or other material that can flow over the beams and fill in the remaining volume within the fencing panel. The foam may provide additional structural support to the fencing panel or improved acoustic properties.
According to another aspect of the invention, the U-shaped supporting beams may have one or more holes in the medial plane of the U-shaped supporting beam to help create a uniform thermal expansion of the foam during temperature change. The U-shaped supporting beam may be comprised of metal or composite material. The thermal expansion rate of the supporting beam is less than the thermal expansion rate of the foam and of the polymer fencing panel. The holes in the center of the supporting beam secure the foam to the beam while allowing the foam and the polymer shell of the fencing panel beyond the vertical centerline to slide or move at a different rate than the supporting beams during thermal expansion or contraction.
According to another aspect of the invention, a reinforcing truss fabricated from a series of disjoint segments of a reinforcing material such as steel wire connected to one another diagonally between their midpoints may serve as a replacement for the U-shaped channels. Of course, one skilled in the art may select any material known to be suitable for creating the truss. The truss may also be molded directly into the outer surface material of the fencing panel, and a reinforcing foam may or may not be used to fill the remaining volume within the fencing panel.
According to another aspect of the invention, the vertical edges of the fencing panels may be constructed with an edge that extends outwards along the lateral planar surface of the fencing panel. This extended edge or “lip” may be used in conjunction with the connecting area of the support posts to secure the panel to the support post during periods of thermal contraction.
According to another aspect of the invention, the connection point between the support post and the fencing panel is formed by flanges and lips on the support post that work in combination with the extended edge on the fencing panels' lateral edges to ensure that the fencing panel remains attached to the support post during thermal contraction while still allowing for tolerances within the connection to allow for thermal expansion. This flexibility in the connection is advantageous in that it allows for increased ease of installation and for placing the fencing panels at an angle relative to the support post. The allowances for thermal expansion and contraction also help to reduce maintenance required of the fence.
According to another aspect of the invention, covers may be installed to surround the support posts that can be molded from a polymeric material like that used to form the fencing panels and can simulate the appearance of the desired fencing material. A cap to go on top of the post may also be installed.
The previously described aspects of the invention have many advantages, including increased ease of installation and repair, reduced weight while retaining sufficient strength to withstand high winds and serve as a partial retaining wall, the ability to undergo thermal expansion or contraction without damage to the fencing components, cost savings, and the ability to select the traditional fencing material or appearance of the fence to be molded during manufacture.
These and other aspects of the present invention are realized in a modular fencing design that can simulate the appearance and texture of stone or other traditional fencing materials as shown and described in the following figures and related description.
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention.
DETAILED DESCRIPTIONThe invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims.
Referring now to
In one embodiment, the “H” shape of the supporting post 1 is formed by affixing two U-shaped beams together at a common center interface 3. The supporting post 1 may be constructed from any material with the structural characteristics known by those skilled in the art to be suitable for fencing. For example, the material may include a roll formed steel affixed together through a joining process, such as clenching process. In some embodiments, the joining process may be selected based on material, strength, and cost considerations.
In some examples, the supporting post 1 may have outer dimensions of 4.5″×5″ with the flange 5 on each extension 4 measuring 0.75″ long and leading to a 0.30″ lip 6 where both the flange 5 and the lip 6 may be at 90° angle from the body of the “H”. Other relative angles are contemplated. The thickness of the material may be adjusted by one skilled in the art to meet the necessary strength requirements based on the material chosen. In some embodiments, at least a portion of the support post 1 may have a thickness of 0.062″ and may be constructed of thick roll-formed steel.
In other examples, the supporting post 1 may have relatively larger outer dimensions of 6.5″×7″ where the flanges 4a, 4b have a length of 1.5″ and the lips 6a, 6b are 0.50″ in length. Changes in the length and other geometries may have corresponding changes in the thickness of the material which may be adjusted by one skilled in the art to meet the strength requirements needed based on the chosen material.
The length of the post may be varied according to the desired usage. The supporting post 1 may be erected by placing one end 10 of the supporting post 1 into a hole of suitable depth within the ground upon which the fence is to be constructed and then securing the supporting post 1 within the hole with a supporting material such as concrete.
The central body interface 2 of the support post 1 may include a hole or cutout near one end of the post 10 to serve as an interlocking hole 8 for supporting material to fill and set within to add additional structural stability to the supporting post 1. In some examples, the interlocking hole 8 may include a 3″ diameter. The diameter of the interlocking hole 8 may be adjusted by one skilled in the art depending on the supporting material selected or other considerations. In another embodiment of the invention, the supporting post 1 may omit the interlocking hole 8.
Some examples of the supporting post 1 may be sized and otherwise configured to accommodate a range of panel heights, thicknesses, and the like. In some embodiments, one or more geometries of the supporting post 1 may be increased, reduced, or otherwise changed while other geometries of the supporting post 1 remain unchanged. For example, the outer dimensions of the supporting post 1 as well as the lengths of the flanges 5 and lips 6 may be increased while the hook hole 7 and the interlocking hole 8 may remain unchanged. Other combinations or changes are also contemplated.
Referring to
The panel face 13 may include textures, patterns, or other variations in the panel face 13. In the illustrated embodiment, grooves are molded or shaped into the outer panel face 13 of the fencing panel 11 to simulate the appearance of stone. The grooves 23 or similar features may also be included to simulate other materials or aesthetic effects. As shown in
Referring now to
In some embodiments, one or more intermediate reinforcing channels 17 may be added between the reinforcing channels 14 disposed at the edges of the fencing panel 11. The illustrated embodiment of
In some embodiments, incorporation of the reinforcing channels 14 and 17 allows the fence panel 11 to resist forces from winds and to serve other structural purposes, such as serving as a partial retaining wall. In some embodiments, a plurality of channels 14 and 17 and could be used as a partial retaining wall. For example, embodiments of the fencing panels 11 may be used for heights of two feet, three feet, four feet, or other heights. In some embodiments, the number of additional reinforcing U-shaped channels 14 and 17 added to the panel 11 corresponds to the specific needs for a particular usage.
Referring now to
In the illustrated embodiment, one or more holes 20 may be formed within the central structure 21 of the reinforcing channel 14 and 17. The one or more holes 20 may allow for a supportive filling to flow around the reinforcing channels 14 and 17 and to help anchor the material and promote more uniform thermal expansion across the length of the fencing panel 11. In some embodiments, the supportive filling is a poured polyethylene foam. Other materials or combination of materials may be selected.
While the illustrated embodiment includes a pair of holes 20 formed in a middle of the reinforcing channels 14 and 17, fewer or more holes 20 may be formed at other locations and at other relative positions along the reinforcing channels 14 and 17. In other embodiments, the holes 20 may be omitted.
Referring now to
As is shown in
Referring to
In the illustrated embodiment, the capstone 12 encapsulates the reinforcing channels 14. In other embodiment, the reinforcing channels 14 are sized to contact an outer threshold of the face panel 13 along an interior surface of the capstone 12. In some embodiments, this relative position of the reinforcing channels 14 and the capstone 12 includes the use of a supportive filling material. In other embodiments, the supportive filling material may be omitted. In another embodiment, one or more truss structures 48 may be used in place of the reinforcing channels 14 and 17.
Referring now to
In
A cross-sectional view of the connection between two fencing panels 11 and a supporting post 1 is shown in
As can be seen in
Referring now to
The column cover 27 may be manufactured from any suitable material chosen by someone skilled in the art. In some embodiments, the column cover 27 is constructed with rotationally molded polyethylene material. The material of the column cover 27 may be similar to or different from material used in the manufacture of the panel face 13. In some embodiments, the choice of similar materials provide cost advantages and also provides all of the outwardly visible component pieces with the same coefficients of thermal expansion and aesthetic characteristics. The column covers 27 may be made with a similar or different surface texture than the fencing panel 11. Shown in
Shown in
The column covers 27 may be put in place around the support post 1 before or after the installation of the fencing panels 11 in accordance with the arrangement shown in
Referring now to
The surface 32 of the gate 31 may be constructed in a similar fashion to the face panel 13 to maintain a consistent aesthetic appearance. In other embodiments, a different material or appearance may be incorporated. In some embodiments, the gate 31 may be constructed using the same polyethylene materials and rotational molding process as was used to manufacture the fencing panels 11. In some embodiments, reinforcing steel tubes 33 may be molded into the gate 31 to increase the strength of the gate 31. Other reinforcing structures may also be incorporated.
Referring to
A perspective view of a post cap 37 is shown in
Referring now to
Referring now to
In the illustrated embodiment, the supporting post 1 extends beyond an upper limit of the fencing panel 11. The distance 43 between the top of the fencing panel 11 and the top of the supporting post 43 may be chosen by someone skilled in the art to be any distance that suits the aesthetic needs of the fence and allows for the post cap 37 to be installed with enough distance between the components to allow for thermal expansion. In some embodiments, this distance 43 will depend on the sizes of the supporting post 1 and the fencing panel 11 selected. The clearance 39 between the ground level and the bottom of the fencing panel 11 may be selected by someone skilled in the art as any distance suitable to allow for thermal expansion based on the sizes of the components and the materials from which the components were manufactured.
There is thus disclosed an improved fence that simulates the appearance of stone or other traditional fencing materials. It will be appreciated that numerous changes may be made to the present invention without departing from the scope of the claims.
Claims
1. A fence system comprising:
- a first fencing panel having a first lip formed on a first side of an edge of the first fencing panel and a second lip disposed on a second side of the edge of the fencing panel, the second side being opposite from the first side; and
- a supporting post having an H-shaped geometry to receive the first lip and the second lip of the first fencing panel to secure the first fencing panel relative to the supporting post.
2. The fence system of claim 1, further comprising a column cover disposed on the supporting post.
3. The fence system of claim 1, wherein the supporting post comprises a roll-formed steel.
4. The fence system of claim 1, wherein the supporting post is configured to receive a second fencing panel opposite the first fencing panel.
5. The fence system of claim 4, wherein the supporting post is configured to allow the first fencing panel and the second fencing panel to be secured in the supporting post and allow the first fencing panel and the second fencing panel to be pivoted about the supporting post to be oriented at a non-zero angle relative to one another.
6. The fence system of claim 1, wherein the first fencing panel further comprises a face panel configured to simulate a natural stone.
7. The fence system of claim 1, wherein the first fencing panel further comprises at least one reinforcing channel.
8. The fence system of claim 7, wherein the at least one reinforcing channel comprises one or more intermediate reinforcing channels disposed within the first fencing panel.
9. The fence system of claim 7, where in the at least one reinforcing channel has a U-shaped geometry.
10. The fence system of claim 7, where in the at least one reinforcing channel is a truss structure.
11. The fence system of claim 10, wherein the truss structure is a disjoint truss with a plurality of disjointed pieces of a reinforcing wire connected at angles to a central wire.
12. The fence system of claim 10, wherein the truss structure is a continuous truss with a continuous reinforcing wire along a length of the first fencing panel.
13. The fence system of claim 1, wherein the first fencing panel further comprises a supportive filling material.
14. The fence system of claim 1, further comprising a column cover to engage with the supporting post to cover a side of the supporting post.
15. A method comprising:
- rotationally molding a first fencing panel, the first fencing panel having a first lip formed on a first side of an edge of the first fencing panel and a second lip disposed on a second side of the edge of the fencing panel, the second side being opposite from the first side;
- roll-forming a steel supporting post to have an H-shaped geometry sized to receive the first lip and the second lip of the first fencing panel to secure the first fencing panel relative to the supporting post.
16. The method of claim 15, further comprising disposing a reinforcing channel within the first fencing panel.
17. The method of claim 16, wherein the reinforcing channel is disposed within the first fencing panel during rotationally molding the first fencing panel.
18. The method of claim 15, wherein rotationally molding the first fence panel comprises forming a panel face in the first fencing panel to simulate a fencing material.
19. The method of claim 15, further comprising disposing a supportive fill material within the first fencing panel.
20. The method of claim 15, further comprising forming a column cover sized to engage with the supporting post to cover a side of the supporting post.
Type: Application
Filed: Mar 23, 2019
Publication Date: Sep 26, 2019
Inventors: Ted W. Nelson (Salt Lake City, UT), David J. Black (Salt Lake City, UT)
Application Number: 16/362,635