Horizontal Fence and Method of Assembly

The invention relates to a system for constructing fences. In particular, the invention relates to residential or commercial fences of the type having a plurality of planks spanning the distance between adjacent vertical posts.

Fencing is widely used in residential settings to provide privacy, to define property lines and restrict access to designated portions of property and to provide decorative landscaping features. Many homeowners appreciate the aesthetic warmth and privacy of a natural wood fence. Unfortunately natural wood fencing can be expensive to install and maintain. Wooden fence planks can be prone to decay in moist conditions, and may warp, fade or crack over time. Regular periodic maintenance is required to maintain the structural integrity and aesthetic appeal of wooden fences.

It is often an object of fencing systems to provide the aesthetic appeal of wooden fencing, while being sturdy, maintenance free and easy to install. A residential yard fence should have the warmth and privacy of a natural wood fence but with a framework that will not warp, crack, lean, nor rot. If and when the wood fence boards become weathered and require replacing they should be easily slipped out of the fence framework and new ones slipped in for a brand new looking fence without having to set new posts in concrete.

It is a further object to provide a modular fencing system which can be easily assembled on site with minimal tools and which does not require woodworking or other specialized skills to install. Such a modular fencing system should be adaptable to accommodate variations in ground elevation and customizable to achieve fences in a variety of heights to meet individual homeowner needs.

A universal support rail for a horizontal fence assembly spans a distance between a pair of adjacent U-shaped members attached to a pair of vertical posts or other flat vertical surfaces. The universal support rail comprises a main body having a first end and a second end. Each of said first and second ends is sized for retention within an opening of a vertical channel formed by one of the pair of U-shaped members. The main body of the universal support rail is formed with a cross-sectional profile having a rail tongue extending from a first side thereof, and a rail groove formed in an opposite side thereof. The rail groove is sized and positioned to retain a plank tongue of a fence plank therein. The rail tongue is sized and positioned to be retained within a plank groove formed in a fence plank. The universal support rail may be positioned on top of the fence plank, or under the fence plank or between two fence planks to retain said fence planks in a stacked configuration between the pair of adjacent U-shaped members.

A horizontal fence assembly comprises a pair of U-shaped members attached to a pair of coaligned and spaced apart vertical posts or other flat vertical surfaces. Each of the U-shaped members defines a vertical channel having an opening for receiving at least one universal support rail and a plurality of fence planks. The plurality of fence planks span the distance between the pair of vertical channels. Each of which fence planks is constructed having a first longitudinal edge forming a plank tongue and an opposing longitudinal edge forming a plank groove. The universal support rail spans the distance between the pair of vertical channels. The universal support rail comprises a main body having a first end and a second end, with each of said first and second ends being sized for retention within the openings of the vertical channels of each of the pair of U-shaped members. The main body is formed with a cross-sectional profile having a rail tongue extending from a first side thereof, and a rail groove formed in an opposite side thereof. The rail groove is sized and positioned to retain the plank tongue of a fence plank therein; and the rail tongue is sized and positioned to be retained within the plank groove of a fence plank. Fastening means secure the universal support rail in the vertical channels of each of the U-shaped members. The universal support rail may be positioned on top of the fence plank, or under the fence plank or between two fence planks to retain said fence planks in a stacked configuration between the pair of adjacent U-shaped members.

The at least one universal support rail comprises a bottom rail attached adjacent to bottom ends of each of the U-shaped members. The at least one universal support rail comprises a top rail attached adjacent top ends of each of the U-shaped members. The bottom rail attached adjacent to the bottom ends of each of the U-shaped members and the top rail attached adjacent to the top ends of each of the U-shaped members together frame the plurality of fence planks.

The at least one universal support rail further comprises a mid rail attached to each of the U-shaped members above at least one of the fence planks and below at least one of the fence planks.

A method of assembling a horizontal fence comprises the steps of providing first and a second vertical channels, respectively defined by first and second U-shaped members and respectively attached to first and second anchored posts. The openings of the first and second vertical channels facing one another. The first universal support rail comprises a main body having a cross-sectional profile having a rail tongue extending from a first side thereof and a rail groove formed in an opposite side thereof. The universal support rail is oriented with the rail tongue pointing upward and the universal support rail is fastened into the first and second vertical channels. The next step is inserting into the first and second vertical channels a plurality of fence planks each having a first longitudinal edge forming a plank tongue and an opposing longitudinal edge forming a plank groove. The plurality of fence planks is oriented with their plank grooves pointing downward in stacked configuration, receiving and resting upon the rail tongue of the first universal support rail. A second universal support rail is fastened into the first and second vertical channels. The second universal support rail comprises a main body having a cross-sectional profile having a rail tongue extending from a first side thereof and a rail groove formed in an opposite side thereof. The universal support rail oriented with the rail tongue pointing upward and the rail groove pointing downward and receiving therein a plank tongue of one of the plurality of fence planks.

The method further comprises the step of inserting into the first and second vertical channels a second plurality of fence planks each having a first longitudinal edge forming a plank tongue and an opposing longitudinal edge forming a plank groove. The second plurality of fence planks is oriented with their plank grooves pointing downward in stacked configuration, receiving and resting upon the rail tongue of the second universal support rail. Then, a third universal support rail is fastened into the first and second vertical channels. The third universal support rail comprises a main body having a cross-sectional profile having a rail tongue extending from a first side thereof, and a rail groove formed in an opposite side thereof. The third universal support rail is oriented with the rail tongue pointing upward and the rail groove pointing downward, receiving therein a plank tongue of one of the second plurality of fence planks.

Certain terminology is used in the following description for convenience only and is not limiting. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element, but instead should be read as meaning “at least one.” The terminology includes the words noted above, derivatives thereof and words of similar import.

While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Where methods described above indicate certain events occurring in certain order, the ordering of certain events may be modified. Additionally, certain of the events may be performed concurrently in a parallel process, when possible, as well as performed sequentially as described above.

Certain terminology is used in the following description for convenience only and is not limiting. The words “lower,” “bottom,” “upper,” and “top” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly,”, “upwardly” and “downwardly”, “axially” and “peripherally” refer to directions toward and away from, respectively, the geometric center of the device, and designated parts thereof, in accordance with the present disclosure. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element, but instead should be read as meaning “at least one.” The terminology includes the words noted above, derivatives thereof and words of similar import. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Where structural elements having the same structural and functional characteristics are used in pairs they may be designated by using a single reference numeral for the element, with the prime (′) symbol designating the two identical structural elements of a pair.

As can be seen in, the present invention is a new horizontal fencing assemblyfor a horizontal fencing system, indicated by general reference, which may be erected as horizontal fence plankssupported by a plurality of adjacent, spread apart vertical posts. The vertical postsare typically 3 inch×3 inch aluminum fence posts, which are installed in in post holesand anchored by concrete. Each horizontal fence assemblyspans a distance between a pair of adjacent spread apart vertical posts.

In a preferred embodiment, each vertically oriented channelis formed as an extruded U-shaped memberwhich may be attached to an outside face of a respective one of the vertical posts during installation on site. Each U-shaped memberwill be positioned on the faceof the vertical postin an orientation with the channel openingfacing an adjacent one of the plurality of vertical posts. Each U-shaped memberwill be fastened to its respective vertical postby conventional means such as post screws. Preferably, the U-shaped members are attached to vertical posts with self drilling screws through the back wall of each of the U-shaped membersthrough counter-sunk apertures to the vertical posts. Vertically oriented posts are not pre-drilled.

It should be noted that in accordance with the present invention, a horizontal fence assemblycan be mounted to any flat vertical surface capable of supporting a fence, such as the side of a building, a stone wall, a gate pillar etc. The U-shaped membersprovide the vertical channelsthat define channel openingsto receive universal support rails and fence planks. The channel openingsof the U-shaped memberson adjacent posts will face each other for receiving at least one universal support railand a plurality of fence plankstherebetween. Virtually any flat vertical surface to which the U-shaped members may be attached can be used to install a horizontal fence assembly. Thus a fence assembly could span two buildings, two anchored posts, or a combination thereof. This allows a fence line to begin on a building or other structure and to continue with free-standing anchored posts.

In most instances the vertical postswill have two of the U-shaped membersattached to opposing faces,thereof to facilitate the longitudinal extension of the horizontal fence between multiple aligned vertical posts along the intended path of the fence. In instances where it is desired to have the fence form a corner and extend in another direction, the U-shaped members may be mounted on adjacent faces,of the vertical post to form a 90 degree turn in the path of the fence. U-shaped members may be attached to three or all four sides of a vertical post if a user wanted multiple fence lines to extend from a single point.

Each U-shaped memberprovides a lower attachment areapositioned adjacent a bottom thereof and an upper attachment areapositioned adjacent a top thereof for fastening the universal support membersbetween the pair of U-shaped members,′. Each U-shaped membermay further comprise a mid attachment areaat a pre-determined position between the lower attachment areaand the upper attachment area. At each of the attachment areas (lower, mid, and upper) each of the U-shaped members,′ define a first pair of apertures,′ through one side thereof along a 45 degree angle from a longitudinal edge of a first sideof said channel. Each of the U-shaped members,′ also defines a second pair of apertures,′ through the opposing sidethereof along a 45 degree angle from a longitudinal edge of the other side of said vertical channel. The two pairs of apertures,′ and,′ are oriented at a 90 degree angle to one another for strength and to ensure that opposing self-drilling screws do not interfere with one another within the U-shaped members,′.

With respect to the placement of the through holes in the top and bottom ends of vertical channels, it should be understood that the apertures in opposing sides need to be offset but not necessarily by 90 degrees. Furthermore the line of apertures on a first side need not necessarily be 90 degrees from vertical, provided that the apertures in the opposing channel side are rotated to be offset from the apertures in the first side.

In accordance with a preferred embodiment of the present invention, the universal support railcomprises a main bodyhaving a first endand a second end. Each of said firstand secondends is sized for retention within the openingof a vertical channeldefined on the face of each of the pair of adjacent vertical posts. The main bodyof the universal support rail is formed with a cross-sectional profilehaving a rail tongueextending from a first sideof the main bodyand a rail grooveformed on a second sidethereof, the second sidebeing opposite to the first side. The universal support rail is sized to fit within and be retained by the opposing vertical channel openingson the U-shaped members attached to adjacent vertical posts.

The rail grooveis sized and positioned to retain the plank tongue of a tongue and groove composite fence planktherein. More specifically, the rail tongueis sized and positioned to be retained within a plank grooveformed in each fence plank. The cross-sectional profileof the main bodyof the universal support railenables the universal support railto be positioned on top of the fence plank, under the fence plankor between two fence planks,to retain said fence planks in a stacked configuration between the pair of adjacent vertical channels.

The first endand the second endof the main bodyof the universal support railare affixed to the first sideand the opposing sideof the U-shaped channelthrough the first pair,of predrilled apertures in the sides of each U-shaped memberwith self-drilling metal screws. The universal support railis not pre-drilled and is intended to be punctured by the self-drilling screws. Preferably a universal support railis attached within the vertical channels of two U-shaped members such that the bottom of the horizontal railis flush with the bottom end of each of the opposing U-shaped channelsto support and secure a plurality of fence planks.

The horizontal fencing system according to the present invention may by constructed using wooden fence planks, but it is preferable to construct the planks from engineered composite materials typically constructed from combinations of plastic and wood fibre. The fence planks are cut to standard lengths typically used in fencing projects. Six feet (72 inches) is a common length. The length of each of the fence planks is approximately ¼ inch less than the total length between the inside of the two vertical channels. The present invention uses tongue and groove fence planks. Each of the fence planksis constructed having an upper longitudinal edge which forms a plank tongueand a lower longitudinal edge forming a plank groove. It will be understood that the plank tongueis sized to be received within the rail grooveof a universal support railand the plank grooveis sized to receive the rail tongueof the universal support rail.

A series of composite fence planksare slid down within the U-shaped vertical channels,of two adjacent U-shaped members. Each of the fence planksis oriented between the vertical channels,such that the plank groovealong the lower edge of a first plank receives the correspondingly sized rail tongueof the first sideof the main bodyof the universal support rail. The remaining fence planks are slid down within the channels,such that the plank groovein the bottom edge of each plank receives the plank tongueof the preceding plank in a stacked configuration.

Once the stack of planks is complete, a second additional universal support railwhich will serve as a top railmay be placed within the vertical channels,to mate with the uppermost composite fence plank by receiving the plank tonguewithin the rail grooveof the horizontal support rail. The top horizontal support railis screwed at its ends,to the sides of the U-shaped members,′ in a similar manner as discussed above. For aesthetic reasons a decorative cap railcan be fitted onto the upwardly protruding rail tongueof the top horizontal support railto cover the protruding rail tongue. Preferably the upper edge of the top universal support railis flush with the top ends of each U-shaped channel but this will depend upon the height of the fence planks.

Both the universal support rails, and the fence planks, may be cut shorter than stock in order to accommodate the actual distance between the inside back walls of opposing vertical channelsin the U-shaped members.

In an alternative embodiment, a modified top rail could be substituted in place of the top universal support rail. The modified top rail would have a main body defining a rail groove for receiving a fence tongue of a lower fence plank, but the main body would not define a protruding rail tongue. Instead, would remain flat to provide a flat edge at the top of the horizontal fence assembly.

Aluminum fence post capsmay be placed over top of each vertical fence post to prevent water from accumulating within them, which water might freeze within hollow fence post cavities, potentially distorting the contour and/or integrity of said vertical fence posts.

The preparation of the area where the horizontal fencing system will be assembled proceeds as follows: When planning the positioning of the fencing system and installation site, map out the positing of the vertical fence posts six feet apart. Next dig post holes 8 inches in diameter to a depth of 36 inches to 48 inches and fill the bottom with a few inches gravel if required. Colder climates may require deeper post-holes. Insert one vertical post into each hole and ensure that the post is at least 76 inches from the ground to the top of the post for a 6 foot fence. Then pour concrete into the hole around the post to set and form a concrete anchor. While the concrete is still wet, lay a 6 foot board on the ground to ensure the proper spacing between the posts, and then level each post within the post hole on both the X and Y Axis, and ensure there at least 76 inches of each vertical post protrudes from the ground.

This procedure is repeated for all posts in fence project. Once each vertical fence postis mounted in a post holeand anchored by concrete to a desired height and the concrete has dried, assembly may proceed. Earth removed from the post holes may be used to shore up one end of the plank to level.

A summary of the principal steps in the process of assembling a fencing system will be discussed briefly in the next 4 paragraphs. Following this summary, a further, more details description of the method will be provided.

ASSEMBLY SUMMARY: The first step in the assembly is providing first vertical channeland second vertical channels′, respectively defined by first and second U-shaped members,′ respectively attached to first and second anchored posts. The openings,′ of said first and second vertical channels,′ are oriented facing one another. A first universal support railcomprising a main bodyhaving a cross-sectional profilehaving a rail tongueextending from a first sidethereof, and a rail grooveformed in an opposite sidethereof is oriented with the rail tonguepointing upward and fastened into the first and second vertical channels,′ as a bottom support rail.

Then, into the first and second vertical channels is inserted a plurality of fence planks. Each of the fence planks has a first longitudinal edge forming a plank tongueand an opposing longitudinal edge forming a plank groove, and the plurality of fence planks is oriented with their plank groovespointing downward in stacked configuration. In this manner the stack of planks rests on the rail tongueof the universal support rail, receiving the rail tonguewithin the plank grooveof the lower most plank. The remaining planks are stacked tongue in groove on top of one another.

A second universal support railis then inserted into the first and second vertical channels to serve as a top rail. The second universal support railhas the same structure as the first one; namely, a main bodyhaving a cross-sectional profilehaving a rail tongueextending from a first side thereof, and a rail grooveformed in an opposite side thereof. Again, the second universal support rail(top rail) is oriented with the rail tonguepointing upward and the rail groovepointing downward and receives therein a plank tongueof one of the uppermost one of the plurality of fence planks. This second universal support rail serves as a top railin 6 foot horizontal fence assemblies. A frameis formed around the fence planks by the bottom universal support railfastenedwithin the two vertical channels,′ supporting the fence planks on top of its rail tongue, and the top universal support railfastened within the two vertically oriented channels,′ and receiving the plank tongueof the uppermost one of the fence planks within its rail groove. This framing effect permits the plurality of fence planksto float freely within the frame, with out the need to fasten every plank to the U-shaped members,′. The free floating capability accommodates any warping or distortion that the composite fence planks may experience due to thermal expansion when exposed to sunlight or heat. If the composite planks were individually fastened to the U-shaped members, they could tear at the fastening points during thermal expansion.

For taller fences it is advantageous to add a third universal support railto serve as a mid railto the horizontal fence assembly. The addition of a mid railis accomplished by fastening another universal support railinto the first and second vertical channels at a selected height in the same manner as the previous installation of the other universal support rails, also oriented with their rail tonguespointing upward and their rail groovespointing downward. A mid attachment areamay be provided on the U-shaped members for this purpose. Another plurality of fence planksis inserted into the first and second vertical channels,′ to rest on the mid universal support rail. Once assembled, the mid railis positioned between two stacks of fence planks. The mid railrelieves some of the weight due to the presence of a larger number of fence planks bearing on the bottom rail, and acts to strengthen the framearound the fence planks to improve strength and stability of the complete horizontal fence assembly.

ASSEMBLY DETAIL: The first assembly step is placing a first U-shaped memberagainst a first faceof a first anchored vertical post, and centering, levelling and orienting said first U-shaped membersuch that a first vertical channeldefined by the first U-shaped memberprovides an openingfor receiving at least one universal support railand a plurality of fence planks. The first U-shaped memberis fastened to the first faceof the first anchored postusing self-drilling screws.

The next step is providing a first universal support railhaving a main bodyformed with a cross-sectional profilehaving a rail tongueextending from a first sidethereof, and a railgroove formed in an opposite sidethereof. To facilitate levelling and alignment, a user should rest a first endof the first universal support railon top of the first U-shaped memberand raise a second endof the universal support railto level against a second anchored vertical post and place a leveling mark on the second anchored vertical post.

Next place a second U-shaped member′ against a first face of the second anchored vertical post, centering, levelling and orienting the second U-shaped member′ at the levelling mark. Then fasten the second U-shaped member′ to the second anchored post in an orientation such that a second vertical channel′ defined by the second U-shaped member′ provides a second opening′ for receiving at least one universal support railand a plurality of fence planks. The second opening′ is oriented facing the openingof the first U-shaped member.

Next, measure the distance between the two anchored posts and subtract ¼ inch to accommodate the thickness of the U-shaped members,′, and cut a second universal support railto the length so calculated.

The first universal support railis then placed in the opposing vertical channels,′ oriented in such a manner that the rail tongueextending from the first side of the rail bodyfaces upward and the rail grooveon the second side of the rail bodyfaces downward and is aligned with the bottom end of each vertically oriented channels,′. The universal support rail is attached to the opposing sides,of the vertical channels,′ in the manner aforesaid with self-drilling screwsthrough the pre-drilled,and,apertures in each of the firstand opposingsides of each vertically oriented channels,′.

Next, lift a first endof the first universal support railflush with a bottom of the first channeland fasten by screwing a self-drilling screw into a pre-drilled hole in an attachment area adjacent the bottom of the first channel. Then lift the second endof the first universal support railflush with a bottom of the second channel′ and screw a self drilling screw into a pre-drilled hole of an attachment area adjacent the bottom of the second channel′ to fasten.

Next, confirm that the first universal support railis level, and fully secure it within the first and second channels,′ by screwing the remaining self-drilling screws into the first U-shaped memberand the second U-shaped member′. Then insert one fence plankhaving a first longitudinal edge forming a plank tongueand an second longitudinal edge forming a plank grooveinto the first channeland the second channel′ of the first U-shaped memberand the second U-shaped member′ oriented to receive the rail tongueof the universal supporting railwithin the plank groove. The universal support installed in this manner which will serve as the bottom universal support rail.

Each of the steps discussed in paragraphs 38-44 should be repeated sequentially for each horizontal fencing assemblyto form a fencing line of the desired length. Install a universal support railbetween the U-shaped members attached to each pair of vertical posts in the fence line before starting to stack the other fence planks. This practice will keep all the vertical posts level in the fencing system straight during installation and prevent them from pulling toward the finished panel.

A series of composite fence planksare then slid into position between opposing vertical channels,′ such that the plank groovealong the bottom longitudinal edge of each fence plank is oriented downwardly to receive the plank tonguealong the upper longitudinal edge of the fence plank immediately below. Once the desired number of planks are installed the last fence plank should have an upwardly oriented protruding plank tonguealong the upper longitudinal edge thereof.

It is preferred to slide the planks into position in a staged manner. Once the universal support railis installed and secured in the vertical channels,′, slip in three or four planks into the channels,′ on top of the bottom universal support railsthroughout the fence line. Do not stack or finish one full horizontal fence assembly at a time. This could pull vertical posts toward the finished panel. Instead, create a low stack (about 4 planks), for each assembly in the fence line, then mid-height (another 4 planks), then top, (last 4 or more planks) until the desired height of the fence is achieved.

Then, insert a second universal support railinto the firstand the second′ vertical channels defined by the first U-shaped memberand second U-shaped member′ to serve as a top universal support rail. The top universal support railis oriented with the rail tonguepointing upward. Preferably the top edge of the top horizontal railwill be flush with the top end of each of the opposing U-shaped members,′. The two ends, andthe top horizontal railis then screwed to one of the opposing U-shaped members,′ with self drilling screws through apertures in each side of the U-shaped channels near the top thereof.

The apertures in opposing sides of each U-shaped memberare oriented on a first side at approximately 45 degrees from vertical and the aperture in a second side of each U-shaped member is oriented at 90 degrees from the aperture on the first side of each U-shaped member. Once all the fence planks have been inserted and the fence looks complete, the tops of the vertical posts may be trimmed if necessary. Finally aluminum fence post capsare attached to the top of each vertical fence post in order to cover and block the open ends of each aluminum fence post from receiving precipitation

It should be understood that the vertical posts, the U-shaped members forming the vertical channels, and the universal support rails are preferably constructed of aluminum, such parts may be made of other materials which could include other metals or alloys, fiberglass composite or other suitable materials of sufficient strength to support the fence planks and withstand wind, and which would not tend to expand or contract in changing weather conditions.