Fence System

This application is a continuation of U.S. patent application Ser. No. 19/257,150, filed on Jul. 1, 2025, which is a continuation of U.S. patent application Ser. No. 17/107,373, now U.S. Pat. No. 12,392,162, filed on Nov. 30, 2020, which is a continuation of U.S. patent application Ser. No. 14/990,552, now U.S. Pat. No. 10,851,560, filed on Jan. 7, 2016, which is a divisional of U.S. patent application Ser. No. 13/968,485 filed on Aug. 16, 2013, which is a divisional of U.S. patent application Ser. No. 12/581,998, now U.S. Pat. No. 8,511,648, filed on Oct. 20, 2009, which claims priority from U.S. Provisional App. Ser. No. 61/106,665 filed on Oct. 20, 2008, U.S. Provisional App. Ser. No. 61/109,764 filed on Oct. 30, 2008, and Canadian Patent App. Ser. No. 2,669,440 filed on Jun. 18, 2009, each of which is hereby incorporated by reference as if fully set forth herein.

The Applicant's teaching disclosed herein relates to fence systems, for example privacy fences and picket fences, and to one or more methods and apparatuses associated with elements of fence systems and the connection structure and assembly thereof.

The following paragraphs are not an admission that anything discussed therein is citable as prior art or part of the general knowledge of people skilled in the art.

U.S. Pat. No. 5,702,090 (Edgman) discloses a plastic fence assembly, particularly adapted for use as residential privacy fencing and the like, comprising plural post members which are formed of hollow extruded plastic and have opposed side walls and end walls intersected by one or more elongated channels. Elongated spacer elements may be inserted in the channels and retained therein by interlocking projections on the spacer elements and recesses formed in the sidewalls of the post channels. The spacer elements support side edges of vertically extending picket members, brackets for horizontally extending center rail members and to position at least one or both of elongated top and bottom rail members of the fence assembly. The top and bottom rail members have elongated slots formed therein for receiving opposite ends of generally planar boardlike picket members. The top and bottom rail members and the spacer members may be cut to length as may the post and picket members to provide fencing of a desirable height and distance between posts.

U.S. Pat. No. 5,988,599 (Forbis) discloses a modular fence system. The system includes fence planks designed for insertion into open channels of upper and lower fence rails. The fence rails are supported in a horizontal orientation between intermittent fence posts, with the fence planks extending vertically between the rails. The planks include resilient protrusions at their upper ends. The protrusions of the planks are designed to fit into internal passages formed in the open channels of the upper fence rail, into engagement with ledges defining the passages, to inhibit inadvertent removal of the planks from the upper rail.

U.S. Pat. No. 6,478,287 (DeSouza) discloses a fence panel constructed from extruded hollow polyvinyl plastic boards. The boards are arranged with vertical end boards and filler boards between the end boards. Three horizontal rails each have a board on each side of the vertical boards with a horizontal filler board between the top rail boards to seal off the upper ends of the vertical boards. All of the boards are secured together with a plastic adhesive without the use of any mechanical fasteners.

U.S. patent application publication 2008/0217598 (Dombroski) discloses a fence assembly that is made up of a plurality of fence sections. Each section is made up of panels with top, bottom and side edges and front and rear surfaces. Slots are spaced from and milled into the panels along one of the sets of edges. A pair of trim extends over and covers the set edges and each trim has projections that snap or slide into the front and rear slots. Alternatively the edges of the panel may be beaded and slid over the slotted side of the trim. The fence sections are coupled pivotably to fence posts such that the panels may pivot, under force of wind, about either their top or bottom end. The panels are restored to generally vertical position by the force of gravity. A counterweight within the fence post linked to the panels can be used to restore panels to their vertical position. In an alternate embodiment, the brackets coupling the panels to the fence posts may slide along the fence posts and the panels bow in response to high winds. The fence panels may include resilient strips along their vertical edges.

U.S. patent application 2008/0023684 (Diamond et al.) discloses a non-metallic fence system that has a singular snap lock mechanism for permitting the easy construction of the fence. It also includes a securing device for fixing a fabric to a fence having a rigid body including at least two prongs therefrom and an open face strut profile capable of receiving the prong therein, wherein the prongs are locked within the open face and the fixture can be removed by twisting 90 degrees.

The following summary is intended to introduce the reader to the disclosure provided herein but not to define any invention. In general, this disclosure describes one or more methods or apparatuses related to injection drive units in injection molding machines.

According to one aspect, a fence system includes a first extruded lineal extending lengthwise along a first longitudinal axis. The first lineal has a sidewall with at least a first slot in the sidewall and the first slot extends generally perpendicular to the longitudinal axis. The fence system also includes a second extruded lineal extending lengthwise along a second longitudinal axis. The second extruded lineal includes at least a corresponding first attachment leg extending outward from the second extruded lineal and parallel to the second longitudinal axis. The first attachment leg is integrally extruded with the second extruded lineal and is received in the first slot to secure together the first and second extruded lineals.

According to some aspects, a fence section comprises: a) a generally horizontal first rail having an upper face with a first panel recess extending lengthwise along the first rail and extending laterally between opposed first recess sidewalls, the first rail including a first tongue extending laterally from one towards the other of the first recess sidewalls and lengthwise along the first rail; b) a generally horizontal second rail spaced vertically above the first rail and having a lower face with a second panel recess extending lengthwise along the second rail and extending laterally between opposed second slot sidewalls, the second rail including a second tongue extending laterally from one towards the other of the second recess sidewalls and lengthwise along the second rail; and c) a plurality of vertical members extending generally vertically between the first rail and the second rail, each vertical member having a panel height extending between upper and lower ends of the panel and a panel thickness extending laterally between opposed front and back panel faces, the lower end of each vertical member being received in the first panel recess and the upper end of each vertical member being received in the second panel recess. Each vertical member has a constant cross-sectional panel profile along the panel height, and each vertical member includes a lower slot and an upper slot extending horizontally across a width of the vertical member and lengthwise of the rail, the lower slot receiving the first tongue therein and the upper slot receiving the second tongue therein.

In some examples, the vertical members can be in the form of fence panels, pickets, boards, or slats. The vertical members and/or the rails can, in some examples, be formed of plastic and can be injection molded.

In some examples, each vertical member comprises an extruded lineal, made of, for example, but not limited to, a plastic material. The upper and lower slots can comprise cuts (for example, saw cuts) or a similar material-removal feature in the lineals. The slots can be parallel to, and spaced equally apart from, the upper and lower edges of panels.

In some examples, the rails can comprise extruded lineals. The rails can have a constant cross-sectional profile along their length. The rails can be made of a plastic material. Each of the rails, including, for example, the first and second rails and an optional third rail can have a common rail profile. In other words, a length of extruded lineal having the common rail profile can be used as any one of the first, second, or third rails.

According to some aspects, a fence section, comprises: a) a generally horizontal lower rail having an upper face with a lower panel recess extending lengthwise along the first rail and extending laterally between opposed first and second lower recess sidewalls, the lower rail including a lower rail first tongue extending laterally from the first lower recess sidewall towards the second lower recess sidewall and lengthwise along the lower rail, and a lower rail second tongue extending laterally from the second lower recess sidewall towards the first lower recess sidewall and lengthwise along the lower rail; b) a generally horizontal upper rail spaced vertically above the lower rail and having a lower face with an upper panel recess extending lengthwise along the upper rail and extending laterally between opposed first and second upper recess sidewalls, the upper rail including an upper rail first tongue extending laterally from the first upper recess sidewall towards the second upper recess sidewall and lengthwise along the upper rail, and a upper rail second tongue extending laterally from the second upper slot sidewall towards the first upper slot sidewall and lengthwise along the upper rail; and c) a plurality of fence panels extending generally vertically between the lower rail and the upper rail, each fence panel having a panel height extending between upper and lower ends of the panel and a panel thickness extending laterally between opposed front and back panel faces, the lower end of each fence panel being received in the lower panel recess and the upper end of each fence panel being received in the upper panel recess. Each fence panel has a constant cross-sectional panel profile along the panel height, and each fence panel includes a first and a second lower groove and a first and a second upper groove extending horizontally across a width of the fence panel and lengthwise of the rail, the first lower groove receiving the lower rail first tongue therein, the second lower groove receiving the lower rail second tongue therein, the first upper groove receiving the upper rail first tongue therein, the second upper groove receiving the upper rail second tongue therein.

In some examples, the front and/or back faces of fence panel can comprise one or more vertical channels extending along the height of the panel. The channel(s) can give the illusion that each panel comprises a plurality of slats. Each channel can comprise a channel face, and opposed lateral faces. The channel can have the same depth as each of the grooves, and each tongue can abut the channel face(s).

In some examples, each fence panel is provided with cooperating male and female engagement elements, such that each fence panel may be connected to one or more other fence panels. The male and female engagement elements can be configured such that when a male engagement element is inserted into a female engagement element, the joint provides the appearance of a channel. For example, each female engagement element can comprise opposed walls, between which the male engagement element is inserted. The opposed walls can be provided at a distance from the front and back faces of the panel, respectively, that is equal to the depth of the channel(s), and the width of each opposed walls can be equal to the width of the channel face.

In some examples, the first and second lower tongues and the first and second upper tongues are joined to the first and second upper and lower slot sidewalls, respectively, at a vertical position generally at the outer ends of the first and second upper and lower sidewalls. In other examples, the first and second lower tongues and the first and second upper tongues are joined to the first and second upper and lower slot sidewalls, respectively, at a vertical position spaced from the outer ends of the first and second upper and lower sidewalls.

According to some aspects, a connection structure for a fence comprises a first extruded lineal extending lengthwise along a first longitudinal axis and having a sidewall with at least a first slot in the sidewall. The first slot extends generally perpendicular to the longitudinal axis. The connection structure also comprises a second extruded lineal extending lengthwise along a second longitudinal axis, the second extruded lineal including at least a corresponding first attachment leg extending outward from the second extruded lineal and parallel to the second longitudinal axis. The first attachment leg can be integrally extruded with the second extruded lineal and is received in the first slot to secure together the first and second extruded lineals.

In some examples, the first extruded lineal comprises a second slot parallel to, and spaced apart from, the first slot, and the second extruded lineal comprises a corresponding second attachment leg parallel to the first attachment leg and received in the second slot.

In some examples, each slot comprises an opening through one sidewall. Each opening may have opposed slot edge faces and opposed slot end faces. Each slot edge face and each slot end face may extend laterally from an outer surface of the sidewall to an inner surface of the sidewall.

In some examples, the slot edge faces are parallel to each other.

In some examples, the slot edge faces are oblique relative to the first longitudinal axis.

In some examples, each attachment leg comprises a distal portion spaced apart from the second extruded lineal and a barb extending from the distal portion. Each barb may comprise an abutment surface that bears against the inner surface of the sidewall adjacent the respective slot into which the attachment leg is received for retaining the attachment leg within the slot when the attachment leg is fully inserted into the respective slot.

In some examples, the second extruded lineal comprises a base surface. Each attachment leg may extend from the base surface. The base surface may oppose the abutment service and be spaced apart from the abutment surface by a distance greater than a thickness of the first extruded lineal sidewall.

In some examples, the slot end faces are spaced apart by a first width and the attachment leg received within each slot has a second width. The second width may be generally equal to the first width so that translation of the first extruded lineal relative to the second extruded lineal along the second longitudinal axis is inhibited when the attachment leg is received within the slot.

In some examples, each barb comprises at least one resilient retaining member. The at least one resilient member may be moveable between insertion and retention positions. When the at least one resilient retaining member is in the insertion position the barb can pass between the slot edge faces, and when the at least one resilient retaining member is in the retention position the barb is inhibited from passing between the slot edge faces.

In some examples, the at least one resilient retaining member comprises the abutment face.

According to some aspects, a fence section comprises an upper horizontal rail and a lower horizontal rail extending along respective upper and lower rail axes. The lower rail is spaced vertically below the upper horizontal rail. Each of the rails can comprise a respective extruded lineal including integrally formed attachment legs. The fence section can further comprise a plurality of vertical members each extending between the upper and lower horizontal rails. Each of the vertical members comprises at least one upper slot and at least one lower slot. At least portions of the attachment legs of the upper and lower rails are received within respective ones of the slots to secure each vertical member to the upper and lower horizontal rails.

In some examples, each of the vertical members extends along a respective vertical axis. The upper and lower slots may be generally elongated in a lateral direction generally perpendicular to the vertical axis, and the slots may be generally narrow in the vertical direction. The upper and lower slots can each have a slot length extending generally perpendicular to the vertical axis, and a slot thickness extending in the vertical direction. The slot thickness can be less than the slot length. In some examples, the slot thickness can be only a fraction of the slot length, for example only about one-fifth, or about one-tenth, or about one-fifteenth, or less than about one-twentieth of the slot length.

In some examples, the upper and lower slots can form an opening through a sidewall of each vertical member. Each opening may comprise opposed slot edge faces and opposed slot end faces. Each slot edge face and each slot end face may extend laterally from an outer surface of the sidewall to an inner surface of the sidewall.

In some examples, the slot edge faces are parallel to each other.

In some examples, the slot edge faces are oblique relative to the outer surface of the sidewall.

In some examples, the slot end faces are parallel to each other and are spaced apart by a slot length and the slot edge faces are spaced apart by a slot height.

In some examples, each attachment leg comprises opposing attachment leg end faces spaced apart by an attachment leg length. The attachment leg length may be less than the slot length of the corresponding slot.

In some examples, each attachment leg includes a barb. Each barb may comprise an abutment surface that bears against the inner surface of the sidewall adjacent the respective corresponding slot, into which the attachment leg is received when the attachment leg is fully inserted into its slot.

In some examples, the upper and lower rails each comprise a base surface. Each attachment leg may extend from one base surface. Each base surface may oppose the abutment surfaces of the attachment legs extending therefrom, and may be spaced apart from the abutment surfaces by a distance greater than a thickness of the sidewall.

In some examples, each barb has a generally wedge-shaped cross-section comprising a leading edge spaced apart from its abutment surface so that the each barb facilitates insertion of the attachment leg into its slot and resists removal of the attachment leg from its slot.

In some examples, each attachment leg is resiliently moveable between a first position for inserting the attachment leg and barb through the respective slot and a second position for retaining the attachment leg within the respective slot. In the second position the abutment surface may engage the inner surface of the sidewall, and the attachment leg may be biased toward the second position.

In some examples, each barb comprises at least one resilient retaining member. The at least one resilient member may be moveable between insertion and retention positions. When the at least one resilient retaining member is in the insertion position, the barb has a barb height that is less than the slot height. When the at least one resilient retaining member is in the retention position, the barb has a barb height that is greater than the slot height.

In some examples, each resilient retaining member is biased toward the retention position.

In some examples, the resilient retaining member comprises the abutment surface. When the attachment leg is fully inserted in its slot and the resilient retaining member is in the retention position, the abutment surface may engage the inner surface of the sidewall.

In some examples, each attachment leg further comprises a protrusion. The protrusion may extend away from the attachment leg and may be intermediate the resilient retaining member and the base surface.

In some examples, each the protrusion has a protrusion height that can be less than the slot height.

In some examples, each protrusion is registered with one slot edge face when the attachment leg is fully received in its slot to inhibit vertical displacement between the vertical members and upper and lower rails.

In some examples, both horizontal rails have a common extruded profile comprising a downward opening, generally C-shaped channel. The channel may have a horizontal upper wall and first and second vertical, laterally spaced apart, integrally formed rail sidewalls. The profile may define an internal cavity between the rail sidewalls and adjacent the upper wall.

In some examples, the upper wall of each horizontal rail comprises a plurality of apertures spaced apart along the length of the rail. The apertures in the upper horizontal rail may be aligned with corresponding apertures in the lower horizontal rail and each vertical member may pass through respective aligned ones of the apertures in the upper and lower horizontal rails.

In some examples, each vertical member extends beyond the upper wall of the upper horizontal rail and extends beyond a bottom edge of the sidewalls of the lower horizontal rail.

In some examples, the attachment legs include laterally opposed first and second attachment legs extending inwardly towards each other from the first and second sidewalls respectively.

In some examples, each vertical member comprises a set of opposing upper slots and a set of opposing lower slots formed in opposing sidewalls of the vertical member for receiving the first and second opposed attachment legs of the upper and lower rails respectively.