US20090321698A1

US20090321698A1 - Panel Fence System and Method

Info

Publication number: US20090321698A1
Application number: US12/495,467
Authority: US
Inventors: John F. Payne
Original assignee: Payne Fence Products LLC
Current assignee: Payne Fence Products LLC
Priority date: 2008-06-30
Filing date: 2009-06-30
Publication date: 2009-12-31
Also published as: WO2010002866A1

Abstract

In certain embodiments, a fence system includes a support member and a rail attached to the support member such that the rail extends across the support member. The fence system further includes a first panel and a second panel each comprising a primary panel portion having a first edge and a second edge. A first flange is located along at least a portion of the first edge of the primary panel portion, and a second flange is located along at least a portion of the second edge of the primary panel portion. The first and second panels are secured to the rail such that the second edge of the primary panel portion of the first panel is adjacent to the first edge of the primary panel portion of the second panel. The second flange of the first panel is matingly coupled to the first flange of the second panel.

Description

RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of the priority of U.S. Provisional Application No. 61/076,973, filed Jun. 30, 2008, entitled “Metal Panel Fence System, and Method Therefor.”

TECHNICAL FIELD

This invention relates generally to fence systems and more particularly to a panel fence system and method.

BACKGROUND

It is often desirable or even necessary to prevent people from crossing boundaries, such as a perimeter of privately-owned real estate or another key asset. Free-standing fences may be used to attempt to prevent people from crossing these boundaries. Conventional fences may include, for example, chain link fencing and barbed wire fencing.

SUMMARY

According to embodiments of the present invention, disadvantages and problems associated with previous fence systems may be reduced or eliminated.
In certain embodiments, a fence system includes a support member and a rail attached to the support member such that the rail extends across the support member. The fence system further includes a first panel and a second panel each comprising a primary panel portion having a first edge and a second edge. A first flange is located along at least a portion of the first edge of the primary panel portion, and a second flange is located along at least a portion of the second edge of the primary panel portion. The first and second panels are secured to the rail such that the second edge of the primary panel portion of the first panel is adjacent to the first edge of the primary panel portion of the second panel. The second flange of the first panel is matingly coupled to the first flange of the second panel.
Particular embodiments of the present invention may provide one or more technical advantages. Conventional fences for preventing movement across a particular boundary may include, for example, chain link fencing and barbed wire fencing. Certain individuals attempting to cross the particular boundary may attempt to breach these conventional fences in a number of ways, such as by climbing over the fence, cutting through the fence (e.g., using a saw, axe, or torch), or disassembling one or more exposed fasteners securing portions of the fence. For various reasons, these conventional fences may be ineffective in preventing these attempted breaches. Certain other conventional fences, such as those made of concrete, bricks, and/or stone, may be less susceptible to breach, but these alternative conventional fences may be prohibitively expensive to construct along boundaries of significant length.
The fence system of the present invention may include a number of panels forming a substantially continuous wall that is less susceptible to breach relative to certain conventional fences. In certain embodiments, the fence system of the present invention may reduce or eliminate hand and foot holds. Thus, the fence system of the present invention may be less susceptible to being breached by an individual attempting to climb over the fence system relative to certain conventional fences. In certain embodiments, the fence system of the present invention provides a substantially continuous wall. Thus, the fence system of the present invention may be less susceptible to being breached by an individual attempting to cut through it (e.g., using a saw, axe, or torch), as compared to certain conventional fences. In certain embodiments, the fence system of the present invention is assembled such that all fasteners are located on one side of the fence system (e.g., the “back side” on which the posts and rails are located). Furthermore, the fence system of the present invention may be oriented such that the back side of the fence system is on the secure side of a boundary other side of the fence system (the “attack side”) is on the non-secure-side of the boundary. Thus, the fence system of the present invention may be assembled and/or repaired from the secure side of the boundary and may be less susceptible to being breached by an individual attempting to disassemble the fence system from the non-secure side of the boundary.
Additionally, the fence system of the present invention may not be prohibitively expensive to construct along boundaries of significant length. Thus, the fence system of the present invention may potentially be a more cost effective solution for certain applications. Furthermore, the fence system of the present invention may be less susceptible to damage than certain conventional fences (e.g., those made of concrete, bricks, metal, and/or stone), such as damage resulting from high winds and/or soil movement.
Certain embodiments of the present invention may include some, all, or none of the above advantages. One or more other technical advantages may be readily apparent to those skilled in the art from the figures, descriptions, and claims included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

To provide a more complete understanding of the present invention and the features and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings, in which:

FIGS. 1A-1E illustrate an example panel fence system, according to certain embodiments of the present invention;

FIGS. 2A-2B illustrate an example configuration of a panel fence system constructed along a boundary having varying slope, according to certain embodiments of the present invention;

FIG. 3 illustrates an example rail hanger of the panel fence system illustrated in FIG. 1, according to certain embodiments of the present invention;

FIGS. 4A-4D illustrate example alternative configurations of a panel of the panel fence system illustrated in FIG. 1, according to certain embodiments of the present invention; and

FIG. 5 illustrates an example method for constructing a panel fence system, according to certain embodiments of the present invention.

DESCRIPTION OF EXAMPLE EMBODIMENTS

FIGS. 1A-1E illustrate an example panel fence system 100, according to certain embodiments of the present invention. Fence system 100 may include a number of support members 102 (referred to throughout the remainder of this description as posts 102 for simplicity) and a number of rails 104. Each rail 104 may be attached to at least one post 102 such that the rail 104 extends across the at least one post 102 to which it is attached. Fence system 100 may also include a number of panels 106 each secured to one or more rails 104.
In general, fence system 100 may deter and/or substantially prevent movement across a particular boundary. Example boundaries include perimeters of critical assets, perimeters of privately-owned real estate, national borders, or any other suitable boundaries. Certain individuals attempting to cross the particular boundary may attempt to breach fence system 100 in a number of ways, such as by climbing over fence system 100, cutting through fence system 100 (e.g., using a saw, axe, or torch), or attempting to remove panels 106 of fence system 100. Because panels 106 may be secured to rails 104 such that hand and foot holds may be reduced or eliminated, fence system 100 may be less susceptible to being breached by an individual attempting to climb over it relative to certain conventional fences. Additionally, because panels 106 may be secured to rails 104 such that panels 106 form a substantially continuous wall, fence system 100 may be less susceptible to being breached by an individual attempting to cut through it relative to certain conventional fences. Additionally, because panels 106 may be secured to rails 104 such that all fasteners are located on one side (the “back side”) of the fence system, fence system 100 may be less susceptible to being breached by an individual attempting to remove panels 106 of fence system 100 relative to certain conventional fences. Thus, in certain embodiments, fence system 100 may be more effective in preventing movement across a particular boundary relative to certain conventional fences.
Posts 102 may be constructed from aluminum, iron, stainless steel, galvanized steel, brass, plastic, or any other suitable material. Furthermore, posts 102 may have any suitable size and shape. For example, posts 102 may be constructed from tubing material of any desired cross section (e.g., rectangular, round, elliptical), solid material of any desired cross section (e.g., rectangular, round, elliptical), channel material, angle iron, I-beam, or any other suitable material. Furthermore, posts 102 may be any suitable length (e.g., four, eight, or twenty feet). As a particular example, posts 102 may be constructed from a twenty-foot length of galvanized steel round tubing. Although fence system 100 is illustrated and primarily described as including a particular number of posts 102, the present invention contemplates fence system 100 including any suitable number of posts 102, according to particular needs.
Posts 102 of fence system 100 may be anchored in the ground (e.g., using concrete 108). In certain embodiments, posts 102 are anchored in the ground such that they are substantially vertical (and, as a result, substantially parallel with one another) regardless of ground slope (as illustrated in FIGS. 2A-2B, described below). Furthermore, the distance between any two adjacent posts 102 (e.g., post 102 a and post 102 b) may be any suitable distance (e.g., ten feet), and may vary from post 102 to post 102 if appropriate.
Rails 104 may be constructed from aluminum, iron, stainless steel, galvanized steel, brass, plastic, or any other suitable material. Furthermore, rails 104 may have any suitable size and shape. For example, rails 104 may be constructed from tubing material of any desired cross section (e.g., rectangular, round, elliptical), solid material of any desired cross section (e.g., rectangular, round, elliptical), channel material, angle iron, I-beam, or any other suitable material. Furthermore, rails 104 may be any suitable length (e.g., four, eight, or twenty feet). As a particular example, rails 104 may be constructed from a twenty foot length of galvanized steel square tubing. Although fence system 100 is illustrated and primarily described as including a particular number of rails 104, the present invention contemplates fence system 100 including any suitable number of rails 104, according to particular needs.
Rails 104 of fence system 100 may each be attached to one or more posts 102. In certain embodiments, a rail 104 may each be attached to a post 102 such that the rail 104 is coupled directly to post 102. For example, the rail 104 may be coupled directly to the post 102 using one or more fasteners, such as screws, bolts, rivets, or any other suitable attachment fasteners. As an additional example, the rail 104 may be coupled directly to post 102 such that the rail 104 is physically connected to the post 102 (e.g., using a weld).
In certain other embodiments, a rail 104 may be attached to a post 102 such that the rail 104 is coupled to the post 102 using a bracket component, such as a rail hanger 110. Rail hanger 110 may include a clamp 112 configured to be attached to a post 102 and a bracket 114 configured to be attached to a rail 104. The bracket 114 may be either physically attached to the clamp 112 (e.g., using a weld) or attached to the clamp 112 using a fastener (e.g., a screw, bolt, rivet, or any other suitable fastener). In certain embodiments, the clamp 112 is attached to a post 102, and a rail 104 is attached to the bracket 114 (either physically attached or attached using a fastener). Thus, rail hanger 110 is adapted to attach the rail 104 to the post 102.
Clamps 112 may include any conventional clamp that may be attached to a post 102, such as by tightening a nut 116 of a clamp bolt 118. In certain embodiments, a clamp 112 may have a size and/or shape that corresponds to the size and/or shape of the post 102 to which the clamp 112 is to be attached. For example, a clamp 112 of a rail hanger 110 to be attached to a round post 102 may include a circular metal band having an inner diameter slightly smaller than the outer diameter of the post 102 to which the rail hanger is to be attached such that the claim 112 may be attached to the post 102 by tightening a nut 116 of a clamp bolt 118 (as illustrated in FIG. 3, described below).
Although particular configurations of rails 104 and rail hangers 110 are illustrated and primarily described, rails 104 and rail hangers 110 may be configured in any of a number of ways.
Panels 106 of fence system 100 may be constructed from aluminum, iron, stainless steel, galvanized steel, brass, plastic, or any other suitable material. As a particular example, panels 106 may be constructed from rolled seven-gauge steel.
In certain embodiments, each panel 106 includes a primary panel portion 120 having a first edge 126 and a second edge 128. Each panel 106 may further include a first flange 122 located along a first edge 126 of the primary panel portion 120 and a second flange 124 located along a second edge 128 of the primary panel portion 120.
Each of the panels 106 of fence system 100 is adapted to be secured to one or more rails 104 such that the first flange 122 and second flange 124 of each panel 106 matingly couple with flanges of adjacent panels 106. More particularly, the first flange 122 of a particular panel 106 may be configured to matingly couple with a second flange 124 of a first adjacent panel 106, and the second flange 124 of the particular panel 106 may be configured to matingly couple with a first flange 122 a second adjacent panel 106 (as described below). As a result, the primary panel portions 120 of the number of panels 106 of fence system 100, when secured to one or more rails 104, may form a substantially continuous wall. Furthermore, because the primary panel portions 120 of panels 106 may form a substantially continuous wall, panels 106 may further include a plurality of apertures 132 that may facilitate visibility through the substantially continuous wall.
Although primary panel portions 106 of panels 106 are described as forming a substantially continuous wall, in certain applications there may be gaps between adjacent edges of primary panel portions 120 of adjacent panels 106. As described in further detail below with respect to FIGS. 2A-2B, an advantage of certain embodiments of the present invention is that the gaps between adjacent edges of primary panel portions 120 of adjacent panels 106 may not pass through fence system 100 as adjacent flanges of the adjacent panels 106 may be matingly coupled such that adjacent flanges close the gap between the adjacent edges.
Panels 106 may be secured to one or more rails 104 using one or more fasteners, such as a screws, bolts, rivets, staples, or any other suitable fasteners. As a particular example, a panel 106 may be secured to one or more rails 104 using a bolt (e.g., bolt 130 a illustrated in FIG. 1C). In certain other embodiments, a panel 106 is secured to a rail 104 by physically joining the panel 106 to the rail 104 (e.g. by welding the panel 106 to the rail 104 or “clinching” the panel 106 to the rail 104). As a particular example, a panel 106 may be clinched the panel 106 to a rail 104 using and a TOG-L-LOC® sheet metal joining system manufactured by BTM CORPORATION (e.g., clinch point 130 b, illustrated in FIG. 1C).
As a particular example, panel 106 g may be secured to one or more rails 104 (e.g., using a fastener or physically joined) such that panel 106 g is adjacent to panel 106 f and panel 106 h (as illustrated in FIGS. 1A-1C). Furthermore, panel 106 g may be oriented with respect to panel 106 f such that first edge 126 g is adjacent to second edge 128 f and first flange 122 g is matingly coupled to second flange 124 f. Additionally, panel 106 g may be oriented with respect to panel 106 h such that second edge 128 g is adjacent to first edge 126 h and second flange 124 g is matingly coupled to first flange 122 h. Thus, the primary panel portions 120 e-120 g of panels 106 e-106 g may form a substantially continuous wall.
In certain embodiments (as illustrated in FIGS. 1D-1E), the first flange 122 of each panel 106 includes a protrusion 122′ extending from the first edge 126 of the primary portion 120 of the panel 106, and a tab 122″ extending from the protrusion 122′. As a particular example, the protrusion 122′ of a first flange 122 of a panel 106 may extend in a direction substantially perpendicular to the primary panel portion 120 of the panel 106, and the second portion 122″ of the first flange 122 may extend in a direction substantially parallel to the primary panel portion 120 of the panel 106. Additionally, in certain embodiments (illustrated in FIGS. 1D-1E), the second flange 124 of each panel 106 includes a protrusion 124′ extending from the second edge 128 of the primary portion 120 of the panel 106 and a tab 124″ extending from the protrusion 124′. As a particular example, the protrusion 124′ of the second flange 124 of a panel 106 may extend in a direction substantially perpendicular to the primary panel portion 120 of the panel 106 and the tab 124″ of the second flange 124 of the panel 106 may extend in a direction substantially parallel to the primary panel portion 120 of the panel 106 (and in the same direction relative to the primary panel portion 120 of the panel 106 as the second portion 122″ of the first flange 122 of the panel 106).
Furthermore, the first flange 122 of a particular panel 106 may be configured to matingly couple with a second flange 124 of a first adjacent panel 106 such that the tab 122″ of the first flange 122 of the particular panel 106 is substantially parallel with the tab 124″ of the second flange 124 of the first adjacent panel 106. The tabs 122″ and 124″ may also be substantially parallel to a rail 104 such that the particular panel 106 and the first adjacent panel 106 may be secured to the rail 104 at a single point using a single fastener. For example, the rail 104 may be attached to tabs 122″ and 124″ using a single bolt 130 a passing through rail 104, tab 122″, an tab 124″. As an additional example, in embodiments in which rail 104 is constructed of a channel, a TOG-L-LOC® sheet metal joining system (described above) may be inserted into the opening defined by the channel such that rail 104 may be attached to tabs 122″ and 124″ using a clinch point 130 b.
Similarly. the second flange 124 of the particular panel 106 may be configured to matingly couple with a first flange 122 of a second adjacent panel 106 such that the tab 124″ of the second flange 124 of the particular panel 106 is substantially parallel with the tab 122″ of the first flange 122 of the adjacent panel 106. The tabs 124″ and 122″ may also be substantially parallel to the rail 104 such that the particular panel 106 and the second adjacent panel 106 may be secured to the rail 104 at a single point using a single fastener. For example, the rail 104 may be attached to tabs 124″ and 122″ using a single bolt 130 a passing through rail 104, tab 124″, an tab 122″. As an additional example, in embodiments in which rail 104 is constructed of a channel, a TOG-L-LOC® sheet metal joining system (described above) may be inserted into the opening defined by the channel such that rail 104 may be attached to tabs 124″ and 122″ using a single clinch point 130 b.
Although adjacent panels 106 are capable of being secured to a rail 104 at a single point (as described above), the present invention contemplates adjacent panels being secured to the rail 104 at any suitable number of points, according to particular needs.
As a particular example, in the above-described example in which panel 106 g is secured to a rail 104 such that panel 106 g is adjacent to panel 106 f and panel 106 h, panels 106 f-106 h may each include a first flange 122 having a protrusion 122′ and tab 122″ and a second flange 124 having a protrusion 124′ and a tab 124″ (as described above).
Furthermore, first flange 122 g of panel 106 g may be matingly coupled with second flange 124 f of panel 106 f such that:

- protrusion 122 g′ of first flange 122 g is adjacent to protrusion 124 f′ of second flange 124 f; and
- tab 122 g″ of first flange 122 g is adjacent to and substantially parallel with tab 124 f″ of second flange 124 f.

In certain embodiments (e.g., embodiments in which panel 106 f and panel 106 g are oriented at substantially the same angle, as illustrated in FIGS. 1A-1C), protrusion 122 g′ of first flange 122 g may be substantially parallel with protrusion 124 f′ of second flange 124 f. In certain other embodiments (e.g., embodiments in panel 106 f and panel 106 g are oriented at different angles, as illustrated in FIGS. 2A-2C) protrusion 122 g′ of first flange 122 g may not be substantially parallel with protrusion 124 f′ of second flange 124 f
Additionally, tab 122 g″ of first flange 122 g and tab 124 f″ of second flange 124 f, in addition to being substantially parallel with one another, may also be substantially parallel with the rail 104 to which panels 106 f and 106 g are attached (or tangent to the rail 104 in embodiments in which the rail 104 is round) such that tabs 122 g″ and 124 f″ (and, as a result, panels 106 f and 106 g) may be attached to one another as well as the rail 104 at a single point using a single fastener. For example, tabs 122 g″ and 124 f″ may be attached to rail 104 using a single bolt 130 a passing through rail 104, tab 122 g″, and 122 f″. Alternatively, in embodiments in which rail 104 is constructed of a channel, a TOG-L-LOC® sheet metal joining system (described above) may be inserted into the opening defined by the channel such that rail 104 may be attached to tabs 122 g″ and 124 f″ using a single clinch point 130 b.
Similarly, second flange 124 g of panel 106 g may be matingly coupled with first flange 122 h of panel 106 h such that:

- protrusion 124 g′ of second flange 124 g is adjacent to protrusion 122 h′ of first flange 122 h; and
- tab 124 g″ of second flange 124 g is adjacent to and substantially parallel with tab 122 h″ of first flange 122 h.

In certain embodiments (e.g., embodiments in panel 106 g and panel 106 h are oriented at the same angle, as illustrated in FIGS. 1A-1C), protrusion 124 g′ of second flange 124 g may be substantially parallel with protrusion 122 h′ of first flange 122 f. In certain other embodiments (e.g., embodiments in panel 106 g and panel 106 h are oriented at different angles, as illustrated in FIGS. 2A-2C) protrusion 124 g′ of second flange 124 g may not be substantially parallel with protrusion 122 h′ of first flange 122 h.
Additionally, tab 124 g″ of second flange 124 g and tab 122 h″ of first flange 122 h, in addition to being substantially parallel with one another, may be substantially parallel with the rail 104 to which panels 106 g and 106 h are attached (or tangent to the rail 104 in embodiments in which the rail is round) such that panels 106 g and 106 h may be attached to the rail 104 at a single point. For example, tabs 122 g″ and 124 f″ may be attached to rail 104 using a single bolt 130 a passing through rail 104, tab 122 g″, and 122 f″. Alternatively, in embodiments in which rail 104 is constructed of a channel, a TOG-L-LOC® sheet metal joining system (described above) may be inserted into the opening defined by the channel such that rail 104 may be attached to tabs 122 g″ and 124 f″ using a clinch point 130 b.
Securing adjacent panels 106 to a rail 104 using tabs of matingly coupled flanges of the adjacent panels 106 (as described above) may allow fence system 100 to be constructed and/or repaired from a single side (i.e., the side on which posts 102 and rails 104 are located), which may be important in applications in which fence system 100 is constructed along a secure boundary. Additionally, in embodiments in which a fastener (e.g., bolt 130 a) is used to secure the tabs of the flanges of adjacent panels 106 to a rail 104, securing adjacent panels 106 to a rail 104 using tabs of the matingly coupled flanges of the adjacent panels 106 (as described above) may prevent the fastener from passing through the primary panel portion 120 of either panel (as illustrated in FIG. 1C), which may reduce the susceptibility of fence system 100 to being breached by an individual attempting remove panels 106 from fence system 100 as well as by an individual attempting to climb over fence system 100 (as a fastener passing through the primary panel portion 120 of a panel may provide a hand or foot hold).
Although panels 106 are illustrated and primarily described above as including primary panel portions 120, first flanges 122, and second flanges 124 each having particular configurations, the present invention contemplates panels 106 comprising primary panel portions 120, first flanges 122, and second flanges 124 having any suitable configurations such that a flange of a first panel 106 is adapted to matingly couple with a flange of an adjacent panel 106 when the panels 106 are secured to one or more rails 104. For example, panels 106 including primary panel portions 120, first flanges 122, and second flanges 124 having example alternative configurations are illustrated in FIGS. 4A-4D, described in further detail below.
Particular embodiments of the present invention may provide one or more technical advantages. Conventional fences for preventing movement across a particular boundary may include, for example, chain link fencing and barbed wire fencing. Certain individuals attempting to cross the particular boundary may attempt to breach these conventional fences in a number of ways, such as by climbing over the fence, cutting through the fence (e.g., using a saw, axe, or torch), or disassembling one or more exposed fasteners securing portions of the fence. For various reasons, these conventional fences may be ineffective in preventing these attempted breaches. Certain other conventional fences, such as those made of concrete, bricks, and/or stone, may be less susceptible to breach, but these alternative conventional fences may be prohibitively expensive to construct along boundaries of significant length.
Because fence system 100 may include a number of panels 106 forming a substantially continuous wall, fence system 100 may be less susceptible to breach relative to certain conventional fences. In certain embodiments, fence system 100 may reduce or eliminate hand and foot holds. Thus, the fence system 100 may be less susceptible to being breached by an individual attempting to climb over fence system 100 relative to certain conventional fences. In certain embodiments, the fence system 100 provides a substantially continuous wall. Thus, the fence system 100 may be less susceptible to being breached by an individual attempting to cut through it (e.g., using a saw, axe, or torch), as compared to certain conventional fences. In certain embodiments, fence system 100 is assembled such that all fasteners are located on one side of the fence system (e.g., the “back side” on which the posts and rails are located). Furthermore, fence system 100 may be oriented such that the back side of the fence system is on the secure side of a boundary other side of the fence system (the “attack side”) is on the non-secure-side of the boundary. Thus, fence system 100 may be assembled and/or repaired from the secure side of the boundary and may be less susceptible to being breached by an individual attempting to disassemble fence system 100 from the non-secure side of the boundary.
Additionally, fence system 100 may not be prohibitively expensive to construct along boundaries of significant length. Thus, fence system 100 may potentially be a more cost effective solution for certain applications. Furthermore, fence system 100 may be less susceptible to damage than certain conventional fences (e.g., those made of concrete, bricks, metal, and/or stone), such as damage resulting from high winds and/or soil movement.
Although a particular implementation of fence system 100 is illustrated and primarily described, the present invention contemplates any suitable implementation of fence system 100 according to particular needs. Although a particular number components of fence system 100 have been illustrated and primarily described above, the present invention contemplates fence system 100 including any suitable number of such components.
FIGS. 2A-2B illustrates an example configuration of a panel fence system 100 constructed along a boundary having varying slope, according to certain embodiments of the present invention. In the illustrated configuration, a number of posts 102 are anchored in the ground (e.g., using concrete 108) such that they are substantially vertical (and, as a result, substantially parallel with one another) regardless of ground slope. Additionally, a number of rails 104 are coupled to the one or more of the posts 102 (e.g., using rail hangers 110, as described above). Each rail 104 may extends across the one or more posts 102 to which it is attached and may be oriented generally parallel to the ground at the location along the boundary at which it is installed.
A number of panels 106 may each be secured to the rails 104. Furthermore, each panel 106 may be oriented substantially perpendicular to the ground at the point along the boundary at which it is located. As a result, adjacent panels 106 may be oriented at different angles such that a gap exists between adjacent edges of the primary panel portions 120 of the adjacent panels 106 (e.g., gap 134 between primary portions 120 a and 120 b of adjacent panels 106 a and 106 b, described below). Furthermore, the gap between adjacent edges of primary panel portions 120 of adjacent panels 106 may vary in width, the variance in width corresponding to the difference in the angles at which the adjacent panels 106 are oriented.
The gap between the adjacent edges of the first portions 120 of the adjacent panels 106, however, may not pass through fence system 100, as adjacent flanges of the adjacent panels 106 may be matingly coupled such that adjacent flanges close the gap between the adjacent edges. In other words, adjacent flanges of adjacent panels 106 may permit a certain degree of “fanning” between the panels such that fence system 100 may be installed along a boundary having varying ground slope.
As a particular example, adjacent panels 106 a and 106 b may each be secured to rails 104 such that second flange 124 a of panel 106 a is matingly coupled to first flange 122 b of panel 106 b. More particularly, second flange 124 a of panel 106 a may be matingly coupled with first flange 122 a of panel 106 a such that protrusion 124 a′ of second flange 124 a is adjacent to protrusion 122 b′ of first flange 122 b and tab 124 g″ of second flange 124 g is adjacent to and substantially parallel with tab 122 h″ of first flange 122 h, as described above. Because the severity of the ground slope is greater at the point at which panel 106 b is located than at the point at which panel 106 a is located, panel 106 a may be oriented at an angle relative to horizontal that is smaller than the angle relative to horizontal at which panel 106 b is oriented. As a result, there may be a gap 134 between second edge 128 a of panel 106 a and first edge 126 b of panel 106 b, gap 134 being widest at the point nearest the ground.
Tab 124 a″ of second flange 124 a of panel 106 a, however, may be sufficiently wide as to close gap 134. In other words, tab 124 a″ may be at least slightly wider that the widest portion of gap 134 (i.e., the point nearest the ground) such that at least a portion of tab 124 a″ overlaps at least a portion of tab 122 b″ of first flange 122 b of panel 106 b at all points along the adjacent edges 128 a and 126 b of panels 106 a and 106 b.
Thus, assuming that fence system 100 is to be installed such that there are no gaps (i.e., all gaps between adjacent edges of primary portions 120 of adjacent panels 106 are filled, as described above), the width of tabs 124″ of second flanges 124 of panels 106 may define the maximum variation in orientation angle between adjacent panels 106 (i.e., the degree of fanning that is permitted between adjacent panels 106). Furthermore, the maximum variation in orientation angle between adjacent panels 106 may define the maximum variation in ground slope over which fence system 100 may be installed. Stated differently, by increasing the width of tabs 124″ of second flanges 124 of panels 106, fence system 100 may be adapted to traverse terrain with greater variations in ground slope.
Additionally, because panels 106 are oriented substantially perpendicular with the ground (as opposed to, for example, substantially parallel with posts 108), the top of fence system 100 may be a generally continuous smooth curve as fence system 100 traverses a boundary of varying ground slope.
FIG. 3 illustrates an example rail hanger 110 of the panel fence system 100 illustrated in FIG. 1, according to certain embodiments of the present invention. Rail hanger 110 may include a clamp 112 configured to be attached to a post 102 and a bracket 114 configured to be attached to a rail 104. The bracket 114 may be either physically attached to the clamp 112 (e.g., using a weld) or attached to the clamp 112 using a fastener (e.g., a screw, bolt, rivet, or any other suitable fastener). In certain embodiments, the clamp 112 is attached to a post 102, and a rail 104 is attached to the bracket 114 (either physically attached or attached using a fastener). Thus, rail hanger 110 is adapted to attach the rail 104 to the post 102.
Clamps 112 may include any conventional clamp that may be attached to a post 102, such as by tightening a nut 116 of a clamp bolt 118. In certain embodiments, a clamp 112 may have a size and/or shape that corresponds to the size and/or shape of the post 102 to which the clamp 112 is to be attached. For example, a clamp 112 of a rail hanger 110 to be attached to a round post 102 may include a circular metal band having an inner diameter slightly smaller than the outer diameter of the post 102 to which the rail hanger is to be attached such that the claim 112 may be attached to the post 102 by tightening a nut 116 of a clamp bolt 118.
FIGS. 4A-4D illustrate example alternative configurations of panels 106 of the panel fence system 100 illustrated in FIG. 1, according to certain embodiments of the present invention. Although particular alternative configurations of panels 106 are illustrated and primarily described, the present invention contemplates any suitable configuration of panels 106, according to particular need. Furthermore, the present invention contemplates fence system 100 as including any suitable combination of panels 106 having varying configurations, according to particular needs.
In the configuration illustrated in FIG. 4A, panel 106 includes a primary panel portion 120 protruding outwardly with respect to a first flange 122 and a second flange 124. The primary panel portion 120 may include a first edge 126 and a second edge 128. The first flange 122 may include a protrusion 122′ extending from the first edge 126 and a tab 122″ extending inwardly from the protrusion 122′ such that the primary panel portion 120, protrusion 122′, and tab 122″ form a channel. The second flange 124 may include a protrusion 124′ extending from the second edge 128 and a tab 124″ extending outwardly from the protrusion 124′ in substantially the same direction as tab 122″ extends from the protrusion 122′. Furthermore, protrusion 122′ may be substantially parallel with protrusion 124′ and tab 122″ may be substantially parallel with tab 124″.
In the configuration illustrated in FIG. 4B, panel 106 includes a primary panel portion 120 protruding inwardly with respect to a first flange 122 and a second flange 124. The primary panel portion 120 may include a first edge 126 and a second edge 128. The first flange 122 may include a protrusion 122′ extending from the first edge 126 and a tab 122″ extending from the protrusion 122′ such that the primary panel portion 120, protrusion 122′, and tab 122″ form a channel. The second flange 124 may include a protrusion 124′ extending from the second edge 128 and a tab 124″ extending outwardly from the protrusion 124′ in substantially the same direction as tab 122″ extends from the protrusion 122′. Furthermore, protrusion 122′ may be substantially parallel with protrusion 124′ and tab 122″ may be substantially parallel with tab 124″.
In the configuration illustrated in FIG. 4C, panel 106 includes a generally planar primary panel portion 120, a first flange 122, and a second flange 124. The primary panel portion 120 may include a first edge 126 and a second edge 128. The first flange 122 may include a protrusion 122′ extending from the first edge 126 and a tab 122″ extending inwardly from the protrusion 122′ such that the primary panel portion 120, protrusion 122′, and tab 122″ form a channel. The second flange 124 may include a protrusion 124′ extending from the second edge 128 and a tab 124″ extending inwardly from the protrusion 124′, tab 124″ extending from the protrusion 124′ such that the primary panel portion 120, protrusion 124′, and tab 124″ form a channel. Furthermore, protrusion 122′ may be substantially parallel with protrusion 124′ and tab 122″ may be substantially parallel with tab 124″.
In the configuration illustrated in FIG. 4B, panel 106 includes a generally planar primary panel portion 120, a first flange 122, and a second flange 124. The primary panel portion 120 may include a first edge 126 and a second edge 128. The first flange 122 may include a protrusion 122′ extending from the first edge 126 and a tab 122″ extending outwardly from the protrusion 122′. The second flange 124 may include a protrusion 124′ extending from the second edge 128 and a tab 124″ extending outwardly from the protrusion 124′. Furthermore, protrusion 122′ may be substantially parallel with protrusion 124′ and tab 122″ may be substantially parallel with tab 124″.
FIG. 5 illustrates an example method 500 for constructing a panel fence system 100, according to certain embodiments of the present invention. The method begins at step 502. At step 504, a first post 102 (e.g., post 102 a) may be set in a foundation (e.g., concrete 108) at a first location. At step 506, a second post 102 (e.g., post 102 b) may be set in a second foundation (e.g. concrete 108) at a second location. In certain embodiments, first post 102 a and second post 102 b may be set in the first and second foundations such that they are substantially vertical regardless of ground slope.
As step 508, a first rail 104 (e.g., rail 104 a) may be coupled to first post 102 a and second post 102 b such that rail 104 a extends across first post 102 a and second post 102 b. At step 510, a second rail 104 (e.g., rail 104 b) may be coupled to first post 102 a and second post 102 b such that rail 102 b extends across first post 102 a and second post 102 b. At step 512, a third rail 104 (e.g., rail 104 c) may be coupled to first post 102 a and second post 102 b such that rail 104 c extends across first post 102 a and second post 102 b. Each rail 104 may be coupled to each post using a rail hanger 110, as described above. In certain embodiments, rails 104 a-104 c may each be attached to posts 102 a-102 b such that rails 104 a-104 c are substantially parallel to the ground.
At step 514, a first panel 106 (e.g., panel 106 f) may be positioned on rails 104 a-104 c, panel 106 f comprising a primary panel portion 120 f having a first edge 126 f and a second edge 128 f. Panel 106 f may also comprise a first flange 122 f located along first edge 126 f and a second flange 124 f located along the second edge 128 f.
At step 516, a second panel 106 (e.g., panel 106 g) may be positioned on rails 104 a-104 c, panel 106 g comprising a primary panel portion 120 g having a first edge 126 g and a second edge 128 g. Panel 106 g may also comprise a first flange 122 g located along first edge 126 g and a second flange 124 g located along the second edge 128 g.
At step 518, the first panel (e.g. panel 106 f) and the second panel (e.g., panel 106 g) may be secured to the first, second, and third rails (e.g., rails 104 a-c) such that the second edge 128 f of the primary panel portion 120 f of panel 106 f is adjacent to the first edge 126 g of the primary panel portion 120 g of the second panel 106 g, the second flange 124 f of panel 106 f being matingly coupled to the first flange 122 g of panel 106 g.
In certain embodiments, second flange 124 f of panel 106 f includes a protrusion 124 f′ extending from the second edge 128 f of the primary portion 120 f of the panel 106 f and a tab 124 f″ extending from the protrusion 124 f′. Additionally, first flange 122 g of panel 106 g includes a protrusion 122 g′ extending from the first edge 126 g of the primary portion 120 g of the panel 106 g and a tab 122 g″ extending from the protrusion 122 g′. Furthermore, second flange 124 f of panel 106 f may be matingly coupled to the first flange 122 g of panel 106 g such that protrusion 124 f′ of second flange 124 f is adjacent to protrusion 122 g′ of first flange 122 g; and tab 124 f″ of second flange 124 f is adjacent to and substantially parallel with tab 122 g″ of first flange 122 g.
Although the present invention has been described with several embodiments, diverse changes, substitutions, variations, alterations, and modifications may be suggested to one skilled in the art, and it is intended that the invention encompass all such changes, substitutions, variations, alterations, and modifications as fall within the spirit and scope of the appended claims.

Claims

1. A fence system, comprising:

a support member;

a rail attached to the support member such that the rail extends across the support member;

a first panel and a second panel each comprising:

a primary panel portion having a first edge and a second edge;

a first flange located along at least a portion of the first edge of the primary panel portion; and

a second flange located along at least a portion of the second edge of the primary panel portion;

the first and second panels secured to the rail such that the second edge of the primary panel portion of the first panel is adjacent to the first edge of the primary panel portion of the second panel, the second flange of the first panel being matingly coupled to the first flange of the second panel.

2. The system of claim 1, wherein the first and second panels comprise one or more apertures, the one or more apertures facilitating visibility through the first and second panels.

3. The system of claim 1, wherein the rail is coupled to the post using a rail hanger component.

4. The system of claim 1, wherein the first and second panels are secured to the rail using one or more fasteners.

5. The system of claim 1, wherein the first and second panels are secured to the rail by clinching the first and second panels to the rail.

6. The system of claim 1, wherein:

the second flange of the first panel comprises:

a protrusion extending from the second edge of the primary panel portion of the first panel; and

a tab extending from the protrusion; and

the first flange of the second panel comprises:

a protrusion extending from the first edge of the primary panel portion of the second panel; and

a tab extending from the protrusion; and

the second flange of the first panel is matingly coupled to the first flange of the second panel such that:

the protrusion of the second flange of the first panel is adjacent to the protrusion of the first flange of the second panel; and

the tab of the second flange of the first panel is adjacent to and substantially parallel with the tab of the first flange of the second panel.

7. The system of claim 6, wherein the tab of the second flange of the first panel and the tab of the first flange of the second panel are both adapted to be secured to the rail and to each other using a single fastening mechanism.

8. The system of claim 6, wherein the protrusion and the tab of the second flange of the first panel form a channel adapted to contain at least a portion of a fastener coupling the first and second panel to the rail.

9. The system of claim 6, wherein:

the protrusion of the second flange of the first panel extends in a direction substantially perpendicular to the primary panel portion of the first panel;

the tab of the second flange of the first panel extends in a direction substantially parallel to the primary panel portion of the first panel;

the protrusion of the first flange of the second panel extends in a direction substantially perpendicular to the primary panel portion of the second panel; and

the tab of the first flange of the second panel extends in a direction substantially parallel to the primary panel portion of the second panel.

10. The system of claim 1, wherein:

the first panel is secured to the rail at a first angle;

the second panel is secured to the rail at a second angle, the second angle being different than the first angle; and

the second flange of the first panel is matingly coupled to the first flange of the second panel such that one or more of the first and second flanges close a gap defined by the second edge of the primary panel portion of the first panel and the first edge of the primary panel portion of the second panel.

11. A method for constructing a fence system, comprising:

setting a support member in a foundation;

attaching a rail to the support member such that the rail extends across the support member;

securing a first panel and a second panel to the rail, the first and second panels each comprising:

a primary panel portion having a first edge and a second edge;

the first and second panels being secured to the rail such that the second edge of the primary panel portion of the first panel is adjacent to the first edge of the primary panel portion of the second panel, the second flange of the first panel being matingly coupled to the first flange of the second panel.

12. The method of claim 11, wherein the first and second panels comprise one or more apertures, the one or more apertures facilitating visibility through the first and second panels.

13. The method of claim 11, comprising coupling the rail to the post using a rail hanger component.

14. The method of claim 11, comprising securing the first and second panels to the rail using one or more fasteners.

15. The method of claim 11, comprising securing the first and second panels to the rail by clinching the first and second panels to the rail.

16. The method of claim 11, wherein:

the second flange of the first panel comprises:

a tab extending from the protrusion; and

the first flange of the second panel comprises:

a tab extending from the protrusion; and

17. The method of claim 16, wherein the tab of the second flange of the first panel and the tab of the first flange of the second panel are both adapted to be secured to the rail and to each other using a single fastening mechanism.

18. The method of claim 16, wherein the protrusion and the tab of the second flange of the first panel form a channel adapted to contain at least a portion of a fastener coupling the first and second panel to the rail.

19. The method of claim 17, wherein:

20. The method of claim 11, wherein

the first panel is secured to the rail at a first angle;

21. A panel, comprising:

a primary panel portion having a first edge and a second edge;

a first flange located along at least a portion of the first edge, the first flange comprising:

a protrusion adjoining the primary panel portion along the first edge and extending in a first direction; and

a tab adjoining the protrusion and extending in a second direction; and

the first flange adapted to matingly couple with a flange of another panel.

22. The panel of claim 21, comprising a second flange located along at least a portion of the second edge, the second flange comprising:

a protrusion adjoining the primary panel portion along the second edge and extending in the first direction; and

a tab adjoining the protrusion and extending in the second direction.