Self-tensioning permanent fence system

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FIELD OF THE INVENTION

The present invention relates to a self-tensioning fencing installation system for plastic fencing material, such as uniaxial and biaxial grid material, knitted mesh and net materials, and even sheet plastic materials.

BACKGROUND OF THE INVENTION

Present fencing systems require erection of structural support posts at some predetermined spacing after which a roll of plastic fencing material is secured at one end to a post and then tensioned from a structural support post at an opposite end so as to stretch the plastic fencing material across the plurality of structural support posts. After stretching, the plastic fencing material is secured to the intermediary structural support posts. Dependent upon the length of the fence to be erected, a great deal of force is required to tension an elongated fence. Accordingly, power driven tools are required to tension an elongated fence.

In an attempt to overcome such disadvantages, a self-tensioning fencing system as disclosed in U.S. Pat. No. 5,409,196 ("the '196 patent") commonly assigned with the instant application and incorporated herein in its entirety by reference, has been developed. According to the invention of the '196 patent, it is possible to tension a plastic grid material or any plastic fencing material across a plurality of structural support posts without the need for full tensioning of the entire length of the plastic fencing material prior to the plastic fencing material being secured to the structural support posts. To achieve this goal, a fastening system is used which is adaptable to both existing and new structural support posts of all common types, such as wood, steel tube and rolled steel sections. An installation method is used to tension the plastic fencing material without the need for specialized equipment after only a manual pre-tensioning of the plastic fencing material.

The self-tensioning fencing system of the '196 patent includes a mounting batten, made of plastic or metal, which is mounted directly to a structural support such as a fence post using standard nails, screws or bolts as required according to the type of a particular fence post. Alternatively, the mounting batten is produced integral with a support post. The mounting batten may be a solid or a thick walled hollow section plastic extrusion or a metal form. The mounting batten is secured to the structural support post so as to space the plastic grid material away from the support post to allow the plastic grid material to be tensioned at a spacing from the structural support posts.

In the system of the '196 patent, a channel batten may be made of pre-coated cold rolled steel or rigid plastic and mounted over the mounting batten and serves to clamp plastic fencing material between the mounting batten and the channel batten. The channel batten when drawn tight against the mounting batten, serves not only to firmly attach the fencing material to the support post but acts as a tensioning device.

The amount of tensioning take-up provided by the channel batten is dependent upon the respective cross-sectional dimensions of the mounting batten and the channel batten. In a typical application, the tensioning capability of the channel batten is in the range of 3/8 of an inch to 7/8 of an inch at each support post, and preferably 5/8 of an inch, which is variable dependent upon the plastic grid material used and the size and shape of the mounting batten and the channel batten. Since full tension is not applied to the entire length of plastic fencing material until each channel batten is secured to a respective mounting batten, the system of the '196 patent can accommodate a varying terrain.

A preferred form of grid-like sheet material used between fence posts, known as an integral geogrid, is commercially available from The Tensar Corporation of Atlanta, Ga. ("Tensar") and is made by the process disclosed in U.S. Pat. No. 4,374,798 ("the '798 patent"), the subject matter of which is incorporated herein in its entirety by reference. Preferably, uniaxially-oriented geogrid materials as disclosed in the '798 patent are used as fencing materials according to this invention, although biaxial geogrids or grid materials that have been made by different techniques such as woven, knitted or netted grid materials formed of various polymers including the polyolefins, polyamides, polyesters and the like or fiberglass, may be used. In addition, it is possible that felt-like fabrics including woven or non-woven, solid or perforated geofabrics, geonets, or even composite materials including some form of geofabric and/or geogrid laminate or solid plastic sheet materials may be used as the tensioned fencing material according to this invention. All of such materials are sometimes referred to herein and in the appended claims as "grid-like sheets of material", "polygrid" or "geogrid", whether they are formed with apertures or not.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an improved self-tensioning fencing system for use with a plastic fencing material.

It is another object of the present invention to provide structural support posts shaped to receive a tensioner bar, over which a trim cap extrusion is placed to aesthetically conceal the tensioner bar.

It is still yet another object of the present invention to tension extended lengths of plastic fencing material across separated structural support posts by securing a tensioner bar to the post and thereafter securing a trim cap extrusion to the tensioner bar with a post cap on top on the post and rails extending between spaced posts with a top rail clip securing the fencing material to the top rail.

It is still a further object of the preset invention to tension extended lengths of plastic fencing material across separated structural support posts by securing a tensioner bar to the posts with the plastic fencing material captured between the tensioner bar and the posts, adjacent posts being connected to each other by rails engaged with cleats on the posts and the fencing material being held to the rail by a rail clip extending between posts.

According to the present invention, a permanent, aesthetically pleasing, self-tensioning fencing system is provided. In accordance with the principles of the present invention, a fencing system is erected, including a plurality of fence posts, preferably separated by a distance of 8 feet from post center to post center. Each post is preferably 87.25 inches long which accommodates a 4 foot width span of polygrid material and 3 foot post footing depth. Also, a top post extension of 0 to 2.5 inches is provided and a bottom ground clearance for the polygrid of 0 to 2 inches is thereby possible.

On one face of the post is a recess for accommodating a tensioner bar which is secured in the recess of the post with geogrid located between the post and tensioner bar. When the tensioner bar is screwed into the post with screws spaced 16 inches on center along the tensioner bar, the side walls of a projection of the tensioner bar presses the plastic grid material along the side walls of the recess in a post so as to impose a tension across the plastic grid material between successively adjacent support posts.

In one embodiment of the present invention, horizontally extending rails are located between adjacent support posts. The rails will preferably have a length of 98 inches and be of a hollow rectangular configuration, preferably measuring 1.5 inches wide by 2.8 inches high.

To secure rails between adjacent support posts, a cleat is secured to the sides of the post by screws and the rail is secured to the cleat, also by screws. The cleats may also be used for joining support braces to the posts, with the braces being anchored in the ground and extending at an angle to the side of the post.

In the embodiment where a top rail is used, a U-shaped clip is placed over the top rail and over the top edge of the geogrid to hide the exposed upper edge of the geogrid. A screw passing through the top rail and into the cleat holds the top rail to the support post and secures the top rails in place at their opposite ends.

As a cosmetic cover for the tensioner bar, a trim cap extrusion is provided which includes a smooth flat surface on one side and two cut-out portions on the opposite sides. The cut-out portions are of a complementary shape to the ends of two arms of the tensioner bar so that the trim cap extrusion may be slid downwardly over the two arms of the tensioner bar to cover the tensioner bar from view. The trim cap extrusion hides the tensioner bar and the recess of the post into which the geogrid has been pressed to tension the geogrid between adjacent support posts. Looking from the side of the flat side of the trim cap extrusion, the geogrid appears as if it extends straight across between adjacent posts without any interruptions or dips for stretching of the geogrid.

To finish off the appearance of the assembled fencing system, a post cap having a peaked top surface is fitted on top of the upper-most end of the post and around the upper-most end of the trim cap extrusion. The post cap includes a projection on one side so as to cover the upper end of the trim cap extrusion, tensioner bar and fence post. The post cap includes a peaked roof so as to provide an appearance of pointed posts when viewing the fencing system from afar.

In an alternate embodiment of the present invention, the top rail, top rail clips and cleats for holding the top rail to the support posts are omitted so that only geogrid extends between adjacent support posts.

These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a transverse cross-sectional view through a support fence post having a recess in one side face.

FIG. 2 is a fragmentary side elevational view of the face of the fence post of FIG. 1.

FIG. 3 is a transverse cross-sectional view through a top rail for use in one embodiment of this invention.

FIG. 4 is a fragmentary side elevational view of the top rail of FIG. 3.

FIG. 5 is a transverse cross-sectional view through a tensioner bar according to this invention, including a projection on one side for insertion into the recess in the side face of a fence post and two arms on the opposite side for cooperating with a trim cap extrusion.

FIG. 6 is a fragmentary side elevational view of the tensioner bar of FIG. 5 shown on a reduced scale from the side having the two arms projecting outwardly and illustrating 16 inch on-center holes for securing the tensioner bar to the fence post.

FIG. 7 is a top plan view of a cleat according to this invention for securing a top rail or a brace to a fence post.

FIG. 8 is a side elevational view of the cleat of FIG. 7.

FIG. 9 is an end elevational view of the cleat of FIG. 7 showing the holes for securing the cleat to a fence post.

FIG. 10 is a transverse cross-sectional view through a top rail clip according to this invention for securing the upper end of geogrid extending between adjacent fence posts to a top rail.

FIG. 11 is a fragmentary side elevational view of the top rail clip of FIG. 10.

FIG. 12 is a transverse