US-12618260-B1 - Fence and gate systems and methods for use

Abstract

A fence system comprises a rail assembly, a post assembly, and a panel insert. The rail assembly comprises at least two rails, and each rail defines at least one rail opening. The post assembly comprises a plurality of posts arranged to support the rails. The panel insert is arranged such that portions of the panel insert extend through at least one of the at least one rail opening in at least one of the at least two rails such that the panel insert is supported by the rail assembly.

Inventors

• Larry Bergsma

Assignees

• Larry Bergsma

Dates

Publication Date

20260505

Application Date

20220210

Claims (18)

1. 1 . A fence system comprising: upper and lower rails, where: each of the upper and lower rails comprises: an elongated hollow body comprising opposing longitudinally-extending first and second side wall portions and opposing longitudinally-extending upper and lower walls defining an inner cavity, an interior barrier extending between the first and second side wall portions to define a first chamber and a second chamber, where: a rail opening is formed in a respective one of the upper and lower walls of each of the upper and lower rails and extends into the inner cavity thereof, in which each rail opening is a slit that extends along the entire length of each of the upper and lower rails, such that portions of the respective upper or lower wall on opposing sides of the slit and extending from the first and second side wall portions of each of the upper and lower rails define first and second flaps, respectively, where the rail opening is between the first and second flaps, and each of the upper and lower rails is configured such that the first and second side wall portions deflect each of the first and second flaps inwardly towards each other; a plurality of posts arranged to support ends of the upper and lower rails; and a panel insert; wherein: the panel insert is arranged such that: an upper edge portion of the panel insert extends through the rail opening in and into the first chamber of the upper rail such that: the upper edge portion of the panel insert engages the interior barrier of the upper rail, and inward deflection of the first and second flaps by the first and second side wall portions of the upper rail grips the upper edge portion of the panel insert; and a lower edge portion of the panel insert extends through the rail opening in and into the first chamber of the lower rail such that: the lower edge portion of the panel insert engages the interior barrier of the lower rail, and inward deflection of the first and second flaps by the first and second side wall portions of the lower rail grips the lower edge portion of the panel insert.
2. 2 . The fence system as recited in claim 1 , in which each of the plurality of posts defines at least one post opening, where the panel insert is arranged such that side edge portions of the panel insert extend through at least one of the at least one post opening in first and second posts of the plurality of posts such that the side edge portions of the panel insert are supported by the first and second posts.
3. 3 . The fence system as recited in claim 2 , in which at least one of the posts is configured to grip at least one of the side edge portions of the panel insert that extend through at least one of the at least one post opening.
4. 4 . The fence system of claim 2 , in which each of the at least one post opening is a slit formed along at least a portion of an inner portion of each of the posts.
5. 5 . The fence system of claim 2 , in which each of the at least one post opening is at least one slit formed in an inner portion of each of the posts between top and bottom openings formed in the each of the posts.
6. 6 . The fence system of claim 2 , in which each of the at least one post opening is a plurality of slits formed in an inner side of each of the posts between top and bottom openings formed in the each of the posts.
7. 7 . The fence system of claim 2 , in which an interior structural member is arranged within at least one of the posts.
8. 8 . The fence system as recited in claim 1 , in which each of the plurality of posts comprises first and second inner portions, wherein: at least one post opening is formed in each of the first and second inner portions of each of the plurality of posts; and first and second panel inserts are arranged such that: a first side edge portion of the first panel insert extends through at least one of the at least one post opening in the first inner portion of a first post of the plurality of posts such that the first post supports the first side edge portion of the first panel insert; and a first side edge portion of the second panel insert extend through at least one of the at least one post opening in the second inner portion of the first post such that the first post supports the first side edge portion of second panel insert.
9. 9 . The fence system of claim 1 , in which at least one stiffening member is arranged within the second rail chamber of at least one of the upper and lower rails.
10. 10 . A method of forming a fence system comprising the steps of: providing upper and lower rails each comprising: an elongated hollow body comprising opposing longitudinally-extending first and second side wall portions and opposing longitudinally-extending upper and lower walls defining an inner cavity, an interior barrier extending between the first and second side wall portions to define a first chamber and a second chamber, where: a rail opening is formed in a respective one of the upper and lower walls of each of the upper and lower rails and extends into the inner cavity thereof, in which each rail opening is a slit that extends along the entire length of each of the upper and lower rails, such that portions of the respective upper or lower wall on opposing sides of the slit and extending from the first and second side wall portions of each of the upper and lower rails define first and second flaps, respectively, where the rail opening is between the first and second flaps, and each of the upper and lower rails is configured such that the first and second side wall portions cause inward deflection of each of the first and second flaps toward each other; providing a plurality of posts; supporting ends of the upper and lower rails on the plurality of posts; and arranging a panel insert such that: an upper edge portion of the panel insert extends through the rail opening and into the first chamber of the upper rail such that: the upper edge portion of the panel insert engages the interior barrier of the upper rail, and inward deflection of the first and second flaps by the first and second side wall portions of the upper rail grips the upper edge portion of the panel insert; and arranging the panel insert such that: a lower edge portion of the panel insert extends through the rail opening and into the first chamber of in the lower rail such that: the lower edge portion of the panel insert engages the interior barrier of the lower rail, and inward deflection of the first and second flaps by the first and second side wall portions of the lower rail grips the lower edge portion of the panel insert.
11. 11 . The method as recited in claim 10 , further comprising the steps of: forming at least one post opening in each of the plurality of posts; and arranging the panel insert such that side edge portions of the panel insert extend through at least one of the at least one post opening in first and second posts of the plurality of posts such that the side edge portions of the panel insert are supported by the by the first and second posts.
12. 12 . The method as recited in claim 11 , further comprising the step of configuring at least one of the posts to grip at least one of the side edge portions of the panel insert that extend through at least one of the at least one post opening.
13. 13 . The method of claim 10 , further comprising the step of: arranging at least one stiffening member within the second rail chamber of at least one of the upper and lower rails.
14. 14 . A fence system comprising: first and second rails, where; each of the first and second rails comprises: an elongated hollow body comprising opposing longitudinally-extending first and second side wall portions and opposing longitudinally-extending upper and lower walls defining an inner cavity, an interior barrier extending between the first and second side wall portions to define a first chamber and a second chamber, where: a rail opening is formed in a respective one of the upper and lower walls of each of the first and second rails and extends into the inner cavity thereof, in which each rail opening is a slit that extends along the entire length of each of the first and second rails, such that portions of the respective upper or lower wall on opposing sides of the slit and extending from the first and second side wall portions of each of the first and second rails define first and second flaps, respectively, where the rail opening is between the first and second flaps, where: each of the first and second rails is configured such that the first and second side wall portions deflect each of the first and second flaps inwardly towards each other; first and second posts arranged to support the first and second rails; and a panel insert; wherein: the panel insert is arranged with first and second edge portions thereof within the rail opening defined by the first and second rails, respectively, such that: the inward deflection of the first and second flaps by the first and second side wall portions of each of the first and second rails grips the first and second edge portions of the panel insert that extend through the rail opening and into the first chamber of each of the first and second rails, and the first and second edge portions of the panel insert engage the interior barriers of the first and second rails when the first and second edge portions of the panel insert are gripped by inward deflection of the first and second flaps by the first and second wall portions of the first and second rails.
15. 15 . The fence system as recited in claim 14 , in which each of the first and second posts defines at least one post opening, where the first and second posts are configured to grip third and fourth side edge portions of the panel insert that extend through the at least one elongate post opening in the first and second posts, respectively.
16. 16 . The fence system as recited in claim 14 , in which each of the first and second posts engages the ground to support the fence system in a desired orientation relative to the ground.
17. 17 . The fence system as recited in claim 14 , further comprising a third post that engages the ground, in which one of the first and second posts is rotatably supported by the third post such that the first and second posts, first and second rails, and panel insert form a gate assembly.
18. 18 . The fence system of claim 14 , in which: at least one stiffening member is arranged within the second rail chamber of at least one of the first and second rails.

Description

RELATED APPLICATIONS This application, U.S. patent application Ser. No. 17/650,556 filed Feb. 10, 2022, claims benefit of U.S. Provisional Application Ser. No. 63/265,009 filed Dec. 6, 2021, the contents of which are incorporated herein by reference. TECHNICAL FIELD The present invention relates to a fence and gate system. BACKGROUND Traditional fence and gate systems include numerous metal fasteners that help to connect the rails to the posts. The fasteners are necessary to provide stability to the fence structure. However, these fasteners are subject to corrosion from exposure to the outdoor elements. Corrosion of the fence fasteners can destabilize the structure and require costly repairs and/or replacement of parts of the fence system. Further, conventional methods of properly fabricating, assembling, and securing fences can be time consuming and thus costly. The need thus exists for improved fence systems and methods that are easier to assemble and minimize the likelihood of improper assembly and/or reduce the need for replacement fencing due to environmental conditions that adversely affect the materials and fastener systems. SUMMARY The present invention may be embodied as a fence system comprising a rail assembly, a post assembly, and a panel insert. The rail assembly comprises at least two rails, and each rail defines at least one rail opening. The post assembly comprises a plurality of posts arranged to support the rails. The panel insert is arranged such that portions of the panel insert extend through at least one of the at least one rail opening in at least one of the at least two rails such that the panel insert is supported by the rail assembly. The present invention may also be embodied as a method of forming a fence system comprising the following steps. At least two rails are provided, and at least one rail opening is formed in each rail. A plurality of posts are provided. The at least two rails are supported on the plurality of posts. A panel insert is arranged such that portions of the panel insert extend through at least one of the at least one rail opening in each of the at least two rails such that the panel insert is supported by the at least two rails. The present invention may also be embodied as a fence system comprising at least first and second rails, at least first and second posts, and a panel insert. Each of the first and second rails defines at least one rail opening. The at least first and second posts are arranged to support the rails. The first and second rails are configured such that each of the first and second rails grips portions of the one panel insert that extend through at least one of the at least one rail opening in each of the first and second rails. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a top plan view of a first example fence system of the present invention; FIG. 2 is a side elevation view of the example fence system; FIG. 3 is a side perspective view of an intermediate post of the example fence system; FIG. 4 is a side perspective view of a corner post of the example fence system; FIG. 5 is a side perspective view of an example securing assembly on an example first end of an example upper horizontal rail; FIG. 6 is a side perspective view of the example securing assembly on an example second end of the example lower horizontal rail; FIG. 7 is a side perspective view of an example elongated post slit of an example intermediate post; FIG. 8 is a side perspective view of an example elongated post slit of the example corner post; FIG. 9 is a side perspective view of an example side of the upper horizontal rail; FIG. 10 is a side perspective view of elongated rail opening on an example side of the example lower horizontal rail; FIG. 11 is an exploded front view of the example fence system; FIG. 12 is a section view taken along lines 12-12 in FIG. 2; FIG. 13 is a section view taken along lines 13-13 in FIG. 2; FIG. 14 is a section view taken along lines 14-14 in FIG. 2; FIG. 15 is a section view taken along lines 15-15 in FIG. 2; FIG. 16 is an end view of a rail illustrating the slot opening in a preferred width ready to receive the mesh rail insert; and FIG. 17 is an end view of a rail after the slot has been cut illustrating the tendency of the side walls to deflect inwardly. DETAILED DESCRIPTION The present disclosure provides a fence system 10. The present fence system 10 is a new design which uses a unique process for joining multiple different materials without requiring the use of fasteners into a fence that is virtually maintenance free and has a significantly greater longevity, thus reducing the cost and the environmental impact. The example fence system 10 includes a rail assembly 12, a post assembly 14, a mesh rail insert 16, and a gate assembly 18. Referring to FIGS. 1 and 2, the example rail assembly 12 includes a plurality of horizontal rails 19 comprising a top horizontal rail 20 and a bottom horizontal rail 22. In some examples, the rail assem