Internally welded barrier
A barrier such as a fence is formed by welding conductive upright members to conductive U-shaped rails by a projection resistance welding process. The rail includes at least one weld-forming region which projects within the rail channel, and may be formed wither as a ridge, or as a longitudinally spaced series of nipple-shaped projections. The upright member is transversely positioned within the rail channel in contact with the weld-forming region. A welding current transmitted between the upright member and the rail causes the weld-forming region to at least partially melt and form a weld within the rail channel.
1 . A barrier comprising:
at least one elongate rail, comprising:
a flat web; and
a pair of opposed side walls extending from the web to define a rail channel, with at least one of the side walls having a weld-forming region which projects within the rail channel; and
at least one vertical upright member partially situated within the rail channel and secured to the rail by a weld formed within the rail channel between the side wall and the upright member at the weld-forming region.
2 - 7 (cancelled).
8 . The barrier of claim 1 in which the weld-forming region comprises a nipple-shaped projection.
9 . The barrier of claim 8 in which the weld-forming region comprises a plurality of longitudinally spaced nipple-shaped projections.
10 . The barrier of claim 1 in which each of the side walls includes a weld-forming region which projects within the rail channel, and in which the vertical upright member is secured to the rail by a pair of welds formed within the rail channel each side wall and the upright member at its respective weld-forming region.
11 - 12 (cancelled).
13 . The barrier of claim 10 in which each weld-forming region comprises a nipple-shaped projection.
14 . The barrier of claim 13 in which each weld-forming region comprises a plurality of longitudinally spaced nipple-shaped projections.
15 (cancelled).
16 . A rail comprising:
an elongate flat web; and
a pair of opposed side walls extending from the web to define a rail channel, with at least one of the side walls having a weld-forming region which projects within the rail channel.
17 - 20 (cancelled).
21 . The rail of claim 16 in which the weld-forming region comprises a nipple-shaped projection.
22 . The rail of claim 21 in which the weld-forming region comprises a plurality of longitudinally spaced nipple-shaped projections.
23 . The rail of claim 16 in which each of the side walls has a weld-forming region which projects within the rail channel.
24 - 25 (cancelled).
26 . The rail of claim 23 in which each weld-forming region comprises a nipple-shaped projection.
27 . The rail of claim 26 in which each weld-forming region comprises a plurality of longitudinally spaced nipple-shaped projections.
28 - 35 (cancelled).
36 . The barrier of claim 1 in which the rail and upright member are each formed from a conductive material.
37 . The barrier of claim 36 in which the weld is a resistance weld.
38 . The rail of claim 16 in which the rail is formed from a conductive material.
39 . The rail of claim 16 characterized by a plurality of longitudinally spaced openings formed therein, each opening sized to clearingly receive a picket.
40 . The rail of claim 39 in which the web is characterized by a pair of opposed ends and a midpoint intermediate the two ends, and in which the plurality openings includes at least one opening situated closer to the midpoint than to either end.
41 . A barrier comprising:
at least one elongate channel-shaped rail, the rail having at least a first structural element having opposed first and second surfaces, in which the first surface is contiguous to the rail channel and has at least one compact projection formed thereon;
an upright member disposed in transverse relationship to the rail and secured to the first surface of the first side wall by at least one weld formed at the projection.
42 . The barrier of claim 41 in which the rail and upright member are each formed from a conductive material.
43 . The barrier of claim 41 in which the weld is a resistance weld.
44 . The barrier of claim 41 in which the rail comprises one of a plurality of rails, the rails disposed in spaced and parallel relationship, and in which the upright member comprises one of a plurality of laterally spaced upright members, with each upright member extending in transverse relationship to the plural rails, with a weld formed between each upright member and each rail at a corresponding projection.
45 . The barrier of claim 44 in which the plural rails comprise:
an upper rail having no openings of sufficient size to receive an upright member; and
a lower rail having a plurality of longitudinally spaced openings formed therein, each opening sized to clearingly receive an upright member.
46 . The barrier of claim 41 in which each rail is characterized by a plurality of longitudinally spaced openings formed therein, each opening sized to clearingly receive an upright member.
47 . The barrier of claim 46 in which the rail is characterized as having a second weldable structural element, spaced from the first weldable structural element, the second weldable structural element having opposed first and second surfaces, in which the first surface is contiguous to the rail channel and has at least one compact projection formed thereon, and in which the upright member is secured to the first surface of the second side wall by at least one weld formed at the projection.
48 . The barrier of claim 41 in which the first weldable structural element comprises a side wall of the rail.
49 . The barrier of claim 47 in which the first and second weldable structural elements comprise side walls of the rail, and in which the upright member is secured to the rail by a pair of welds formed between the upright member and each of the side walls.
50 . The barrier of claim 41 in which a plurality of compact projections are formed in the first surface of the first weldable structural element.
51 . The barrier of claim 47 in which a plurality of compact projections are formed in the first surface of each weldable structural element.
52 . The barrier of claim 48 in which a plurality of compact projections are formed in the first surface of the side wall.
53 . The barrier of claim 49 in which a plurality of compact projections are formed in the first surface of each side wall.
54 . The barrier of claim 51 , in which compact projections extend along at least a portion of the length of the first surface, in which the upright member comprises one of a plurality of laterally spaced upright members, each upright member disposed in transverse relationship to the rail and positioned to contact the first surface of the first structural element at a compact projection formed thereon, with a separate weld formed between the upright member and the first side wall at its area of contact with the projection.
55 . A rail formed from a conductive material comprising:
an elongate web; and
a pair of opposed first and second side walls depending from the web to define a rail channel, the first side wall having opposed first and second surfaces, with the first surface contiguous to the rail channel and having at least one compact weldable projection formed thereon.
56 . The rail of claim 55 in which a plurality of longitudinally spaced compact weldable projections are formed on the first surface of the first side wall.
57 . The rail of claim 55 characterized by a plurality of longitudinally spaced openings formed therein, each opening sized to clearingly receive a picket.
58 . The rail of claim 57 in which the web is characterized by a pair of opposed ends and a midpoint intermediate the two ends, and in which the plurality openings includes at least one opening situated closer to the midpoint than to either end.
59 . The rail of claim 55 in which the second side wall has opposed first and second surfaces, with the first surface contiguous to the rail channel and having at least one compact weldable projection formed thereon.
60 . The rail of claim 56 in which a plurality of longitudinally spaced compact weldable projections are formed on the first surface of the first side wall.
61 . A fence panel formed from a plurality of rails as defined in claim 55 and a plurality of laterally spaced pickets, the rails disposed in spaced and parallel relationship, and each picket extending in transverse relationship to the plural rails, with a weld formed between each picket and each rail at a projection in the first side wall.
62 . A fence panel formed from a plurality of rails as defined in claim 59 and a plurality of laterally spaced pickets, the rails disposed in spaced and parallel relationship, and each picket extending in transverse relationship to the plural rails, with a pair of welds formed between each picket and each rail at the projections in the first surfaces of the rail side walls.