COMPOSITE FENCE
The apparatus and method of the present invention is directed to an improved composite fence and, more particularly, to a composite fence made of cellulosic fillers and/or inorganic fillers. An alternative embodiment of the present invention is directed to a fence in which a substrate is embedded in a plastic composite. One example of a component of the present invention is comprised of a substrate sheet that is embedded in a plastic composite. Another example of a component of the present invention is a perforated substrate that is embedded in a plastic composite.
1 . A fence rail comprising:
a substrate; and
a composite layer comprising a plastic and at least one filler, said composite covering said substrate such that all sides of said substrate are coated by said composite layer;
wherein said substrate has a higher bending strength than a comparable size piece of said composite or said substrate is adapted to improve a fastener retention ability of said fence rail.
2 . The fence rail of claim 1 wherein said substrate is comprised of metal.
3 . The fence rail of claim 1 wherein said substrate is comprised of fiberglass.
4 . The fence rail of claim 1 wherein said substrate is a substantially flat sheet.
5 . The fence rail of claim 1 wherein said substrate has at least one perforation such that said composite passes through said at least one perforation.
6 . The fence rail of claim 1 wherein said plastic comprises polyethylene.
7 . The fence rail of claim 1 wherein said at least one filler is selected from the group consisting of cellulosic fillers and inorganic fillers.
8 . The fence rail of claim 1 wherein:
said at least one filler comprises cellulosic filler in an amount from about 25% to about 65% by weight of said composite; and
said plastic comprises polyethylene in an amount from about 15% to about 55% by weight of said composite.
9 . The fence rail of claim 8 wherein said composite further comprises inorganic filler in an amount less than about 25% by weight of said composite.
10 . The fence rail of claim 1 wherein:
said substrate is comprised of a substantially flat sheet of metal having at least one perforation such that said composite passes through said at least one perforation;
said at least one filler comprises cellulosic filler in an amount from about 25% to about 65% by weight of said composite; and
said plastic comprises polyethylene in an amount from about 15% to about 55% by weight of said composite.
11 . A fence comprising:
a plurality of spaced-apart posts;
a rail extending between said posts, said rail comprising:
a) a substrate; and
b) a composite layer comprising a plastic and at least one filler, said composite covering said substrate such that all sides of said substrate are coated by said composite layer;
wherein said substrate has a higher bending strength than a comparable size piece of said composite or said substrate is adapted to improve a fastener retention ability of said rail.
12 . The fence of claim 11 wherein said substrate is comprised of metal.
13 . The fence of claim 11 wherein said substrate is comprised of fiberglass.
14 . The fence of claim 11 wherein said substrate has at least one perforation such that said composite passes through said at least one perforation.
15 . The fence of claim 11 wherein:
said at least one filler comprises cellulosic filler in an amount from about 25% to about 65% by weight of said composite; and
said plastic comprises polyethylene in an amount from about 15% to about 55% by weight of said composite.
16 . The fence of claim 15 wherein said composite further comprises inorganic filler in an amount less than about 25% by weight of said composite.
17 . The fence of claim 11 wherein:
said substrate is comprised of a substantially flat sheet of metal having at least one perforation such that said composite passes through said at least one perforation;
said at least one filler comprises cellulosic filler in an amount from about 25% to about 65% by weight of said composite; and
said plastic comprises polyethylene in an amount from about 15% to about 55% by weight of said composite.
18 . The fence of claim 11 further comprising at least one plank connected to said rail by a fastener such that said fastener extends through said substrate.
19 . A fence comprising:
a plurality of spaced-apart posts;
a rail extending between said posts, said rail comprising:
a) a substrate comprised of a substantially flat sheet of metal having at least one perforation; and
b) a composite layer covering said substrate such that all sides of said substrate are coated by said composite and said composite passes through said at least one perforation, said composite comprising:
i) cellulosic filler in an amount from about 25% to about 65% by weight of said composite; and
ii) plastic in an amount from about 15% to about 55% by weight of said composite; and
a plank connected to said rail, said plank comprised of a composite, said composite comprising:
a) cellulosic filler in an amount from about 15% to about 55% by weight of said composite; and
b) plastic in an amount from about 30% to about 70% by weight of said composite.
20 . The fence of claim 19 wherein:
said plank is a picket of said fence; and
said plank is connected to said rail by a fastener such that said fastener extends through said substrate.