Thermoplastic fencing construction and method of assembly thereof

Abstract

A fencing construction made of thermoplastic materials which can be easily assembled utilizing ultrasonic welding and which can include a unique configuration for the ultrasonic welding surfaces which prevents the flow of melted thermoplastic materials outwardly onto the decorative outer surfaces of the various fencing parts. Any excess thermoplastic material is designed to pass inwardly toward the longitudinally extending bore defined in the various fencing construction parts. This concept is particularly useful for attaching capping fence members which are injection molded onto structural fence members which are extruded.

1 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof comprising: 
 A. a structural fence member of thermoplastic material including: 
 (1) a hollow body member of thermoplastic material defining a bore means extending longitudinally therethrough, said hollow body member also defining at least one bore opening means therein in fluid flow communication with respect to said bore means;  
 (2) an inner wall surface defining said bore means within said hollow body member;  
 (3) an outer wall surface positioned oppositely from said inner wall surface and facing outwardly from said hollow body member;  
 (4) a structural securement zone defined extending about said hollow body member and around said bore opening means;  
 (5) a structural securement zone outer boundary line defined extending along said structural securement zone adjacent said outer wall surface; and  
 (6) a structural securement zone inner boundary line defined extending along said structural securement zone and positioned spatially disposed from said structural securement zone outer boundary line to define said structural securement zone therebetween;  
   B. a capping fence member of thermoplastic material selectively positionable in abutment with respect to said structural fence member to facilitate securement with respect thereto by ultrasonic welding for extending over said bore opening means for capping thereof, said capping fence member comprising: 
 (1) a capping body member of thermoplastic material;  
 (2) a capping securement zone defined extending around said capping body member and positionable adjacent to and in registration with respect to said structural securement zone of said structural fence member to facilitate securement with respect thereto by ultrasonic welding;  
 (3) a capping securement zone outer boundary line defined extending along said capping securement zone and registrable with respect to said structural securement zone outer boundary line responsive to positioning of said capping securement zone adjacent to said structural securement zone for facilitating securement together by ultrasonic welding; and  
 (4) a capping securement zone inner boundary line defined extending along said capping securement zone and positioned spatially disposed from said capping securement zone outer boundary line to define said capping securement zone therebetween, said capping securement zone inner boundary line being registrable with respect to said structural securement zone inner boundary line responsive to positioning of said capping securement zone of said capping fence member adjacent to said structural securement zone of said structural fence member for facilitating securement together by ultrasonic welding; and  
 (5) a plurality of welding rib means of thermoplastic material mounted on said capping fence member within said capping securement zone thereof and extending outwardly therefrom, said welding rib means adapted to melt responsive to ultrasonic welding thereof to facilitate securement with respect to said structural securement zone of said structural fence member for capping thereof.  
   
     
     
         2 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said capping securement zone is angularly oriented with respect to said structural securement zone in order to urge melted thermoplastic material to travel toward said structural securement zone inner boundary line and said capping securement zone inner boundary line during ultrasonic welding thereof and to discourage movement thereof outwardly toward said structural securement zone outer boundary line and toward said capping securement zone outer boundary line.  
     
     
         3 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said structural securement zone is angularly oriented with respect to said capping securement zone with the distance between said capping securement zone outer boundary line and said structural securement zone outer boundary line being less than the distance between said capping securement zone inner boundary line and said structural securement zone inner boundary line prior to ultrasonic welding thereof to encourage flow of thermoplastic material inwardly toward said bore means of said structural fence member during ultrasonically welding thereof.  
     
     
         4 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 3  wherein said structural securement zone is angularly oriented with respect to said capping securement zone at an acute angle.  
     
     
         5 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 3  wherein said structural securement zone is angularly oriented with respect to said capping securement zone at an acute angle of approximately five to 15 degrees.  
     
     
         6 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said capping fence member includes an alignment pin means extending outwardly therefrom and adapted to extend through said bore opening means into said bore means to facilitate alignment of said capping fence means with respect to said structural fence member during ultrasonic welding thereof, said alignment pin means including a crush rib means of thermoplastic material extending outwardly therefrom and adapted to be positioned in abutment with said structural fence member during attachment of said capping fence member thereto, said crush rib means being capable of deforming to facilitate attachment therebetween.  
     
     
         7 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said structural fence member is formed by injection molding and wherein said capping fence member is formed by extruding.  
     
     
         8 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said welding rib means are positioned on said capping securement zone of said capping fence member closer to said capping securement zone inner boundary line than to said capping securement zone outer boundary line to discourage flow of ultrasonically melted thermoplastic material thereover and onto said outer wall surface of said structural fence member.  
     
     
         9 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said welding rib means are positioned spatially separated from said capping securement zone outer boundary line to discourage flow of ultrasonically melted thermoplastic material thereover and onto said outer wall surface of said structural fence member.  
     
     
         10 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 9  wherein said welding rib means are positioned spatially distant from said capping securement zone outer boundary line by at least 0.010 inches to discourage flow of ultrasonically melted thermoplastic material thereover and onto said outer wall surface of said structural fence member.  
     
     
         11 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said welding rib means are oriented perpendicularly with respect to said capping securement zone outer boundary line.  
     
     
         12 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said welding rib means are oriented parallel with respect to said capping securement zone outer boundary line.  
     
     
         13 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said welding rib means are located on said capping fence member within said capping securement zone thereof immediately adjacent to said capping securement zone inner boundary line.  
     
     
         14 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said structural fence member is extruded from polyvinyl chloride thermoplastic material and wherein said capping fence member is injection molded from polyvinyl chloride thermoplastic material.  
     
     
         15 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said structural securement zone is defined extending across and around said outer wall surface of said structural fence member.  
     
     
         16 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 1  wherein said structural securement zone is defined extending around said bore opening means of said hollow body member between said outer wall surface and said inner wall surface thereof.  
     
     
         17 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof comprising: 
 A. a structural fence member extruded from thermoplastic material and including: 
 (1) a hollow body member of thermoplastic material and defining a bore means extending longitudinally therethrough, said hollow body member also defining at least one bore opening means therein in fluid flow communication with respect to said bore means;  
 (2) an inner wall surface defining said bore means within said hollow body member;  
 (3) an outer wall surface positioned oppositely from said inner wall surface and facing outwardly from said hollow body member;  
 (4) a structural securement zone defined extending about said hollow body member and around said bore opening means;  
 (5) a structural securement zone outer boundary line defined extending along said structural securement zone adjacent said outer wall surface; and  
 (6) a structural securement zone inner boundary line defined extending along said structural securement zone and positioned spatially disposed from said structural securement zone outer boundary line to define said structural securement zone therebetween;  
   B. a capping fence member formed by injection molding of thermoplastic material and being selectively positionable in abutment with respect to said structural fence member to facilitate securement with respect thereto by ultrasonic welding for extending over said bore opening means for capping thereof, said capping fence member comprising: 
 (1) a capping body member of thermoplastic material;  
 (2) a capping securement zone defined extending around said capping body member and positionable adjacent to and in registration with respect to said structural securement zone of said structural fence member to facilitate securement with respect thereto by ultrasonic welding;  
 (3) a capping securement zone outer boundary line defined extending along said capping securement zone and registrable with respect to said structural securement zone outer boundary line responsive to positioning of said capping securement zone adjacent to said structural securement zone for facilitating securement together by ultrasonic welding; and  
 (4) a capping securement zone inner boundary line defined extending along said capping securement zone and positioned spatially disposed from said capping securement zone outer boundary line to define said capping securement zone therebetween, said capping securement zone inner boundary line being registrable with respect to said structural securement zone inner boundary line responsive to positioning of said capping securement zone of said capping fence member adjacent to said structural securement zone of said structural fence member for facilitating securement together by ultrasonic welding;  
 (5) a plurality of welding rib means of thermoplastic material mounted on said capping fence member within said capping securement zone thereof and extending outwardly therefrom, said welding rib means being oriented perpendicularly with respect to said capping securement zone outer boundary line, said welding rib means adapted to melt responsive to ultrasonic welding thereof to facilitate securement with respect to said structural securement zone of said structural fence member for capping thereof, said welding rib means being positioned spatially separated from said capping securement zone outer boundary line by at least 0.010 inches to discourage flow of ultrasonically melted thermoplastic material thereover and onto said outer wall surface of said structural fence member, said structural securement zone being angularly oriented with respect to said capping securement zone at an acute angle of approximately ten degrees and with the distance between said capping securement zone outer boundary line and said structural securement zone outer boundary line being less than the distance between said capping securement zone inner boundary line and said structural securement zone inner boundary line prior to ultrasonic welding thereof to encourage flow of thermoplastic material inwardly toward said bore means of said structural fence member during ultrasonically welding thereof; and  
 (6) an alignment pin means extending outwardly from said capping body member and adapted to extend through said bore opening means into said bore means of said structural fence member to facilitate alignment of said capping fence means with respect to said structural fence member during ultrasonic welding thereof.  
   
     
     
         18 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof comprising: 
 A. a structural fence member of thermoplastic material including: 
 (1) a hollow body member of thermoplastic material defining a bore means extending longitudinally therethrough, said hollow body member also defining at least one bore opening means therein in fluid flow communication with respect to said bore means;  
 (2) an inner wall surface defining said bore means within said hollow body member;  
 (3) an outer wall surface positioned oppositely from said inner wall surface and facing outwardly from said hollow body member;  
 (4) a structural securement zone defined on said inner wall surface within said hollow body member;  
 (5) a structural securement zone outer boundary line defined extending along said structural securement zone on said inner wall surface of said structural fence member; and  
 (6) a structural securement zone inner boundary line defined on said inner wall surface at a position extending along said structural securement zone and positioned spatially disposed from said structural securement zone outer boundary line to define said structural securement zone therebetween;  
   B. a capping fence member of thermoplastic material selectively positionable in abutment with respect to said structural fence member to facilitate securement with respect thereto by ultrasonic welding for extending over said bore opening means for capping thereof, said capping fence member comprising: 
 (1) a capping body member of thermoplastic material;  
 (2) an alignment rim including a plurality of alignment panels of thermoplastic material extending outwardly from said capping body member and adapted to extend through said bore opening means into said bore means to a position adjacent said inner wall surface to facilitate alignment and engaging abutment of said capping body member with respect thereto responsive to ultrasonic welding thereof;  
 (3) a capping securement zone defined upon said alignment rim of said capping body member and positionable adjacent to and in registration with respect to said structural securement zone of said structural fence member defined on said inner wall surface thereof to facilitate securement therebetween by ultrasonic welding;  
 (4) a capping securement zone outer boundary line defined extending along said capping securement zone and being registrable with respect to said structural securement zone outer boundary line responsive to positioning of said capping fence member within said bore means of said structural fence member with said capping securement zone thereof positioned adjacent to said structural securement zone for facilitating securement therebetween by ultrasonic welding;  
 (5) a capping securement zone inner boundary line defined extending along said capping securement zone and positioned spatially disposed from said capping securement zone outer boundary line to define said capping securement zone therebetween, said capping securement zone inner-boundary line being registrable with respect to said structural securement zone inner boundary line responsive to positioning of said capping securement zone of said capping fence member adjacent to said structural securement zone of said structural fence member for facilitating securement therebetween by ultrasonic welding; and  
 (6) a plurality of welding rib means of thermoplastic material positioned on said alignment rim of said capping fence member within said capping securement zone thereof and extending outwardly therefrom, said welding rib means adapted to be at least partially transformed into a fluid state temporarily during ultrasonic welding thereof to facilitate securement of said capping securement zone of said capping fence member with respect to said structural securement zone of said structural fence member for securement therebetween with said capping fence member extending over and capping of said bore opening means of said structural fence member.  
   
     
     
         19 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said structural securement zone is defined on said inner wall surface of said hollow body member at a position immediately adjacent to said bore opening means.  
     
     
         20 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said capping securement zone is positioned on said alignment rim of said capping fence member at a position immediately adjacent to said capping body member.  
     
     
         21 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said structural securement zone outer boundary line is positioned on said inner wall surface closer to said bore opening means than said structural securement zone inner boundary line while defining said structural securement zone therebetween.  
     
     
         22 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said capping securement zone outer boundary line is positioned on said alignment rim closer to said capping body member than said capping securement zone inner boundary line while defining said capping securement zone therebetween.  
     
     
         23 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said capping securement zone extends around the exterior of said alignment rim facing outwardly therefrom to facilitate registration with said structural securement zone defined on said inner wall surface of said hollow body member to facilitate securement therebetween responsive to ultrasonic welding thereof.  
     
     
         24 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said structural fence member defines a structural abutment edge and wherein said capping fence member defines a capping abutment edge, said structural abutment edge and said capping abutment edge adapted to be positioned in mutual abutment responsive to positioning of said capping fence member extending over and within said bore opening means within said structural securement zone and said capping securement zone in adjacently positioned registration.  
     
     
         25 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 24  wherein said welding rib means are defined on said alignment rim such that positioning of said capping fence member extending through said bore opening means into said bore means of said structural fence member with abutment between said capping abutment edge and said structural abutment edge will position said welding ribs entirely within said bore means and inside of the position of abutment between said capping abutment edge and said structural abutment edge to prevent the flow of thermoplastic material made fluid during ultrasonic welding thereof outwardly onto the outer wall surface of said structural fence member during ultrasonic welding.  
     
     
         26 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said welding ribs means positioned on said capping securement zone extend longitudinally with respect to said bore means of said structural fence member responsive to said capping fence member being positioned therewithin.  
     
     
         27 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said welding ribs are tapered in a direction extending away from said capping securement zone to facilitate ultrasonic welding therewith.  
     
     
         28 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said alignment rim includes truncated corner panels to facilitate placement thereof through said bore opening means into said bore means and to further prevent flow of thermoplastic material outwardly onto said outer wall surface of said structural fence member.  
     
     
         29 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said alignment rim includes: 
 A. a first alignment panel;    B. a second alignment panel oriented parallel with respect to said first alignment panel;    C. a third alignment panel extending between said first alignment panel and said second alignment panel and oriented approximately perpendicular with respect thereto; and    D. a fourth alignment panel extending between said first alignment panel and said second alignment panel and oriented approximately perpendicular with respect thereto, said fourth alignment panel being positioned spatially disposed from said third alignment panel.    
     
     
         30 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 29  wherein said welding ribs are positioned only upon said first alignment panel.  
     
     
         31 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 29  wherein said welding ribs are positioned only upon said first alignment panel and said second alignment panel.  
     
     
         32 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 29  wherein said welding ribs are positioned upon all four of said alignment panels.  
     
     
         33 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 29  wherein each of said welding rib means includes a first rib wall section and a second rib wall section extending approximately parallel to one another and spatially disposed from one another to define therebetween a main rib section positioned immediately adjacent to said alignment rim and extending outwardly therefrom.  
     
     
         34 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 33  wherein each of said welding rib means includes a third rib wall section adjacent to said first rib wall section and extending outwardly therefrom to a position farther away from said alignment rim, each of said welding rib means also including a fourth rib wall section adjacent to said second rib wall section and extending outwardly therefrom farther away from said alignment rim, said third rib wall section and said fourth rib wall section being angularly oriented with respect to one another to define therebetween a tapered rib section to facilitate ultrasonic welding therewith.  
     
     
         35 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 34  wherein said third rib wall section and said fourth rib wall section are tapered to form an outermost edge therebetween to further facilitate ultrasonic welding therewith.  
     
     
         36 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said structural fence member is formed by injection molding and wherein said capping fence member is formed by extruding.  
     
     
         37 . A thermoplastic fencing construction which facilitates assembly by ultrasonic welding thereof as defined in  claim 18  wherein said structural fence member is extruded from polyvinyl chloride thermoplastic material and wherein said capping fence member is injection molded from polyvinyl chloride thermoplastic material.  
     
     
         38 . A method for assembly of a thermoplastic fencing construction comprising: 
 A. providing a structural fence member of thermoplastic material with a bore extending longitudinally therethrough and defining a structural securement zone adapted to be securable with respect thereto;    B. providing a capping fence member of thermoplastic material with a plurality of welding ribs extending outwardly therefrom to facilitate ultrasonic welding thereof and defining a capping securement zone for placement adjacent to the structural securement zone for mutual securement by ultrasonic welding together;    C. positioning of the capping fence member extending over the bore defined in the structural fence member with the welding ribs in abutment with the structural member and with the capping securement zone in registration with respect to the structural securement zone; and    D. securing of the capping fence member to the structural fence member by ultrasonically melting of the welding ribs positioned therebetween to affix the capping securement zone with respect to the structural securement zone.    
     
     
         39 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said providing a structural fence member includes extruding of a structural fence member from thermoplastic material.  
     
     
         40 . A method for assembly of a thermoplastic fencing construction as defined in  claim 39  wherein the thermoplastic material is polyvinyl chloride.  
     
     
         41 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said providing a capping fence member includes injection molding of a capping fence member from thermoplastic material.  
     
     
         42 . A method for assembly of a thermoplastic fencing construction as defined in  claim 41  wherein the thermoplastic material is polyvinyl chloride.  
     
     
         43 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said providing of a capping fence member includes defining of a plurality of welding ribs thereon formed of thermoplastic material.  
     
     
         44 . A method for assembly of a thermoplastic fencing construction as defined in  claim 43  wherein the thermoplastic material is polyvinyl chloride.  
     
     
         45 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said positioning of the capping fence member is performed with the capping securement zone defined thereon oriented angularly with respect to a structural securement zone defined on the structural fence member to urge thermoplastic material during ultrasonic welding to flow toward the bore defined in the structural fence member.  
     
     
         46 . A method for assembly of a thermoplastic fencing construction as defined in  claim 45  wherein said positioning of the capping fence member is performed with the plane of the capping securement zone oriented at an acute angle with respect to the plane of the structural securement zone.  
     
     
         47 . A method for assembly of a thermoplastic fencing construction as defined in  claim 45  wherein said positioning of the capping fence member is performed with the capping welding zone oriented at an angle of approximately five to fifteen degrees with respect to the structural welding zone.  
     
     
         48 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein the outermost boundary lines of the capping securement zone on the capping fence member and the structural securement zone on the structural fence member are urged into abutment with respect to one another during ultrasonic welding of the capping fence member to the structural fence member into order to urge excess thermoplastic material to flow toward the bore defined in the structural fence member.  
     
     
         49 . A method for assembly of a thermoplastic fencing construction as defined in  claim 48  wherein the innermost boundary lines of the capping securement zone on the capping fence member and the structural securement zone on the structural fence member are maintained spaced apart from one another at all times during ultrasonic welding thereof together as the capping fence member is secured to the structural fence member into order to urge excess thermoplastic material to flow toward the bore defined in the structural fence member.  
     
     
         50 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said capping fence member is provided with alignment pins means extending outwardly therefrom to facilitate aligning of the capping fence member with the structural fence member during securing thereof together by ultrasonic welding.  
     
     
         51 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein the capping fence member is provided with the welding ribs positioned spatially distant from the outer surface thereof to minimize flow of thermoplastic material onto the exposed portion of the outer surface of the capping fence member and the structural fence member during ultrasonic welding thereof.  
     
     
         52 . A method for assembly of a thermoplastic fencing construction as defined in  claim 51  wherein the capping fence member is provided with welding ribs positioned greater than 0.010 inches from the outermost boundary line of the capping securement zone of the capping fence member.  
     
     
         53 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein said providing of the capping fence member is performed with the welding ribs oriented approximately perpendicularly with respect to the outer wall thereof.  
     
     
         54 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein the capping fence member is secured by ultrasonic welding thereof to an edge of the structural fence member defined between the inner wall surface and the outer wall surface.  
     
     
         55 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein the capping fence member is secured by ultrasonic welding thereof to the outer wall surface of the structural fence member.  
     
     
         56 . A method for assembly of a thermoplastic fencing construction as defined in  claim 55  wherein the capping fence member is secured by ultrasonic welding thereof extending across at least a portion of the outer wall surface of the structural fence member.  
     
     
         57 . A method for assembly of a thermoplastic fencing construction as defined in  claim 38  wherein the capping fence member is provided with an alignment rim extending outwardly therefrom with welding ribs positioned thereon which is positioned entirely within the bore defined in the structural member during ultrasonic welding thereof to prevent flow of thermoplastic material onto the exposed portion of the outer surface of the capping fence member and the structural fence member by containing thereof within the bore.