Fence system with pultruded rail sections

Abstract

A fence system includes hollow post structures and upper and lower rail structures each comprising a hollow rail and a rail mounting bracket for mounting the rail to each post structure. Hollow balusters may also extend between the upper and lower rail structures. At least one of the hollow structural members, preferably including each of the rails, includes a pultruded structure and preferably a topcoat which is co-extruded with the pultruded structure. The pultruded structure provides substantially increased strength and the topcoat a highly colorable and long-wearing decorative outer layer, the latter preferably formed of acrylic or polyvinyl chloride. The rail mounting brackets are preferably injection molded with a substrate and a topcoat which matches the topcoat of the structural members.

1 . A fencing system comprising: 
 a first post;    a first rail mounted on the post; and    at least one of the post and the first rail including a pultruded substrate comprising resin-embedded fibers.    
   
   
       2 . The system of  claim 1  wherein the at least one of the post and the first rail includes a pultruded substrate comprising resin-embedded fibers and an extruded topcoat which are integrally formed as a one-piece member.  
   
   
       3 . The system of  claim 2  wherein the topcoat is an acrylic material.  
   
   
       4 . The system of  claim 2  wherein the topcoat is made of a PVC material.  
   
   
       5 . The system of  claim 1  wherein each of the post and first rail includes a pultruded substrate comprising resin-embedded fibers and an extruded topcoat which are integrally formed as a one-piece member.  
   
   
       6 . The system of  claim 1  wherein a rail mounting bracket is mounted on the post and supports a portion of the first rail whereby the first rail is mounted on the post; and wherein the rail mounting bracket includes a substrate and a topcoat.  
   
   
       7 . The system of  claim 6  wherein the topcoat of each of the first rail and the rail mounting bracket is an acrylic material.  
   
   
       8 . The system of  claim 7  wherein the rail mounting bracket has an outer surface which includes visible and non-visible surfaces when the bracket is mounted on the post and the rail is mounted on the bracket; and wherein the acrylic material forms the entire visible surface.  
   
   
       9 . The system of  claim 8  wherein the non-visible surface is substantially free of the acrylic material of the topcoat of the rail mounting bracket.  
   
   
       10 . The system of  claim 6  wherein the rail mounting bracket has an outer surface which includes visible and non-visible surfaces when the bracket is mounted on the post and the rail is mounted on the bracket; wherein the topcoat forms the entire visible surface; and wherein the non-visible surface is substantially free of the topcoat.  
   
   
       11 . The system of  claim 2  wherein an injection-molded rail mounting bracket is mounted on the post and supports a portion of the first rail whereby the first rail is mounted on the post; and wherein the rail mounting bracket includes a substrate and a topcoat.  
   
   
       12 . The system of  claim 11  wherein the substrate and topcoat of the rail mounting bracket are together a two-shot injection-molded member.  
   
   
       13 . The system of  claim 1  wherein the first rail includes a first pultruded substrate comprising resin-embedded fibers and a first topcoat which is integrally formed with the first pultruded structure; and wherein a second rail is mounted on the post and includes a second pultruded substrate comprising resin-embedded fibers and a second topcoat which is integrally formed with the second pultruded structure.  
   
   
       14 . The system of  claim 13  further including a plurality of balusters each extending between and mounted on the first and second rails; and wherein each baluster includes a pultruded substrate comprising resin-embedded fibers.  
   
   
       15 . The system of  claim 13  wherein the first rail is an upper rail having first and second ends and being elongated between said ends; wherein the second rail is a lower rail having first and second ends and being elongated between said ends; wherein the upper rail defines a downwardly opening cavity extending from the first end thereof to the second end thereof; wherein the lower rail defines an upwardly opening cavity extending from the first end thereof to the second end thereof; and further including a plurality of balusters each having an upper end disposed in the downwardly opening cavity and a lower end disposed in the upwardly opening cavity.  
   
   
       16 . The system of  claim 15  wherein the upper rail defines an interior chamber which is disposed above the downwardly opening cavity and which extends from the first end to the second end of the upper rail; and wherein the lower rail defines an interior chamber which is disposed below the upwardly opening cavity and which extends from the first end to the second end of the lower rail.  
   
   
       17 . The system of  claim 16  wherein the upper rail includes a separating wall which separates the interior chamber thereof from the downwardly opening cavity; and wherein the lower rail includes a separating wall which separates the interior chamber thereof from the upwardly opening cavity.  
   
   
       18 . The system of  claim 16  wherein the interior chamber of the upper rail is generally T-shaped.  
   
   
       19 . The system of  claim 1  wherein the first rail includes a pultruded substrate comprising resin-embedded fibers.  
   
   
       20 . The system of  claim 1  wherein each of the post and the first rail includes a pultruded substrate comprising resin-embedded fibers.