Fiber cement fence system

Abstract

A durable, moisture and insect resistant fence system made from fiber cement is provided. The fence system includes one or more fiber cement pickets aligned between two posts that are anchored to the ground. The fiber cement pickets are formed into the desired shape and dimension prior to curing of the fiber cement. One end of the pickets can be formed into popular pickets designs such as square cut, dog-eared, French gothic, scalloped, pointed, and saw-toothed. The fence system can be easily assembled using conventional techniques such as nailing or stapling. The fiber cement pickets can be formed to resemble conventional fence pickets made from natural wood, masonry, or other materials. Patterns, textures, finishes and designs are applied to the pickets using man-made processes so that the pickets have a consistent appearance.

1 . A fence system, comprising: 
 a mounting surface; and    a plurality of individual members attached to the mounting surface and aligned in a manner so as to form a barrier, wherein at least one individual member comprises fiber cement, the at least one individual member being made into a desired shape for use in a fence prior to curing of said fiber cement, whereby the at least one individual member does not exhibit any substantial fraying of the fibers along surfaces of the at least one individual member after curing.    
     
     
         2 . The fence system of  claim 1 , wherein the at least one individual member has at least one surface that has a pre-finish thereon.  
     
     
         3 . The fence system of  claim 1 , wherein the at least one individual member resembles a picket.  
     
     
         4 . The fence system of  claim 4 , wherein the at least one individual member resembles a wooden picket.  
     
     
         5 . The fence system of  claim 3 , wherein the at least one individual member has a first end, said first end being formed into a shape selected from the group consisting of square cut, dog-eared, French gothic, scalloped, pointed and saw-toothed.  
     
     
         6 . The fence system of  claim 1 , wherein the at least one individual member has a first surface, wherein the first surface has a finish that resembles wood.  
     
     
         7 . The fence system of  claim 1 , wherein the at least one individual member has a first surface, wherein the first surface has a finish that resembles masonry.  
     
     
         8 . The fence of  claim 2 , wherein the at least one surface comprises two opposing sides of the individual member.  
     
     
         9 . The fence system of  claim 1 , wherein the fiber cement forming the at least one individual member incorporates a low-density additive.  
     
     
         10 . The fence system of  claim 10 , wherein the low-density additive comprises microspheres.  
     
     
         11 . The fence system of  claim 10 , wherein the low-density additive comprises volcanic ash.  
     
     
         12 . The fence system of  claim 1 , wherein the fiber cement forming the at least one individual member comprises moisture resistant cellulose fibers.  
     
     
         13 . The fence system of  claim 1 , wherein the mounting surface has a longitudinal axis, and the at least one individual member is positioned in a manner such that a longitudinal axis of the individual member is substantially perpendicular to the longitudinal axis of the mounting surface.  
     
     
         14 . The fence system of  claim 1 , wherein the mounting surface comprises a rail.  
     
     
         15 . A fence system, comprising: 
 a mounting surface; and    a plurality of individual members attached to the mounting surface and aligned in a manner so as to form a barrier, wherein at least one individual member comprises fiber cement, the at least one individual member being made into a desired shape for use in a fence prior to curing of said fiber cement, whereby the at least one individual member comprises a plurality of fiber cement layers and does not show any substantial visible separation of the layers.    
     
     
         16 . The fence system of  claim 15 , wherein the at least one individual member includes at least one surface that has a pre-finish thereon.  
     
     
         17 . The fence system of  claim 16 , wherein the at least one individual member resembles a picket.  
     
     
         18 . The fence system of  claim 15 , wherein the at least one individual member has at least one surface that is embossed with a pattern.  
     
     
         19 . The fence system of  claim 17 , wherein the at least one individual member has a first end, said the first end being formed into a shape selected from the group consisting of square cut, dog-eared, French gothic, scalloped, pointed, and saw-toothed.  
     
     
         20 . A method of forming a fiber cement composite fence component, comprising: 
 providing a fiber cement article having a first and a second surface;    forming a pattern on the first and second surfaces of the fiber cement article;    cutting the fiber cement article into a plurality of members of pre-selected shapes and dimensions prior to curing the fiber cement article, wherein said shapes and dimensions are configured such that at least one of the members resembles a picket; and    curing the individual members of the fiber cement article to form the fiber cement composite fence component.    
     
     
         21 . The method of  claim 20 , wherein cutting the fiber cement article further comprises forming a shape on a first end of each member, said shape being selected from the group consisting of square cut, dog-eared, French gothic, scalloped, pointed, and saw-toothed.  
     
     
         22 . The method of  claim 20 , wherein forming a pattern on the first and second surfaces comprises forming a pattern substantially simultaneously on the first and second surfaces.  
     
     
         23 . The method of  claim 22 , wherein forming a pattern comprises using a plurality of rollers, wherein each roller has a textured surface and is adapted to turn at a predetermined speed relative to the fiber cement article to achieve a high fidelity transfer of the pattern to the first and second surfaces of the fiber cement article.  
     
     
         24 . The method of  claim 22 , wherein forming a pattern comprises using a plurality of rollers, wherein each roller has a substantially smooth surface and is adapted to turn at a predetermined speed relative to the fiber cement article so as to smoothen and planarize the first and second surfaces of the fiber cement article.  
     
     
         25 . A picket for a fence, wherein the picket is made of a fiber cement material, the fiber cement being made into a desired shape for use as said picket prior to curing of said fiber cement, whereby the picket does not exhibit any substantial fraying of the fibers along surfaces after curing.  
     
     
         26 . The picket of  claim 25 , wherein at least one exterior surface of the picket has a pre-finish thereon.  
     
     
         27 . The picket of  claim 26 , wherein the at least one exterior surface of the picket is painted to resemble the color of wood.  
     
     
         28 . The picket of  claim 26 , wherein the at least one exterior surface of the picket comprises two opposing sides of the picket.  
     
     
         29 . The picket of  claim 25 , wherein at least one exterior surface of the picket is stained.  
     
     
         30 . The picket of  claim 25 , wherein at least one exterior surface of the picket is textured.  
     
     
         31 . The picket of  claim 30 , wherein the at least one exterior surface of the picket is textured to resemble wood.  
     
     
         32 . The picket of  claim 25  having a surface finish that resembles masonry.  
     
     
         33 . The picket of  claim 25 , wherein the picket can be nailed onto a fence rail.  
     
     
         34 . A fence system, comprising: 
 a plurality of pickets each having an elongate configuration extending between an upper end and a lower end, each picket being made of fiber cement and formed into a desired shape, sized and configured for use in a fence prior to curing of said fiber cement, said plurality of pickets being installed generally perpendicular to a ground surface and in substantially parallel relationship to one another.    
     
     
         35 . The fence system of  claim 34 , wherein the pickets after curing do not exhibit any substantial fraying of the fibers along surfaces of the pickets.  
     
     
         36 . The fence system of  claim 34 , wherein each picket is formed of a plurality of layers, said pickets do not exhibit any substantial visible separation of layers.  
     
     
         37 . The fence system of  claim 34 , wherein each of said pickets has an aspect ratio of between 4 and 12.  
     
     
         38 . The fence system of  claim 34 , wherein each of said pickets is spaced from one another by a distance of between about ½ and 1 inch.  
     
     
         39 . The fence system of  claim 34 , wherein each of said pickets has a length between about 2 and 10 feet.  
     
     
         40 . The fence system of  claim 34 , wherein each of said pickets has a width between about 4 and 12 inches.  
     
     
         41 . The fence system of  claim 34 , wherein each of said pickets has a thickness of between about {fraction (5/16)} and ¾ inch.  
     
     
         42 . The fence system of  claim 34 , wherein each of said pickets has a pre-finish thereon.  
     
     
         43 . The fence system of  claim 34 , comprising a pair of mounting rails each extending substantially perpendicular to the pickets.  
     
     
         44 . The fence system of  claim 43 , wherein a first mounting rail is secured to the pickets at an upper location of the pickets, and a second mounting rail is secured to the pickets along a lower location of the pickets.  
     
     
         45 . The fence system of  claim 44 , comprising at least two posts, each of said posts having an elongate configuration extending between an upper end and a lower end and being substantially parallel to the pickets, said posts being secured to the mounting rails, wherein the lower ends of the posts extend below the lower ends of the pickets to secure the posts in a ground location.  
     
     
         46 . A method of forming a fence component, comprising: 
 providing an uncured article comprising fiber cement;    forming at least one fence component from the uncured article, the fence component having a shape configured to be used as a fence picket; and    curing the at least one fence component to form at least one fence picket.    
     
     
         47 . The method of  claim 46 , wherein the at least one fence component has a length between about 2 and 10 feet.  
     
     
         48 . The method of  claim 47 , wherein the at least one fence component has an aspect ratio of between about 9 and 12.  
     
     
         49 . The method of  claim 46 , wherein the at least one fence component has a width between about 4 and 12 inches.  
     
     
         50 . The method of  claim 46 , wherein the at least one fence component has a thickness between about {fraction (5/16)} and ¾ inch.  
     
     
         51 . The method of  claim 46 , wherein the at least one fence component has a pre-finish thereon.  
     
     
         52 . The method of  claim 46 , comprising forming a plurality of fence components from the uncured article.  
     
     
         53 . The method of  claim 46 , comprising cutting at least one fence component from the uncured article.  
     
     
         54 . The method of  claim 46 , wherein the at least one fence component has a substantially rectangular traverse cross-section.  
     
     
         55 . The method of  claim 46 , wherein the at least one fence component has a first surface, a second surface, and a pair of sides adjoining said first and second surfaces, and comprising applying a pattern to at least one of said surfaces prior to curing said article.  
     
     
         56 . The method of  claim 55 , comprising applying a pattern simultaneously to both surfaces.  
     
     
         57 . The method of  claim 56 , wherein applying a pattern simultaneously to both surfaces comprises using a plurality of embossing rollers.  
     
     
         58 . A method of constructing a fence, comprising: 
 providing at least one fiber cement picket, each of said at least one picket being formed into its substantially finished shape prior to curing of said picket; and    installing said at least one fiber cement picket at a desired fencing location, said picket being installed in substantially parallel relationship with respect to other pickets, to form a desired barrier between opposite sides of said barrier.    
     
     
         59 . The method of  claim 58 , wherein each of said at least one picket is mounted to a fence rail.  
     
     
         60 . The method of  claim 59 , wherein said at least one picket is mounted adjacent to and in substantial parallel relationship to a plurality of wooden pickets.  
     
     
         61 . The method of  claim 58 , wherein each of said at least one picket has a length of between about 2 and 10 feet.  
     
     
         62 . The method of  claim 61 , wherein each of said at least one picket has an aspect ratio of between about 9 and 12.  
     
     
         63 . The method of  claim 58 , wherein each of said at least one picket is spaced from one another by a distance of between about ½ and 1 inch.  
     
     
         64 . The method of  claim 58 , wherein each of said at least one picket has a width of between about 4 and 12 inches.  
     
     
         65 . The method of  claim 58 , wherein each of said at least one picket includes at least one surface that has a pre-finish thereon.  
     
     
         66 . The method of  claim 58 , wherein each of said at least one picket has an upper end, wherein each of said upper ends has a shaped selected from the group consisting of square cut, dog-eared, French gothic, scalloped, pointed, and saw-toothed.  
     
     
         67 . The method of  claim 58 , wherein each of said at least one picket has at least one surface that is embossed with a design.  
     
     
         68 . An elongate member made of fiber cement, wherein the elongate member in its uncured state is sized and configured for use as a picket for a fence.  
     
     
         69 . The elongate member of  claim 68  having a first end, said first end has a dog-eared shape, which is formed in the elongate member in its uncured state.  
     
     
         70 . The elongate member of  claim 68  having a pre-finish on at least one surface.  
     
     
         71 . The elongate member of  claim 68  having a length of between 6 and 8 feet.  
     
     
         72 . A fence picket, comprising an elongate member made of fiber cement sized and configured for use as a fence picket, said elongate member having a length defined between an upper end and a lower end, a first surface and a second surface, and substantially parallel sides adjoining said first surface and second surface, wherein at least one of said surfaces has a pre-finish thereon.  
     
     
         73 . The fence picket of  claim 72 , wherein the length of said fence picket is between about 2 and 10 feet.  
     
     
         74 . The fence picket of  claim 72 , wherein the width of said fence picket is between about 4 and 12 inches.  
     
     
         75 . The fence picket of  claim 72 , wherein the upper end is shaped with a design selected from the group consisting of square cut, dog-eared, French gothic, scalloped, pointed, and saw-toothed.  
     
     
         76 . The fence picket of  claim 72 , wherein the first surface is provided with a pattern  
     
     
         77 . The fence picket of  claim 72 , wherein said pattern resembles wood.  
     
     
         78 . The fence picket of  claim 72 , wherein said pattern is substantially smooth.