Composite fence

Abstract

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.