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  Composite fenceRelated Patent Categories: Fences, MiscellaneousThe Patent Description & Claims data below is from USPTO Patent Application 20070235705. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] This is a continuation of U.S. application Ser. No. 10/920,037, filed Aug. 17, 2004, which is a continuation-in-part of U.S. application Ser. No. 10/758,737, filed Jan. 16, 2004, which is a continuation-in-part of U.S. application Ser. No. 10/452,612, filed Jun. 2, 2003, which claims the benefit of U.S. Provisional Application No. 60/450,415, filed Feb. 27, 2003, each of which is hereby incorporated by reference in its entirety. BACKGROUND AND SUMMARY OF THE INVENTION [0002] The present invention relates generally to components made from composite materials. More particularly, the present invention is directed to a fence and/or its components made from a composite material. Examples of composite materials include plastic composites that include cellulosic fillers and/or inorganic fillers. Cellulosic-filled plastic composites may also be known as synthetic wood composites or, more simply, wood composites. [0003] Generally, fence components such as fence rails, picket panels, posts, etc. are continuously exposed to environmental conditions, such as rain, ice, and snow. In fact, it is well known that the retention of moisture is a primary cause of the warping, splintering, discoloration, and general deterioration of natural woods. In order to slow this degradation of a wood fence, the wood is typically pre-treated with a water-proofing chemical to prevent it from retaining moisture. This pre-treatment adds to the initial cost of the fence. Also, in order to continue to maintain the moisture resistance of the wood, the fence must be regularly treated, preferably annually, with the water-proofing chemical. This regular waterproofing increases the time and costs to maintain the wood fence. Even with this preventative maintenance, wood fences still experience many, if not all, of the deteriorating effects described above. [0004] In addition, the supply of natural woods for construction and other purposes is dwindling. When a tree is harvested for manufacturing purposes, it takes many years to grow another tree of similar size in its place. As a result, many are concerned about conserving the world's forests, and the cost of natural woods has risen. In light of these factors, a tremendous demand has developed in recent years for wood composites that exhibit the look and feel of natural woods. [0005] Wood fiber/polymer composites and wood flour/polymer composites have been used as replacements for all-natural wood, particle board, wafer board, and other similar materials. Wood composites may provide desired appearance, strength, durability, weatherability, and other structural characteristics. As compared to natural woods, wood fiber/polymer composites and wood flour/polymer composites may offer superior resistance to wear and tear. In addition, wood fiber/polymer composites and wood flour/polymer composites may have enhanced resistance to moisture. Moreover, wood fiber/polymer composites and wood flour/polymer composites may be sawed, sanded, shaped, turned, fastened, and finished in a similar manner as natural woods. [0006] In addition, like natural wood, plastic composites are subject to stress caused by load conditions or the conditions of the environment. For instance, plastic composites can expand, contract, bend, warp, creep, or undergo other structural changes over time in response to environmental or load conditions. In addition, fasteners may withdraw from plastic composite fences in a manner similar to which fasteners back out of natural wood. Accordingly, there is a need for further improving the structural characteristics of plastic composite fences. [0007] 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 to further improve the strength of a fence component and fastener retention. Any of a variety of substrates and plastic composites may be used to achieve the desired component characteristics. One example of a composite fence component of the present invention is a picket panel comprised of a cellulosic filler, a polymer, a lubricant, and an inorganic filler. Another example of a composite fence component includes the previous ingredients plus an endothermic or exothermic blowing agent. In another alternative embodiment of a composite fence of the present invention, the composite fence includes a first fence component comprised of a cellulosic filler, a polymer, a lubricant, an inorganic filler, and a exothermic or endothermic blowing agent and a second fence component comprised of a plastic composite having a substrate sheet embedded in it, wherein the plastic composite may be comprised of a cellulosic filler, a polymer, a lubricant, and an inorganic filler. [0008] In addition to the novel features and advantages mentioned above, other features and advantages of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a partial, perspective view of an exemplary embodiment of a composite fence of the present invention. [0010] FIG. 2 is a partial, side elevational view of an alternative embodiment of a composite fence component of the present invention, wherein a substrate is exposed for illustrative purposes. [0011] FIG. 3 is an end elevation view of the composite fence component of FIG. 2, wherein a substrate is exposed for illustrative purposes. [0012] FIG. 4 is a partial, perspective view of an alternative embodiment of a composite fence of the present invention including the component of FIG. 2. [0013] FIG. 5 is a diagram of an exemplary embodiment of an extruder and an inline die system. DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S) [0014] The apparatus and method of the present invention is directed to a composite fence. More particularly, the apparatus and method of the present invention is directed to a fence made of plastic composites that include cellulosic fillers and/or inorganic fillers. Cellulosic-filled plastic composites may also be known as synthetic wood composites or, more simply, wood composites. [0015] The inventors have discovered that a fence, in particular, may benefit from the present invention. For the same reasons, various fence components may also benefit from the present invention. The fence of the present invention may take any form of a fence including, but not limited to, split rail, picket, privacy, and any other type of fence. FIG. 1 shows an exemplary embodiment of a composite fence 10 of the present invention. The fence or assembly 10 includes a post 12, plank 14, and rail 16. The plank 14 may be connected to rail 16 by fasteners 18, which extend through plank 14 and into rail 16. The size and position of the fasteners 18 may vary without changing the scope of the present invention. [0016] Fence 10 may have one component or more components comprised of cellulosic-filled and/or inorganic-filled plastic composites of the present invention. Examples of plastic composites include, but are not limited to, polyolefin composites and polyvinyl chloride composites. A cellulosic-filled plastic composite may be comprised of materials that include, but are not limited to, cellulosic fillers, polymers, inorganic fillers, cross-linking agents, lubricants, process aids, stabilizers, accelerators, inhibitors, enhancers, compatibilizers, blowing agents, foaming agents, thermosetting materials, pigments, anti-oxidants, and other suitable materials. Examples of cellulosic fillers include sawdust, newspapers, alfalfa, wheat pulp, wood chips, wood fibers, wood particles, ground wood, wood flour, wood flakes, wood veneers, wood laminates, paper, cardboard, straw, cotton, rice hulls, coconut shells, peanut shells, bagass, plant fibers, bamboo fiber, palm fiber, kenaf, flax, and other similar materials. [0017] Examples of polymers include multilayer films, high density polyethylene (HDPE), low density polyethylene (LDPE), chlorinated polyethylene (CPE), polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile butadiene styrene (ABS), ethyl-vinyl acetate (EVA), other similar copolymers, other similar, suitable, or conventional thermoplastic materials, and formulations that incorporate any of the aforementioned polymers. Examples of inorganic fillers include talc, calcium carbonate, kaolin clay, magnesium oxide, titanium dioxide, silica, mica, barium sulfate, and other similar, suitable, or conventional materials. [0018] Examples of cross-linking agents include polyurethanes, such as isocyanates, phenolic resins, unsaturated polyesters, epoxy resins, and other similar, suitable, or conventional materials. Combinations of the aforementioned materials are also examples of cross-linking agents. Examples of lubricants include zinc stearate, calcium stearate, esters, amide wax, paraffin wax, ethylene bis-stearamide, and other similar, suitable, or conventional materials. Examples of stabilizers include light stabilizers, tin stabilizers, lead and metal soaps such as barium, cadmium, and zinc, and other similar, suitable, or conventional materials. In addition, examples of process aids include acrylic modifiers and other similar, suitable, or conventional materials. Examples of pigments include titanium dioxide and other similar or suitable white or color additives. [0019] One example of a polyolefin composite used in the present invention is a cellulosic/HDPE material. The composite material may be comprised of at least one cellulosic filler in an amount of about 10% to about 70% by weight, more preferably about 30% to about 50%. Additionally, the composite material may be comprised of HDPE material in an amount of about 10% to about 70% by weight, more preferably about 30% to about 55% by weight. The HDPE material is comprised of HDPE. The HDPE may be of any desired type, and it may have any desired melt index (MI). The HDPE may be incorporated in any desired form, but powder reactor flake form is preferred to facilitate mixing with the cellulosic filler. Optionally, the HDPE material may include other ingredients in addition to the HDPE. For instance, lubricants may be included in the amount of 0% to about 15% by weight of the composite, more preferably about 1% to about 7% by weight of the composite. Examples of lubricants include, but are not limited to, wax, zinc stearate, and other types of stabilizers, e.g., metal soaps. Furthermore, the HDPE material may include at least one inorganic filler, e.g., talc and other mineral fillers, in the amount of 0% to about 25% by weight of the composite, more preferably about 5% to about 20% by weight of the composite. The composite may also optionally include an endothermic or exothermic blowing agent from 0% to about 15% by weight, preferably from 0% to about 6% by weight. [0020] On the other hand, an example of a polyvinyl chloride composite used in the present invention may include at least one cellulosic filler in the amount of about 30% to about 60% by weight, more preferably about 40% to about 50% by weight, and still more preferably about 45% to about 50% by weight. The composite may also include a PVC material in the amount of about 40% to about 70% by weight, more preferably about 50% to about 60% by weight, and still more preferably about 50% to about 55% by weight. The PVC material may include stabilizer(s) in an amount of about 1 to about 10 parts, more preferably about 3 to about 5 parts, per 100 parts of the PVC resin. The lubricant(s) may be present in an amount of about 2 to about 12 parts, more preferably about 4 to about 8 parts, per 100 parts of the PVC resin. Also, process aid(s) may be included in an amount of about 0.5 to about 8 parts, more preferably about 1 to about 3 parts, per 100 parts of the PVC resin. Optionally, at least one inorganic filler may be added in an amount of up to about 10 parts, more preferably up to about 5 parts, per 100 parts of the PVC resin. [0021] As previously mentioned, an example of a cellulosic filler is wood flour. In an exemplary embodiment of the present invention, the wood flour may have a mesh size from about 40 to about 100, preferably from about 40 to about 60. The wood flour may be selected from any desired type of wood including, but not limited to, oak, maple, and pine. Continue reading... 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