Modular Fence Panel Sub-Assemblies with Concealed Fasteners
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Solution Overview
Problem
Current fence panels are often time-consuming and expensive to construct, and/or too bulky or large to transport easily, posing challenges in efficiency and cost-effectiveness.
Innovation Solution
The fence panel system consists of sub-panel assemblies, panel rails, and spacers, where sub-panel assemblies are coupled by sub-panel rails and separated by spacers, allowing for efficient assembly and transport in a compact kit form, with panel rails receiving the sub-panel rails and spacers, enabling precise construction without protruding fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fence panels are constructed using conventional methods, then structural integrity is achieved, but construction time and cost increase significantly
Solution Approach 1:
The fence panel is divided into multiple sub-panel assemblies, each comprising a subset of fence boards coupled by sub-panel rails. These modular sub-assemblies can be pre-fabricated off-site and transported efficiently, then quickly assembled on-site by connecting them with panel rails, significantly reducing on-site construction time and improving productivity.
Solution Approach 2:
Sub-panel assemblies are pre-fabricated with fence boards and sub-panel rails assembled in advance at a manufacturing facility. This preliminary construction allows for quality control and precision work to be done in a controlled environment, reducing the time and complexity required for final assembly at the installation location.
2Ease of operation
If fence panels are constructed as single integrated units, then structural strength is maintained, but transportability and storage efficiency deteriorate
Solution Approach 1:
The fence panel system is segmented into multiple sub-panel assemblies that can be transported separately in compact configurations. Each sub-assembly maintains sufficient structural integrity through its internal sub-panel rails and fence board construction, while the modular nature allows for efficient stacking and transportation without requiring the entire panel to be assembled as one large unit.
Solution Approach 2:
Sub-panel assemblies can be nested or stacked within each other during transport and storage, maximizing space efficiency. The sub-panel rails and fence boards are arranged to allow compact packaging, reducing transportation costs and storage requirements while maintaining the ability to assemble a complete, structurally sound fence panel at the installation site.
3Manufacturing precision
If fence panels use traditional assembly methods with protruding fasteners, then ease of assembly is achieved, but aesthetic quality and surface smoothness worsen
Solution Approach 1:
The protruding fastener elements are extracted or removed from the exterior surfaces of the fence panel. Fasteners are either concealed within the sub-panel assemblies, embedded in the fence boards, or positioned on the rear side only, eliminating unsightly protrusions from the visible exterior while maintaining secure assembly through the rail and board connections.
4Productivity
If fence panels are pre-fabricated as complete units, then installation speed is improved, but transport cost and difficulty increase
Solution Approach 1:
The complete fence panel is segmented into lighter sub-panel assemblies that can be transported more easily and at lower cost. These sub-assemblies weigh less than a complete pre-fabricated panel, reducing transportation requirements and costs, while still allowing for rapid installation through modular assembly on-site using panel rails to connect the sub-assemblies quickly.
Data Source
AI summary
A fence panel is provided having a plurality of sub-panel assemblies positioned in a linear arrangement and coupled together via panel rails extending between opposing lateral ends of the fence panel. Each sub-panel assembly may include a plurality of fence boards coupled together by sub-panel rails that extend between opposing lateral ends of the sub-panel assembly. The panel rails may insertably receive a respective linear arrangement of the sub-panel rails. In addition, a respective sub-panel assembly spacer may be positioned between adjacent ones of the sub-panel assemblies to separate the sub-panel assemblies from each other. The fence panel may be provided in a kit consisting of a single packaged arrangement of fence panel components comprising or consisting of the sub-panel assemblies, sub-panel assembly spacers and the panel rails.