U.S. patent application number 12/180378 was filed with the patent office on 2009-01-29 for picket and rail fence.
Invention is credited to Mark Kofford, Kevin Love, Arie Tremblay.
Application Number | 20090026431 12/180378 |
Document ID | / |
Family ID | 40294436 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090026431 |
Kind Code |
A1 |
Tremblay; Arie ; et
al. |
January 29, 2009 |
PICKET AND RAIL FENCE
Abstract
A picket and rail fence is provided. In one embodiment, the
invention relates to a fence including a rail including a tube
having a rectangular cross section including a top, a bottom, two
sides, and at least one cutout, a picket including a bar configured
to fit within the at least one cutout of the rail, a retaining bar
having a lengthwise rectangular shape, the retaining bar including
a first substantially flat longitudinal portion, a second
substantially flat longitudinal portion, wherein the first portion
and the second portion are separated by a middle portion having a
cross section forming a protrusion extending away from the first
portion and the second portion, wherein the retaining bar is
configured to slide within the rail such that a bottom of the
retaining bar abuts one of the two sides of the rail, and wherein
the picket bar includes a notch configured to receive at least a
portion of the protrusion of the retaining bar.
Inventors: |
Tremblay; Arie; (Gardena,
CA) ; Kofford; Mark; (Dana Point, CA) ; Love;
Kevin; (Dana Point, CA) |
Correspondence
Address: |
CHRISTIE, PARKER & HALE, LLP
PO BOX 7068
PASADENA
CA
91109-7068
US
|
Family ID: |
40294436 |
Appl. No.: |
12/180378 |
Filed: |
July 25, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60951923 |
Jul 25, 2007 |
|
|
|
Current U.S.
Class: |
256/65.03 ;
256/22; 256/59; 256/65.02 |
Current CPC
Class: |
E04H 17/1439 20130101;
E04H 17/1447 20210101 |
Class at
Publication: |
256/65.03 ;
256/59; 256/22; 256/65.02 |
International
Class: |
E04H 17/14 20060101
E04H017/14; E04H 17/16 20060101 E04H017/16 |
Claims
1. A fence comprising: a rail comprising a tube having a
rectangular cross section comprising a top, a bottom, two sides,
and at least one cutout; a picket comprising a bar configured to
fit within the at least one cutout of the rail; a retaining bar
having a lengthwise rectangular shape, the retaining bar comprising
a first substantially flat longitudinal portion, a second
substantially flat longitudinal portion, wherein the first portion
and the second portion are separated by a middle portion having a
cross section forming a protrusion extending away from the first
portion and the second portion; wherein the retaining bar is
configured to slide within the rail such that a bottom of the
retaining bar abuts one of the two sides of the rail; and wherein
the picket bar includes a notch configured to receive at least a
portion of the protrusion of the retaining bar.
2. The fence of claim 1, further comprising a grommet having a
rectangular shape and a rectangular opening configured to receive
the picket, wherein the grommet is configured to slide onto the
picket and to fit within the at least one cutout of the rail.
3. The fence of claim 2, wherein the grommet comprises a
substantially square shape.
4. The fence of claim 2, wherein the grommet has a flat front face,
a flat rear face, and two side walls extending from the rear face
and in a direction normal to the rear face along opposing sides of
the opening of the grommet, where the side walls of the grommet are
configured to abut the at least one rail cutout.
5. The fence of claim 2, wherein the grommet is configured to
prevent the rail from contacting the picket.
6. The fence of claim 2, wherein the grommet is comprised of
polyvinyl chloride.
7. The fence of claim 1, wherein the rail and the picket have cross
sections that are substantially square in shape.
8. The fence of claim 1, wherein the rail, the picket and the
retaining bar are comprised of galvanized steel.
9. The fence of claim 1, wherein the picket bar comprises a rigid
tube having a rectangular cross section comprising four picket
sides.
10. The fence of claim 9, wherein the notch comprises a
semicircular cutout extending through at least two sides of the
picket.
11. The fence of claim 1: further comprising a grommet having a
rectangular shape and a rectangular opening configured to receive
the picket; wherein the at least one cutout is disposed on the top
of the rail; wherein the bottom comprises at least one bottom
cutout; wherein the at least one top cutout and the at least one
bottom cutout are configured to receive the picket; wherein the
grommet is configured to slide onto the picket and to fit within
the at least one top cutout of the rail.
12. The fence of claim 11: wherein the at least one top cutout is
substantially square in shape; and wherein the at least one bottom
cutout is rectangular in shape.
13. The fence of claim 12, wherein a center of the at least one top
cutout is not aligned with a center of the at least one bottom
cutout.
14. The fence of claim 1, wherein the fence section is configured
to allow for up to 25 percent raking.
15. The fence of claim 1, wherein a cross section of the protrusion
comprises a V-shape wherein a vertex of the V-shape is disposed
along a line normal to the first portion and the second
portion.
16. A fence comprising: a picket bar having a notch; a grommet
configured to slide onto the picket bar; a rail comprising a tube
having a rectangular cross section comprising a top, a bottom, two
sides, and a cutout configured to receive the picket bar and the
grommet; and a retaining bar having a lengthwise protrusion;
wherein the retaining bar is configured to slide within the rail;
and wherein the notch is configured to receive the lengthwise
protrusion of the retaining bar when the picket and the retaining
bar have been inserted into the rail.
17. The fence of claim 16: wherein the grommet comprises a
rectangular shape and a rectangular opening configured to receive
the picket; wherein the at least one cutout is disposed on the top
of the rail; wherein the bottom comprises at least one bottom
cutout; and wherein the at least one top cutout and the at least
one bottom cutout are configured to receive the picket.
18. The fence of claim 17: wherein the at least one top cutout is
substantially square in shape; and wherein the at least one bottom
cutout is rectangular in shape.
19. The fence of claim 18, wherein a center of the at least one top
cutout is not aligned with a center of the at least one bottom
cutout.
20. A method for installing a fence, the method comprising:
inserting a picket into a cutout of a rail comprising a tube having
a rectangular cross section; sliding a retaining bar into the rail,
wherein the retaining bar comprises a lengthwise rectangular shape
with a protrusion extending substantially from a centerline along a
length of the lengthwise rectangular shape; and attaching the rail
to a post.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of Provisional
Application No. 60/951,923, filed Jul. 25, 2007, entitled "FENCE
WITH LOCKING GROMMETS", the contents of which are expressly
incorporated herein by reference in their entirety.
BACKGROUND
[0002] The present invention relates generally to picket and rail
fences, and more particularly to a picket and rail fence design
that provides for easy assembly and tamper resistant
construction.
[0003] Picket fences are often used for security and/or ornamental
purposes. They can keep out intruders including trespassers or
animals. As the size of a potential intruder varies, picket fences
are constructed to restrict a number of different sized intruders.
Materials used to construct picket fences can include vinyl,
aluminum, steel, composites and wood. The style and appearance of a
fence can be chosen to suit a particular architecture, such as a
building or other structure being protected, or the preference of
the owner of the fence.
[0004] A typical structure of a picket fence includes a number of
vertical sections or pickets, a number of horizontal sections or
rails and at least two posts. The assembly of such fences often
requires several tools. The tools are used to install any number of
fastening devices that couple the pickets, rails and posts. In
other cases, the fence components are coupled using tools to weld
the components to one another. Use of either method of attachment
often leads to premature rust. The fasteners and the welds are
generally more likely to rust before other fence components. In
addition, welded joint attachments provide for minimal flexibility
in the fence structure. Flexibility is important when the span of
post is not precisely uniform and when there is vertical variance
of terrain.
SUMMARY
[0005] Aspects of the present invention relate to a picket and rail
fence. In one embodiment, the invention relates to a fence
including a rail including a tube having a rectangular cross
section including a top, a bottom, two sides, and at least one
cutout, a picket including a bar configured to fit within the at
least one cutout of the rail, a retaining bar having a lengthwise
rectangular shape, the retaining bar including a first
substantially flat longitudinal portion, a second substantially
flat longitudinal portion, wherein the first portion and the second
portion are separated by a middle portion having a cross section
forming a protrusion extending away from the first portion and the
second portion, wherein the retaining bar is configured to slide
within the rail such that a bottom of the retaining bar abuts one
of the two sides of the rail, and wherein the picket bar includes a
notch configured to receive at least a portion of the protrusion of
the retaining bar.
[0006] In another embodiment, the invention relates to a fence
including a picket bar having a notch, a grommet configured to
slide onto the picket bar, a rail including a tube having a
rectangular cross section including a top, a bottom, two sides, and
a cutout configured to receive the picket bar and the grommet, and
a retaining bar having a lengthwise protrusion, wherein the
retaining bar is configured to slide within the rail, and wherein
the notch is configured to receive the lengthwise protrusion of the
retaining bar when the picket and the retaining bar have been
inserted into the rail.
[0007] In yet another embodiment, the invention relates to a method
for installing a fence, the method including inserting a picket
into a cutout of a rail including a tube having a rectangular cross
section, sliding a retaining bar into the rail, wherein the
retaining bar includes a lengthwise rectangular shape with a
protrusion extending substantially from a centerline along a length
of the lengthwise rectangular shape, and attaching the rail to a
post.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1a is a side view of a section of a picket and rail
fence in accordance with an embodiment of the present
invention;
[0009] FIG. 1b is a sectional view of the picket and rail fence of
FIG. 1a taken along the section A-A;
[0010] FIG. 1c is an enlarged view of a portion of the sectional
view of FIG. 1b showing the relationship of a rail, a retaining
bar, a picket, and a grommet in an assembled configuration;
[0011] FIG. 2a is a perspective cut away view of a rail, a
retaining bar, a picket, and a grommet in an assembled
configuration in accordance with an embodiment of the present
invention;
[0012] FIG. 2b is a perspective view of a rail grommet in
accordance with an embodiment of the present invention;
[0013] FIG. 2c is a top view of a retaining bar in accordance with
an embodiment of the present invention;
[0014] FIG. 2d is a side view of the retaining bar of FIG. 2c;
[0015] FIG. 2e is a top view of a rail in accordance with an
embodiment of the present invention;
[0016] FIG. 2f is a cross sectional view of the rail of FIG.
2e;
[0017] FIG. 2g is a side view of the rail of FIG. 2e;
[0018] FIG. 3a is a perspective view of a section of a fence with
locking grommets in accordance with an embodiment of the present
invention;
[0019] FIG. 3b is a side view of the fence of FIG. 3a;
[0020] FIG. 3c is an expanded view of a joint including the top
rail and one post of the fence shown in FIG. 3b;
[0021] FIG. 3d is an expanded view of a joint including the bottom
rail and one picket of the fence shown in FIG. 3b;
[0022] FIG. 4a is a perspective view of a fence post in accordance
with an embodiment of the present invention;
[0023] FIG. 4b is a perspective view of the opposite side of the
fence post shown in FIG. 4a;
[0024] FIG. 4c is a front view of the fence post shown in FIG.
4a;
[0025] FIG. 4d is a side view of the fence post shown in FIG.
4a;
[0026] FIG. 4e is a rear view of the fence post shown in FIG.
4a;
[0027] FIG. 5a is a perspective view of a top rail in accordance
with an embodiment of the present invention;
[0028] FIG. 5b is a side view of the rail shown in FIG. 5a;
[0029] FIG. 5c is an expanded view of one end of the rail shown in
FIG. 5a;
[0030] FIG. 5d is a bottom view of the rail shown in FIG. 5a;
[0031] FIG. 6a is a perspective view of a bottom rail in accordance
with an embodiment of the present invention;
[0032] FIG. 6b is a top view of the rail shown in FIG. 6a;
[0033] FIG. 6c is a side view of the rail shown in FIG. 6a;
[0034] FIG. 6d is an expanded view of one end of the rail shown in
FIG. 6c;
[0035] FIG. 6e is an expanded view of one end of a bottom rail in
accordance with an embodiment of the present invention;
[0036] FIG. 7a is a perspective view of a picket in accordance with
an embodiment of the present invention;
[0037] FIG. 7b is a front view of the picket shown in FIG. 7a;
[0038] FIG. 7c is a side view of the picket shown in FIG. 7a;
[0039] FIG. 7d is an expanded view of the upper end of the picket
shown in FIG. 7c;
[0040] FIG. 7e is a sectional view of a portion of a picket and a
picket grommet in accordance with an embodiment of the present
invention;
[0041] FIG. 8a is a perspective view of a picket grommet in
accordance with an embodiment of the present invention;
[0042] FIG. 8b is a side view of the picket grommet shown in FIG.
8a;
[0043] FIG. 8c is a top view of the picket grommet shown in FIG.
8a;
[0044] FIG. 8d is a front view of the picket grommet shown in FIG.
8a;
[0045] FIG. 8e is a top sectional view taken along the section A-A
of the picket grommet shown in FIG. 8d;
[0046] FIG. 8f is a perspective view of a small rail grommet in
accordance with an embodiment of the present invention;
[0047] FIG. 9a is a perspective view of a post grommet in
accordance with an embodiment of the present invention;
[0048] FIG. 9b is a front view of the post grommet shown in FIG.
9a;
[0049] FIG. 9c is a rear view of the post grommet shown in FIG.
9a;
[0050] FIG. 9d is a side sectional view taken along the section A-A
of the post grommet shown in FIG. 9c;
[0051] FIG. 9e is a bottom view of the post grommet shown in FIG.
9a;
[0052] FIG. 10a is a top view of a post bracket in accordance with
an embodiment of the present invention;
[0053] FIG. 10b is a side view of the post bracket shown in FIG.
10a;
[0054] FIG. 10c is a rear view of the post bracket shown in FIG.
10a;
[0055] FIG. 11a is a top sectional view of a rail and a picket in
accordance with an embodiment of the present invention;
[0056] FIG. 11b is a side sectional view of a post and a rail in
accordance with an embodiment of the present invention;
[0057] FIG. 12a is a perspective view of a post grommet in
accordance with another embodiment of the present invention;
[0058] FIG. 12b is a front view of the post grommet shown in FIG.
12a;
[0059] FIG. 12c is a rear view of the post grommet shown in FIG.
12a;
[0060] FIG. 12d is a side sectional view taken along the section
A-A of the post grommet shown in FIG. 12c;
[0061] FIG. 12e is a bottom view of the post grommet shown in FIG.
12a;
[0062] FIG. 13a is a perspective view of a large rail grommet in
accordance with another embodiment of the present invention;
[0063] FIG. 13b is a front view of the large rail grommet shown in
FIG. 13a;
[0064] FIG. 13c is a rear view of the large rail grommet shown in
FIG. 13a;
[0065] FIG. 13d is a side sectional view taken along the section
A-A of the large rail grommet shown in FIG. 13c;
[0066] FIG. 13e is a bottom view of the large rail grommet shown in
FIG. 13a;
[0067] FIG. 14a is a perspective view of a picket grommet in
accordance with the embodiment of the large rail grommet shown in
FIG. 11a;
[0068] FIG. 14b is a side view of the picket grommet shown in FIG.
14a;
[0069] FIG. 14c is a top view of the picket grommet shown in FIG.
14a;
[0070] FIG. 14d is a front view of the picket grommet shown in FIG.
14a;
[0071] FIG. 14e is a top sectional view taken along the section A-A
of the picket grommet shown in FIG. 14d;
[0072] FIG. 14f is a perspective view of a small rail grommet in
accordance with the embodiment of the post grommet shown in FIG.
10a;
[0073] FIG. 15a is an sectional view of a joint including the top
rail and one picket in accordance with an embodiment of the present
invention;
[0074] FIG. 15b is an sectional view of a joint including the top
rail and one post in accordance with an embodiment of the present
invention; and
[0075] FIG. 15c is an sectional view of a joint including the top
rail and one post in accordance with the embodiment shown in FIG.
15b.
DETAILED DESCRIPTION
[0076] Referring now to the drawings, embodiments of fences having
rails that enclose locking bars for securing pickets, are assembled
with a minimal number of tools, eliminate or minimize metal on
metal connections, and are sufficiently flexible to allow for
substantial raking are shown. The fences commonly include grommets
preventing metal on metal contact between pickets and rails.
Embodiments of fences having enclosed or tubular rails which
include square or rectangular cross sections provide increased
strength in comparison to convention rails used in picket and rail
fences. In particular, a closed rail design can prevent sag common
to some rail designs, such as, for example, a rail having an open
bottom. In several embodiments, the tubular rails are made from
galvanized steel.
[0077] In some embodiments, the enclosed rails can bear more weight
than an open bottom rail. Consequently, to achieve the same
strength for a given rail, an enclosed rail can use less steel than
an open rail. In such case, and with the high cost of building
materials such as steel, enclosed rails are cheaper to manufacturer
than open rail systems. In a number of embodiments, the rails are
coated with various materials to protect against corrosion.
[0078] Embodiments of fences having a locking or retaining bar that
slides into a rail and secures the pickets in place enable quick
assembly and provide for added security. In such embodiments, for
example, it is very difficult for a potential intruder to gain
access to the mechanism (e.g., locking bar) responsible for
securing the assembled fence. The locking bar can take a number of
suitable shapes for retaining pickets.
[0079] Embodiments of fences having grommets prevent metal on metal
connections, enable easy assembly, and allow the fence to be raked.
Metal on metal connections can cause a number of problems including
rust, noise and lack of flexibility. Use of fasteners, welds or
other connection methods often results in metal on metal
connections. Embodiments of fences in accordance with the present
invention can prevent contact between metal components and damage
to special coatings. In accordance with the use of grommets and the
locking bar, embodiments of fences accommodate variations in
terrain, incline or rake, component construction or other atypical
conditions. The choice of materials for the fence components,
including grommets, can allow for a desired flexibility in the
fence.
[0080] FIG. 1a is a side view of a section of a picket and rail
fence with in accordance with an embodiment of the present
invention. The fence section 10 includes two posts 12 mounted
within the ground 13 or another foundation. An upper rail 16 and a
lower rail 18 are mounted to the posts 12 using a number of
mounting clamps 26. A plurality of pickets 20 are coupled to the
rails (16, 18).
[0081] In one embodiment, the fence posts 12 are buried in the
ground 13 at 36 inches below grade. In one embodiment, the posts
extend 72 inches above the ground 13. In one embodiment, the fence
section and rails extend approximately 96 inches lengthwise. In
some embodiments, the posts are square shaped tubes having sides
that are 2.5 inches wide. In other embodiments, different
dimensions can be used for any of the fence components.
[0082] FIG. 1b is a sectional view of the picket and rail fence of
FIG. 1a taken along the section A-A.
[0083] FIG. 1c is an enlarged view of a portion of the sectional
view of FIG. 1b showing the relationship of the upper rail 16, a
retaining bar 25, a picket 20, and a grommet 21 in an assembled
configuration. The picket 20 is disposed within square or
rectangular cutouts (not visible) in the upper rail 16. The grommet
21 is inserted into one of the rail cutouts and secures the picket
20 within the rail. The grommet 21 can prevent lateral movement of
the picket within the rail and can prevent metal on metal coupling
between the picket and the rail at the rail cutout. The upper rail
16 is secured to the post 12 by mounting clamp 26. A flat bottom of
a locking bar 25 is disposed vertically within the square shaped
rail 16 along one side of the rail 16. The locking bar 25 has a
triangular or V-shaped protrusion that extends, at least in part,
into a cutout 27 within the picket 20. The picket cutout 27 is
shaped such that the cutout or notch can receive at least a portion
of the V-shaped protrusion of the locking bar 25. The locking or
retaining bar 25 effectively retains the picket 20 within the rail
16. In particular, the locking bar 25 resists the gravitational
force on the picket 20 and therefore prevents the picket 20 from
falling toward the ground 13. The spacing between the cutout and
the locking bar protrusion enables the fence, at least in part, to
rake.
[0084] FIG. 2a is a perspective cut away view of a portion of a
fence showing a rail 16, a retaining bar 25, a picket 20, and a
grommet 21 in an assembled configuration in accordance with an
embodiment of the present invention. In operation, a grommet 21
having a square opening is placed on a square shaped picket 20 and
moved to an appropriate position along the picket. The square
picket 20 and surrounding grommet 21 are inserted into a square
cutout in the rail 16. The grommet 21 retains the position of the
picket 20 within the rail, at least in part, and prevents any metal
on metal connection. The locking bar 25 is inserted into the rail
16 such that a flat bottom of the locking bar 25 abuts a side of
the rail 16 and a triangular or V-shaped protrusion 28 of the
locking bar extends in a direction normal to the flat bottom. The
cutout 27 of the picket 20 is shaped to receive a portion of the
triangular protrusion 28 of the locking bar 25. In the illustrated
embodiment, the picket cutout 27 has a semicircular or arc shaped
cutout.
[0085] In other embodiments, other suitable shapes can be used for
the picket cutout in accordance with the shape of the locking bar
protrusion. In other embodiments, the locking bar protrusion can
take other suitable shapes. In a number of embodiments, the
pickets, rails and posts are made of galvanized steel or aluminum
and coated using special coating processes to protect the
components against corrosion. In one embodiment, an electrolytic
paint dip coat is applied to outer surfaces of the posts, rails and
pickets. In some embodiments, the electrolytic paint dip coat is
also applied to the locking bar. In several embodiments, a
polyester powder coat is applied to the posts, rails and pickets.
In embodiments including any of the coating processes, the grommets
can prevent the coated components from making contact with one
another and therefore damaging the protective coatings. In other
embodiments, other protective coatings and coating processes can
also be used.
[0086] The use of the grommets also enables the improved fences to
be assembled quicker than other picket and rail fences. The use of
the locking bar improves ease of assembly by locking the pickets
into place without requiring tools or fasteners. The combination of
the locking bar, picket cutouts and grommets also allows the fence
to be raked or inclined to follow the grade of a ground surface. In
some embodiments, fences using the grommets and locking bar of the
present invention can achieve up to a 25 percent rake. In many
embodiments, the use of the locking bar provides a higher degree of
security than conventional picket and rail fences as the mechanism
for securing or locking the fence together, the locking bar, is not
accessible. In such case, disassembly by an intruder is made
difficult, and the locking bar essentially makes the tamper
resistant.
[0087] In the embodiment illustrated in FIG. 2a, the rail 16 has a
hollow tube shape with a square cross section. The rail 16 spans a
distance between the posts 12. In other embodiments, the rail can
have another suitable shape. In one such embodiment, the rail has a
rectangular cross section. In other embodiments, more than two
rails are used.
[0088] In the embodiment illustrated in FIG. 2a, the picket 20 has
a hollow tube shape having a square cross section. In one
embodiment, the sides are 0.75 inches wide and 0.065 inches thick.
In one embodiment, the picket cutout is in the shape of a
semicircle having a radius of 0.25 inches. In the embodiment
illustrated in FIG. 1a, the picket 20 spans a distance from the
lower rail 18 to slightly above the upper rail 16. In other
embodiments, the pickets can extend below the lower rail or extend
only as high as the upper rail. In other embodiments, the pickets
can have another suitable shape. In one such embodiment, the
pickets have a rectangular cross section. In another embodiment,
the pickets have a circular cross section.
[0089] In other embodiments, the grommet 21 is inserted into a
cutout on the bottom of the rail. In such case, the picket 20 does
not extend upward beyond the rail. One such configuration is known
at a flat top picket and rail fence. In such case, the upper rail
has no cutouts on the top of the rail and is therefore well
protected from rain water and other elements likely to cause decay
of the fence.
[0090] FIG. 2b is a perspective view of a rail grommet 21' in
accordance with an embodiment of the present invention. The grommet
21' has a flat square shaped front face (not visible) and a square
shaped opening 30 for receiving a picket. The grommet 21' also has
a flat square shaped rear face 31. Two side walls 32 extend normal
to the surface of the rear face 31. In the assembled position, the
side walls 32 make contact with the opening or cutout of the rail.
Each side wall 32 has a locking tab 34 for locking the grommet 21'
into place once it has been slid onto the picket and into the rail.
The locking tab 34 can retain the grommet against the cutout wall
of the rail.
[0091] In the embodiment in FIG. 2b, the grommet 21' has two side
walls. In other embodiments, the grommets can have more than two
side walls. In the embodiment illustrated in FIG. 2a, for example,
the grommets have four side walls. In one embodiment, the front
face of the grommet is 1.2 inches by 1.2 inches. In some
embodiments, the side walls are 0.98 inches apart at their outer
surfaces, and have widths of 0.855 inches. In other embodiments,
different dimensions can be used for any of the fence
components.
[0092] FIG. 2c is a top view of a locking bar 25 in accordance with
an embodiment of the present invention. FIG. 2d is a side view of
the locking bar 25 of FIG. 2c. The locking bar 25 has an overall
rectangular shape when viewed from above. The locking bar 25
includes an upper flat section 36, a lower flat section 38, and a
middle rounded protrusion section 28. The protrusion 28 has a
V-shape where the prominent end of the V-shape is rounded and
directed away from the upper and lower flat sections in a direction
normal to the upper and lower flat sections. In other embodiments,
the protrusion can take other shapes. In one such embodiment, the
protrusion is a wall normal to the upper flat section and lower
flat sections such that the cross section takes the shape of a "T"
rotated 90 degrees counter-clockwise. In other embodiments, the
cross section can be L-shaped.
[0093] In one embodiment, the locking bar is 90 inches long and
1.25 inches wide. In some embodiments, the upper flat section and
lower flat section are each 0.347 inches wide. In one embodiment,
the V-shaped protrusion extends approximately 0.438 inches from the
flat bottom of the locking bar. In one embodiment, the angle of the
V-shaped protrusion is approximately 40 degrees. In other
embodiments, different dimensions can be used for any of the fence
components.
[0094] FIG. 2e is a top view of a rail 16 in accordance with an
embodiment of the present invention. The rail 16 has a rectangular
shape lengthwise along with a square cross section. FIG. 2f is a
cross sectional view of the rail 16 of FIG. 2e. The rail 16 further
includes a number of square shaped top cutouts 40 having rounded
corners disposed on a top side of the rail 16, and a number of
rectangular shaped bottom cutouts 42 disposed on a bottom side of
the rail 16. In the illustrated embodiment, the bottom cutouts 42
each have a length that is longer than that of the square shaped
top cutouts 40. The increased length on the bottom cutout can allow
for flexibility in the fence and the ability of the fence to rake
up to 25 percent. In addition, the top cutouts 40 are not centered
with respect to the bottom cutouts 42 to allow increased raking in
a particular direction.
[0095] In some embodiments, the rail is approximately 92 inches
long and 1.5 inches wide on each side of its cross section. In some
embodiments, the top cutout is square shaped and each side is
approximately 0.875 inches long. In various embodiments, the bottom
cutout is approximately 1.6 inches long, and wide enough to
accommodate the width of a picket. In other embodiments, different
dimensions can be used for any of the fence components.
[0096] FIG. 2g is a side view of the rail 16 of FIG. 2e. The rail
16 further includes two mounting holes 44 at either end of the rail
for attachment using the mounting clamps 26 (see FIG. 1a) that have
been attached to the posts.
[0097] In another embodiment, picket and rail fences are assembled
without a locking bar using several inter-locking or locking
grommets. In such case, a number of different sized locking
grommets or inserts are inserted and/or locked into the posts,
rails and pickets without tools. Embodiments of such fences
including posts, rails, pickets and grommets are assembled without
tools. The grommets can be made of any number of materials such as
rubber or polyvinyl chloride or (PVC).
[0098] Embodiments of fences having locking grommets similarly
avoid or eliminate metal on metal connections. As indicated above,
metal on metal connections can cause a number of problems including
rust, noise and lack of flexibility. The use of fasteners, welds or
other connection methods often results in metal on metal
connections. Embodiments of fences in accordance with the present
invention can include interlocking grommets that are installed in
joints typically including metal on metal connections in prior art
systems. Embodiments of fences having locking grommets are flexible
yet robust. Such fences also accommodate variations in terrain,
height, component construction or other atypical conditions. The
numerous locking and interlocking components of these fences add
strength to the overall structure to make it robust.
[0099] FIG. 3a is a perspective view of a section of a fence with
locking grommets in accordance with an embodiment of the present
invention. FIG. 3b is a side view of the fence shown in FIG. 3a.
The fence 110 includes two posts 112, 114, a top rail 116, a bottom
rail 118, three pickets 120, six large rail grommets 122, two post
grommets 124, and two mounting clamps 126. The two posts 112, 114
can be mounted vertically such that the lower portion of each is
supported in the ground or by other support means. The top rail 116
and the bottom rail 118 can be mounted to the posts using the two
mounting clamps 126 on one side and two post grommets 124 and two
small rail grommets 130 (see FIG. 3c) on the other side. The three
pickets 120 are mounted to the top rail 116 and bottom rail 118
using the six large rail grommets 122 and six picket grommets 132
(see FIG. 3d). The top rail 116 and the bottom rail 118 each
include three channel shaped cutouts or recesses 128 (see FIG. 3c),
where each cutout is configured to receive a small rail grommet 130
for facilitating lateral adjustments.
[0100] In other embodiments, more than or less than three channel
cutouts 128 can be used for each rail. In another embodiment, post
114 is configured to receive the rails using locking grommets
rather than mounting clamps. In such case, the rails would have
channel shaped cutouts 128 on both ends configured to receive small
rail grommets 130, and the posts 112, 114 would have cutouts
(similar to 134 in FIG. 4a) on both sides to receive the ends of
the rails.
[0101] The fence can be assembled by first attaching the pickets
120 to the rails 116 and 118. The six picket grommets 132 can be
inserted into six channel shaped picket cutouts or recesses 146
(see FIG. 7a) of the three pickets (see FIG. 3d), where each of the
pickets 120 has two picket cutouts 146 to engage with the two rail
grommets 122. The large rail grommets 122 can each be inserted into
each of the rail cutouts 138 (see FIG. 5a) and 40 (see FIG. 6a).
The upper ends of the pickets 120 can be inserted into the large
rail grommets 122 until the picket grommets 132 are within the
large rail grommets in the top rail. The picket grommets 132 can be
locked onto a portion of the cutouts 138 located on the rail as
each picket grommet 132 receives and snaps onto a portion of a rail
116 to secure the picket to the lower rail (FIG. 3d, 11a).
[0102] While FIG. 3d depicts a picket engaged with the bottom rail,
the connection is substantially similar for a picket engaged with
the top rail. These steps can be repeated until the upper ends of
each picket 120 are locked into place using the large rail grommets
122. A similar process can be performed with the bottom rail 118
and the lower ends of the pickets 120 such that each picket 120 is
attached to both the top rail 116 and the bottom rail 118 using
both the picket grommets 132 and the large rail grommets 122. In
this way, metal on metal connections are avoided or eliminated from
the connections of the pickets and rails. The resulting
configuration is held together by a number of interlocking
grommets.
[0103] Once the picket and rail structure or lattice has been
assembled, it can be attached to the posts 112 and 114. In some
instances, an installer will set the posts in the ground first and
then attach the picket and rail lattice. In other instances, the
installer may attach the picket and rail lattices to all the posts
and set the posts last. In either case, the rails 116, 118 are
attached to the posts 112, 114.
[0104] In attaching the rails and posts, each of the small rail
grommets 130 can be inserted into one of the channel shaped cutouts
128 of the rails 116 and 118. Any of the three channel shaped
cutout of the rails (see FIG. 3c) can be used by the installer to
adjust for the separation between the posts. That is, any of the
three cutout positions can be used to provide for lateral
adjustments in connecting the rails to the two posts. This provides
a tolerance for inexact separation between posts during post
installation or slightly non-vertical post installation. Any number
of factors can create an atypical or non-ideal separation between
posts. In one embodiment, less than or more than three channel
shaped cutouts can be used.
[0105] The two post grommets 124 can be inserted into the two post
cutouts 134 (see FIG. 4c). The rails 116, 118 can be inserted into
the two post grommets 124 (see FIG. 3c) in the post 112 until the
small rail grommets are within the post grommets. Once the small
grommets are within the post grommets, the installer engages and
locks onto a lower edge of each cutout 134 (see FIGS. 3c, 9a and
11b) using the small rail grommets 130 within each of the post
grommets. The resulting configuration is held together by the
combination of interlocking grommets.
[0106] The rails 116, 118 can be attached to post 114 using
mounting clamps 126 and methods known to one of ordinary skill in
the art. In one embodiment, post 112 and post 114 are identical. In
such case, rails 116, 118 are attached to post 114 using the
assembly process described above with regard to post 112. In
another embodiment, post 112 and 114 are not identical. In several
embodiments, any number of identical posts are attached using any
number of the above described picket and rail lattices.
[0107] In one embodiment, the posts, rails, and pickets can be made
of a hollow material taking the form of square tubes. In one
embodiment, the material can be a metal such as steel, aluminum or
a metal composite and can be coated with powder or other anti-rust
agents. In other embodiments, the material can be PVC or vinyl. In
one embodiment, the hollow material can take the form of a
cylindrical tube or other appropriate shapes. In one embodiment,
the material is solid rather than hollow.
[0108] In the embodiment illustrated in FIG. 3b, there are three
pickets and two rails. In other embodiments, any number of pickets
and rails can be used. The pickets and rails can be attached using
the locking combination of grommets (interlocking grommets)
described above.
[0109] FIG. 3c illustrates an expanded view of a joint including
the top rail and one post of the fence shown in FIG. 3b. The joint
includes the top rail 116, the post 112, the small rail grommet 130
and the post grommet 124. These components can be assembled as
discussed above.
[0110] FIG. 3d illustrates a expanded view of a joint including the
bottom rail and one picket of the fence shown in FIG. 3b. The joint
includes a picket 120, the bottom rail 118, a picket grommet 132
and a large rail grommet 122. These components can be assembled as
discussed above.
[0111] FIG. 4a illustrates a perspective view of a fence post in
accordance with an embodiment of the present invention. The post
112 includes circular cutouts 134, each configured to receive a
rail, and mounting holes 136 (see FIG. 4e) for use with the
mounting brackets. FIGS. 4b-4e illustrate various views the fence
post shown in FIG. 4a. As shown in FIG. 4e, the post is configured
to receive mounting clamps. In other embodiments, the post can be
configured with cutouts on both sides of the posts to accommodate
rail attachment using interlocking grommets on both sides. In one
embodiment, the square posts are 2.25 inches wide on each side and
the post material is 60 mils thick.
[0112] FIG. 5a illustrates a perspective view of a top rail in
accordance with an embodiment of the present invention. The top
rail 116 includes three circular cutouts 138, three channel shaped
cutouts 128, and mounting holes 139. The three circular cutouts are
each configured to receive a large rail grommet. The three channel
shaped cutouts are each configured to receive a small rail grommet.
FIG. 5b illustrates a side view of the top rail shown in FIG. 5a.
FIG. 5c is an expanded view of one end of the rail shown in FIG.
5a. The channel shaped cutouts 128 can be 0.25 inches wide and 0.25
inches deep, as a non-limiting exemplary embodiment. In one
embodiment, the rail is a square material having sides of 1.25
inches. FIG. 5d is a bottom view of the rail shown in FIG. 5a.
[0113] FIG. 6a illustrates a perspective view of a bottom rail in
accordance with an embodiment of the present invention. FIGS. 6b-6d
illustrate top, side and expanded views, respectively, of the
bottom rail shown in FIG. 6a. The bottom rail 118 includes three
circular cutouts 140 disposed on the top of the rail, three channel
shaped cutouts 128 and a mounting hole 142. The three circular
cutouts are each configured to receive a large rail grommet. The
three channel shaped cutouts are each configured to receive a small
rail grommet. The channel shaped cutouts 128 can be 0.25 inches
wide and 0.25 inches deep. The rail can have a square shape with
sides of 1.25 inches. In the illustrated embodiment, the bottom
rail 118 has an open bottom. In other embodiments, the bottom can
be enclosed to form a hollow tube like structure.
[0114] As indicated above, the rails 116, 118 can have three
channel shaped cutouts 128 at one end of the rails. In other
embodiments, more than or less than three channel shaped cutouts
can be used. For example, in one embodiment, only one channel
shaped cutout is used at one end of the rails. In other
embodiments, both ends of the rails can have channel shaped
cutouts. In other embodiments, more than or less than three
circular cutouts can be used. In other embodiments, the cutouts
configured to receive the pickets can take other shapes.
[0115] FIG. 6e illustrates an expanded view of one end of a rail in
accordance with an embodiment of the present invention. The three
channel shaped cutouts 144 are substantially trapezoidal in shape
rather than square. In one embodiment, the end to end width of each
cutout opening can be 0.25 inches and the depth can be 0.375
inches. In the illustrated embodiment, the angled walls of the
cutout can help retain a small rail grommet once locked in
position.
[0116] FIG. 7a illustrates a perspective view of a picket in
accordance with an embodiment of the present invention. The picket
120 includes two channel shaped cutouts 146. FIG. 7b illustrates a
front view of the picket shown in FIG. 7a. FIG. 7c illustrates a
side view of the picket shown in FIG. 7a. FIG. 7d is an expanded
view of one end of the picket shown in FIG. 7c. Each channel shaped
cutout is configured to receive a picket grommet.
[0117] FIG. 7e is a sectional view of a portion of a picket 120 and
a picket grommet 132' provided in accordance with an embodiment of
the present invention. The picket grommet 132', another embodiment
of which is discussed with reference to FIGS. 8a-8f, is disposed
within the exterior wall of the picket 120. The picket grommet 132'
is mounted within the picket by squeezing the two arms 147 and
forcing the locking members 145 through the cutout 146. The
expanding locking members 145 of the picket grommet 132' retain the
picket grommet within the picket. Expansive forces from the outer
arms 147 of the picket grommet 132' help retain the picket grommet
in the locked position depicted. Once a portion of the rail (not
shown) is inserted into the picket grommet 132', it provides
additional expansive force to the outer arms 147 in an outward
direction. The additional expansive force further locks the grommet
into the locked position.
[0118] FIG. 8a illustrates a perspective view of a picket grommet
132 in accordance with an embodiment of the present invention. The
illustrated embodiment is similar to that of FIG. 7e while the
angle of the outer arms is slightly varied. The picket grommet 132
includes an expanding locking member 145 and a channel 150
configured to receive an edge of a rail to engage the picket to the
rail. FIGS. 8b-8e illustrate various views of the picket grommet
shown in FIG. 8a. In one embodiment, the picket grommet has a
height and width of 0.25 inch and a length of 0.625 inch. In other
embodiments, other dimensions can be used.
[0119] FIG. 8f is a perspective view of a small rail grommet in
accordance with an embodiment of the present invention. The small
rail grommet 130 includes an expanding locking member 148' and a
channel 150' configured to receive a sheet of material having a
circular cutout. FIGS. 8b-8e illustrate various views of a grommet
similar to the small rail grommet shown in FIG. 8f. In the
illustrated embodiment, the small rail grommet differs from the
picket grommet only in length. In one embodiment, the length of the
rail channel insert grommet is 1.25 inches. In other embodiments,
other dimensions can be used.
[0120] FIG. 9a illustrates a perspective view of a post grommet in
accordance with an embodiment of the present invention. FIGS. 9b-9e
show front, side, rear and bottom views, respectively, of the post
grommet shown in FIG. 9a. The post grommet 124 includes a front
surface 152, a rear surface 153, an opening 154 and an insert
portion 156. The front surface 152 is rectangular in shape. The
rear surface 153 is configured to sit flush against a flat surface
such as the side of a post or the side of a rail.
[0121] The opening 154 is generally square in configuration and
slightly larger than the rail dimensions so as to receive an end of
a rail. The insert portion 156 is shaped like a beveled cylinder at
the top with a lengthwise planar section removed from the bottom.
The insert portion 156 has an upper recess 155 and lower recesses
157 where it abuts the rear surface. The recesses are configured to
receive an edge of a sheet or planar material having a circular
cutout, such as the edge of a post or rail. The insert portion of
the post grommet can be sized to fit within a circular cutout and
the opening 154 can be sized to receive a rail.
[0122] The FIGS. 9a-9e also illustrate an embodiment of the large
rail grommet 122. The large rail grommet can be smaller than the
illustrated post grommet such that the insert portion is sized to
fit into a circular cutout on a rail. In such case, the opening 154
is sized to receive a picket.
[0123] The grommets can be made from any number of materials
including rubber, PVC or vinyl. As fences are not shielded from the
elements, materials which are resistant to rust are particularly
well suited, though other materials can be used as well.
[0124] FIG. 10a illustrates a top view of a post bracket in
accordance with an embodiment of the present invention. FIG. 10b is
a side view of the post bracket shown in FIG. 10a. FIG. 10c is a
front view of the post bracket shown in FIG. 10a. The post bracket
126 includes two sides 158, a back 159, a slotted opening 160 and
two mounting holes 162. The assembly of the bracket is known in the
art.
[0125] FIG. 11a illustrates a top sectional view of a rail and a
picket in accordance with an embodiment of the present invention.
This view illustrates a sectional view, of the top rail as if the
top of the top rail were removed, and the orientation of a top rail
116' with a picket 120' locked in using a picket grommet (not
shown). The illustrated joint has yet to be locked with a large
rail grommet.
[0126] FIG. 11b illustrates a side sectional view of a post and a
rail in accordance with an embodiment of the present invention.
This view illustrates a sectional view, as if the rear side of the
post were removed, and the orientation of a post 112' and a top
rail 116' locked in using a small rail grommet (not shown). The
illustrated joint has yet to be locked with a post grommet.
[0127] Returning briefly to FIG. 4a, the post 112 has two circular
openings or cutouts 134. In another embodiment, the two openings
can be square or rectangular. In such case, the insert portion of
the post grommets can be configured to accommodate a square or
rectangular opening.
[0128] FIG. 12a is a perspective view of a post grommet in
accordance with another embodiment of the present invention. The
post grommet 224 includes a front surface 252, a rear surface 253,
and a square shaped opening 254. The square shaped opening 254 has
rounded corners. The front surface 252 is substantially square in
shape. The post grommet 224 further includes two side walls 264 and
a bottom wall 266 of roughly equal length protruding substantially
normal to the rear surface 253. An angled wall 268 protrudes from
the rear surface 253 at a slight angle and along a bottom edge of
the opening 254. In the illustrated embodiment, the angled wall 268
protrudes at angle of fifteen degrees from a line extending normal
from the rear surface. The angled wall 268 provides a biasing force
against a rail surface to force an edge of the opening of the post
into the channel of the rail grommet, as shown with reference to
FIG. 15c. In the illustrated embodiment, the post grommet is square
and the sides of the front and rear surfaces are 2.25 inches while
the sides of the opening are 1.53 inches. In other embodiments, the
post grommets can take other shapes and dimensions. The post
grommet can be made from any number of materials including rubber,
PVC or vinyl.
[0129] FIGS. 12b-12e illustrate front, rear, side sectional and
bottom views, respectively, of the post grommet of FIG. 12a.
[0130] Returning briefly to FIG. 5a and FIG. 6a, the top rail 116
and bottom rail 118 have circular picket openings or cutouts 138
and 140, respectively. In another embodiment, the openings can be
square or rectangular. In such case, the insert portion of the
large rail grommets can be configured to accommodate a square or
rectangular opening.
[0131] FIG. 13a is a perspective view of a large rail grommet in
accordance with another embodiment of the present invention. The
large rail grommet 222 includes a front surface 252', a rear
surface 253', and a square shaped opening 254'. The square shaped
opening 254' has rounded corners. The front surface 252' is
substantially square in shape. The large rail grommet 222 further
includes two side walls 264' and a bottom wall 266' of roughly
equal length protruding substantially normal to the rear surface
253'. An angled wall 268' protrudes from the rear surface 253' at a
slight angle and along a bottom edge of the opening 254'. In the
illustrated embodiment, the angled wall 268' protrudes at angle of
ten degrees from a line extending normal from the rear surface. In
the illustrated embodiment, the large rail grommet is square and
the sides of the front and rear surfaces are 1.25 inches while the
sides of the opening are 0.76 inches. In other embodiments, the
large rail grommets can take other shapes and dimensions. The large
rail grommet can be made from any number of materials including
rubber, PVC or vinyl.
[0132] FIGS. 13b-13e illustrate front, rear, side sectional and
bottom views, respectively, of the large rail grommet of FIG.
13a.
[0133] FIG. 14a is a perspective view of a picket grommet in
accordance with the embodiment of the large rail grommet shown in
FIG. 13a. The picket grommet 232 includes an expanding locking
member 248 and a channel 250, where the channel is configured to
receive an edge of a square or rectangular cutout. The expanding
locking members are disposed on both the top and bottom sides of
the small rail grommet and are configured to retain the grommet
within a channel shaped cutout on a rail, once inserted into the
cutout. The picket grommet includes rounded ends to tightly abut
the large rail grommet 222 of FIG. 13a in the interlocked position.
The picket grommet can be inserted into a picket channel cutout 146
(see FIG. 3d and FIG. 7c). The large rail grommet 222 of FIG. 13a
can be inserted into a square or rectangular opening or cutout 140
(see FIG. 6a but with a square or rectangular opening) of the
bottom rail 118 (see FIG. 3b). The picket having the picket grommet
can be inserted through the bottom rail until the picket grommet on
the picket is within the large rail grommet. Once the picket
grommet is within the large rail grommet, the picket is moved such
that the channel of the picket grommet receives an edge of the
square or rectangular cutout 140 (see FIG. 6a but with a square or
rectangular opening). The interlocked position of the picket
grommet and large rail grommet is similar to the embodiment shown
in FIG. 3d.
[0134] FIG. 14f is a perspective view of a small rail grommet in
accordance with the embodiment of the post grommet shown in FIG.
12a. The small rail grommet 230 includes an expanding locking
members 248' and a channel 250', where the channel is configured to
receive an edge of a square or rectangular cutout. The expanding
locking members are disposed on both the top and bottom sides of
the small rail grommet and are configured to retain the grommet
within a channel shaped cutout on a rail, once inserted into the
cutout. The small rail grommet includes rounded ends to tightly
abut the post grommet 224 of FIG. 12a in the interlocked position.
The small rail grommet can be inserted into a rail channel cutout
128 (see FIG. 3c) of the top rail (see FIG. 3c). The post grommet
224 of FIG. 12a can be inserted into a square or rectangular cutout
134 (see FIG. 4a but with a square or rectangular shape) on a post
112. The top rail 116 having the small rail grommet can be inserted
into the post until the small rail grommet on the top rail is
within the post grommet. Once the small rail grommet is within the
post grommet, the top rail is moved such that the channel of the
small rail grommet receives an edge of the square or rectangular
cutout 134 (see FIG. 4a but with a square or rectangular opening).
The interlocked position of the small rail grommet and post grommet
is similar to the embodiment shown in FIG. 3c.
[0135] In one embodiment, fences are assembled using the grommets
illustrated in FIGS. 12a, 13a, 14a and 14f and the methods
described previously in the discussion of FIGS. 3a-3d.
[0136] FIG. 15a is an sectional view of a joint including the top
rail 216 and one picket 220 in accordance with an embodiment of the
present invention. A picket grommet 232 is disposed within a
channel shaped opening in the picket 220. A large rail grommet 222
is disposed within a substantially square opening having four edges
in the top rail 216. In the illustrated embodiment, one edge of the
opening is disposed within a recessed channel of the picket grommet
232. The grommets are effectively interlocked in the illustrated
embodiment.
[0137] FIG. 15b is an sectional view of a joint including the top
rail 216 and a post 212 in accordance with an embodiment of the
present invention. A post grommet 224 is disposed within an opening
of the post 212. The top rail 216 is disposed within an opening of
the post grommet 212. The post grommet 224 includes a front surface
252, a side wall 264, a top wall 266, and an angled wall 268 (not
visible). A small rail grommet 230 (not visible) is disposed within
a channel shaped cutout in the top rail 216 and engages the lower
edge of the post opening (not visible).
[0138] FIG. 15c is an sectional view of a joint including the top
rail 216 and a post 212 in accordance with the embodiment shown in
FIG. 15b. The illustrated sectional view shows the physical
relationship of the top rail 216, post 212, post grommet 224 and
small rail grommet 230. The angled wall 268 of the post grommet
exerts a downward force on the top rail 216 to maintain the
engagement of the small rail grommet 230 and the lower edge of the
substantially square opening in the post.
[0139] Specific shapes of fence components such as the rails,
posts, and pickets are depicted in a number of figures and
described herein. However, as the style and particular applications
for picket and rail fences can suggest changes in the size and
design of fence components, any of the fence components can have
different shapes in accordance with the present invention.
[0140] Similarly, in a number of embodiments, specific dimensions
have been discussed. However, the size of embodiments of fences in
accordance with the present invention can vary significantly.
Accordingly, in several embodiments, different dimensions can be
used for any of the fence components.
[0141] While the above description contains many specific
embodiments of the invention, these should not be construed as
limitations on the scope of the invention, but rather as an example
of one embodiment thereof. Accordingly, the scope of the invention
should be determined not by the embodiments illustrated, but by the
appended claims and their equivalents.
* * * * *