U.S. patent application number 11/903381 was filed with the patent office on 2009-03-26 for gate building kit.
This patent application is currently assigned to Elixer Industries, Inc.. Invention is credited to Donald B. Cruzan.
Application Number | 20090078839 11/903381 |
Document ID | / |
Family ID | 40470621 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090078839 |
Kind Code |
A1 |
Cruzan; Donald B. |
March 26, 2009 |
Gate building kit
Abstract
A hardware kit for constructing a gate frame from standard board
lumber includes a triple-junction bracket for joining three board
members including a first horizontal board member and first and
second equal length non-horizontal board members, and two
mirror-image double-junction brackets each joining one of the
non-horizontal members to a lower horizontal member of the frame.
The triple-junction bracket has two attachment surfaces offset by
90 degrees, one of the surfaces having two attachment lengths
diverging at an acute angle. Each double-junction bracket has a
first attachment surface orthogonal to second and third attachment
surfaces, the second attachment surface extending at an obtuse
angle with respect to the third attachment surface, the obtuse
angle exceeding 90 degrees by a number of degrees equal to half of
the acute angle.
Inventors: |
Cruzan; Donald B.;
(Carmichael, CA) |
Correspondence
Address: |
SNELL & WILMER LLP (OC)
600 ANTON BOULEVARD, SUITE 1400
COSTA MESA
CA
92626
US
|
Assignee: |
Elixer Industries, Inc.
Gardena
CA
|
Family ID: |
40470621 |
Appl. No.: |
11/903381 |
Filed: |
September 21, 2007 |
Current U.S.
Class: |
248/201 |
Current CPC
Class: |
E06B 3/7003
20130101 |
Class at
Publication: |
248/201 |
International
Class: |
A47B 96/06 20060101
A47B096/06 |
Claims
1. A hardware kit for facilitating construction of a wooden frame
for a gate using standard board lumber, the kit comprising: a
triple-junction bracket for joining three board members, including
a first horizontal board member and first and second non-horizontal
board members; and two double-junction brackets, each for joining a
second horizontal board member to one of the non-horizontal board
members.
2. The hardware kit of claim 1 wherein the triple-junction bracket
comprises a first planar attachment surface angularly offset from a
second planar attachment surface by about 90 degrees.
3. The hardware kit of claim 2 wherein the first planar attachment
surface includes two frame member attachment lengths extending from
the second planar attachment surface and defining an acute angle
between the two frame member attachment lengths.
4. The hardware kit of claim 1 wherein the triple-junction bracket
defines a sight hole for locating the triple-junction bracket on
one of the frame members.
5. The hardware kit of claim 1 wherein the double-junction brackets
are mirror-image brackets.
6. The hardware kit of claim 1 wherein each double-junction bracket
further comprises first, second, and third planar attachment
surfaces, the first planar attachment surface orthogonal to both
the second and third planar attachment surfaces.
7. The hardware kit of claim 6 wherein for each double-junction
bracket the first planar attachment surface is hexagonal.
8. The hardware kit of claim 7 wherein the first planar attachment
surface and the second planar attachment surface share a common
edge.
9. The hardware kit of claim 8 wherein the second planar attachment
surface and the third planar attachment surface share a common edge
from which the second planar attachment surface extends at an
obtuse angle with respect to the third planar attachment
surface.
10. The hardware kit of claim 9 wherein the triple-junction bracket
comprises a first planar attachment surface angularly offset from a
second planar attachment surface by about 90 degrees, the second
planar attachment surface of the triple-junction bracket having two
frame member attachment lengths extending from the first planar
attachment surface of the triple-junction bracket and forming an
acute angle between the two frame member attachment lengths; and
wherein the obtuse angle between the second and third planar
attachment surfaces of each double-junction bracket exceeds ninety
degrees by a number of degrees approximately equal to half of the
acute angle formed between the two frame member attachment
lengths.
11. The hardware kit of claim 1 wherein the non-horizontal board
members are of equal length.
12. A triple-junction bracket for joining three members of a gate
frame, comprising: a first planar attachment surface angularly
offset from a second planar attachment surface by about 90 degrees
and including two frame member attachment lengths extending from
the second planar attachment surface and defining an acute angle
between the two frame member attachment lengths.
13. The triple-junction bracket of claim 12 defining a sight hole
for locating the triple-junction bracket on a frame member
supported by the second planar attachment surface.
14. The triple-junction bracket of claim 12 formed from a
heptagonal plate.
15. The triple-junction bracket of claim 12 wherein the two frame
member attachment lengths form a notch having an apex displaced
from the second planar attachment surface by a distance less than a
width of either of the frame member attachment lengths.
16. A double-junction bracket for joining two members of a gate
frame, comprising: first, second, and third planar attachment
surfaces; wherein the first planar attachment surface is orthogonal
to both the second and third planar attachment surfaces.
17. The double-junction bracket of claim 16 wherein the first
planar attachment surface is hexagonal.
18. The double-junction bracket of claim 17 the first planar
attachment surface and the second planar attachment surface share a
common edge.
19. The double-junction bracket of claim 18 wherein the second
planar attachment surface and the third planar attachment surface
share a common edge from which the second planar attachment surface
extends at an obtuse angle with respect to the third planar
attachment surface.
20. The double-junction bracket of claim 18 wherein the first
planar attachment surface forms an irregular hexagon having two
edges parallel to the second planar attachment surface.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to hardware for
constructing gates, and more specifically to a hardware kit for
constructing a wooden gate.
[0003] 2. Description of Related Art
[0004] For homeowners and professionals alike, gate construction is
often the most difficult aspect to constructing a fence. One common
design for constructing a gate calls for a Z-shaped frame that
supports a row of parallel planks extending from a ground position
below the lower horizontal member of the Z to a high position above
the upper horizontal member of the Z, where the distance from the
ground position to the high position is approximately the height of
the fence. Each plank is typically fastened to the Z-shaped frame
along the diagonal member and along both horizontal members. Hinges
are attached to the ends of the horizontal members at one side for
connecting the gate to a fence post.
[0005] The design described in the preceding paragraph is certainly
easier to express in words than it is to construct by hand. The
gate builder typically struggles with the frame members and planks,
trying to line them up properly for construction. The frame members
can be difficult to assemble because the Z-shaped frame positioned
vertically has a tendency to rack (or collapse) during assembly
when the diagonal member is being attached, or when there is
nothing supporting the free end of the upper horizontal member. If
instead the frame members are positioned horizontally on the
ground, it becomes difficult to maintain the proper angle or
positioning of the diagonal member with respect to the horizontal
members while subjecting those same members to the forces of
hammering or drilling. A more reliable way to quickly assemble a
wooden gate is long overdue.
SUMMARY OF THE INVENTION
[0006] The present invention provides a hardware kit for building a
wooden gate that is safe, secure, and durable. The kit allows an
assembler to construct a gate frame from standard board lumber in a
capital Roman numeral V configuration, having two non-horizontal
members that form a V between an upper horizontal member and a
lower horizontal member. The assembler may then attach a row of
parallel planks and other hardware to the frame to complete the
gate.
[0007] The kit includes a triple-junction bracket joining the upper
horizontal member and the two non-horizontal members of the frame,
and two mirror-image double-junction brackets each joining one of
the non-horizontal members to the lower horizontal member of the
frame. The triple-junction bracket has two attachment surfaces
offset by 90 degrees, one of the surfaces having two attachment
lengths diverging at an acute angle. Each double-junction bracket
has a first attachment surface orthogonal to second and third
attachment surfaces. The second attachment surface of the double
junction bracket extends at an obtuse angle with respect to the
third attachment surface, and the obtuse angle exceeds 90 degrees
by a number of degrees equal to half of the acute angle between the
two attachment surfaces of the triple-junction bracket. The
brackets are preferably formed from galvanized or stainless steel
plate, the triple-junction bracket formed from an irregular
heptagonal plate and the double-junction bracket formed from an
irregular hexagonal plate. To facilitate assembly, the
triple-junction bracket may define a notch or a sight hole for
locating the triple-junction bracket on a frame member. A plurality
of holes may be provided in both brackets for attaching the
brackets to the frame members with wood screws.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Other systems, methods, features and advantages of the
invention will be or will become apparent to one with skill in the
art upon examination of the following figures and detailed
description. It is intended that all such additional systems,
methods, features and advantages be included within this
description, be within the scope of the invention, and be protected
by the accompanying claims. Component parts shown in the drawings
are not necessarily to scale, and may be exaggerated to better
illustrate the important features of the invention. In the
drawings, like reference numerals designate like parts throughout
the different views, wherein:
[0009] FIG. 1 is a frontal view of a wooden gate constructed using
a gate kit according to one embodiment of the invention.
[0010] FIG. 2 is a frontal view of one embodiment of a
double-junction bracket according to the invention.
[0011] FIG. 3 is a bottom view of the double-junction bracket of
FIG. 2.
[0012] FIG. 4 is a left side view of the double-junction bracket of
FIG. 2.
[0013] FIG. 5 is an isometric drawing of the double-junction
bracket of FIG. 2.
[0014] FIG. 6 is a frontal view of one embodiment of a
triple-junction bracket according to the invention.
[0015] FIG. 7 is a top view of the triple-junction bracket of FIG.
6.
[0016] FIG. 8 is a right side view of the triple-junction bracket
of FIG. 6.
[0017] FIG. 9 is an isometric drawing of the triple-junction
bracket of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a hardware kit for building a
safe, secure, and durable gate for a wooden fence using standard
board lumber. The hardware kit includes two types of brackets to be
used in combination for quick and easy construction of a frame for
the gate. In one embodiment, a hardware kit according to the
invention provides a means for constructing a gate frame in the
shape of an inverted capital Roman numeral V, having two
non-horizontal members that form the V, one horizontal member
bordering the top of the V, and another horizontal member bordering
the bottom of the V. The non-horizontal members may have the same
length or different lengths. A triple-junction bracket joins the
non-horizontal members and one of the horizontal members at the
apex of the V, and each of two double-junction brackets joins a
non-horizontal member with the other horizontal member on the
opposite side of the V. The double-junction brackets may be a set
of mirror-image brackets consisting of a left-hand double-junction
bracket and a right-hand double-junction bracket. Other embodiments
of the kit are possible that include a combination of one or more
triple-junction brackets and one or more double-junction brackets,
for example, to construct a frame having multiple V's. Throughout
the disclosure, the term double-junction implies a bracket that
connects two members, and the term triple-junction implies a
bracket that connects three members.
[0019] FIG. 1 illustrates a wooden gate 100 constructed using a
gate kit according to one embodiment of the invention. The gate kit
includes a left-hand double-junction bracket 11, a triple-junction
bracket 13, and a right-hand double-junction bracket 15. These
three brackets provide a means for constructing a frame for gate
100 that consists of an upper horizontal member 17, a lower
horizontal member 19, a left non-horizontal member 21, and a right
non-horizontal member 23. As shown, the left-hand double-junction
bracket 11 joins the left non-horizontal member 21 to the lower
horizontal member 19. The triple-junction bracket 13 joins both the
left non-horizontal member 21 and the right non-horizontal member
23 to the upper horizontal member 17. And the right-hand
double-junction bracket 15 joins the right non-horizontal member 23
to the lower horizontal member 19 to complete the frame. The
horizontal and non-horizontal members may be cut from standard
board lumber such as common softwood or hardwood two-by-four.
[0020] A row of parallel planks 25 may be fastened to the frame and
typically extend from a ground position below the lower horizontal
member 19 to a high position above the upper horizontal member 17,
as shown. A hinge 27 may be fastened to one end of each of the
horizontal members 17 and 19 to prepare gate 100 for installation
to a fence post. Conventional wood screws may be used to connect
the horizontal and non-horizontal members 17, 19, 21, and 23 to the
brackets 11, 13, and 15, and to connect hinges 27 to a fence post
and to horizontal members 17 and 19. In one embodiment, a kit
according to the invention may include hinges 27 and a sufficient
quantity of wood screws.
[0021] FIG. 2 shows a frontal view of one embodiment of a
double-junction bracket 11 according to the invention. FIG. 3 shows
a bottom view of double-junction bracket 11, and FIG. 4 shows a
left side view of double-junction bracket 11. Double junction
bracket 11 may be formed from a metal plate, for example, by
stamping, cutting, bending, and drilling. The metal may be any
material suitable for the purpose of connecting wooden frame
sections, such as aluminum, iron, carbon steel, stainless steel, or
a metal that is coated, plated, or galvanized. The metal plate may
have a thickness suitable for bending to form planes up to 90
degrees without introducing undue risk of fatigue or fracture. For
example, plate thickness suitable for forming brackets according to
the invention may be between about 1/32 inches and about 1/16
inches. Thicknesses in this range are typically suitable for
residential gate construction. As the scale of construction
increases for heavier duty, greater plate thicknesses may be
used.
[0022] Double-junction bracket 11 joins a horizontal frame member
to a non-horizontal frame member lying substantially in the same
plane as the horizontal frame member. To accomplish this securely,
double-junction bracket 11 provides a first planar attachment
surface 29, a second planar attachment surface 31, and a third
planar attachment surface 33. The first planar attachment surface
29 is preferably orthogonal to both second planar attachment
surface 31 and third planar attachment surface 33. In other words,
a line normal to the plane defined by planar attachment surface 29
is orthogonal to a line normal to the plane defined by planar
attachment surface 31 and orthogonal to a line normal to the plane
defined by planar attachment surface 33. The second planar
attachment surface 31 may extend at an angle .alpha. with respect
to the third planar attachment surface 33. Preferably, angle
.alpha. is an obtuse angle between 90 and 180 degrees, and
corresponds to an angle that a non-horizontal member 21 or 23 makes
with respect to a horizontal member 17 or 19. In one embodiment,
angle .alpha. is about 108 degrees.
[0023] In one embodiment, planar attachment surface 29 has a first
portion 35 for aligning with a non-horizontal frame member, and a
second portion 37 for aligning with a horizontal frame member. In
one embodiment, the borderline between first portion 35 and second
portion 37 of planar attachment surface 29 lies in the plane
defined by planar attachment surface 33. Planar attachment surface
29 may form various shapes, such as a rectangle, a pentagon, or a
hexagon. In the embodiment shown throughout the figures, planar
attachment surface 29 forms an irregular hexagon having two edges
41 and 43 that are parallel to planar attachment surface 31. A
plurality of screw holes 39 may be cut or drilled through any of
planar attachment surfaces 29, 31, and 33 to facilitate fastening
double-junction bracket 11 to the frame members.
[0024] FIG. 5 shows an isometric drawing of the double-junction
bracket of FIG. 2. This drawing illustrates an embodiment where
common edges are shared between two planar attachment surfaces.
Edge 41 is shared between or borders planar attachment surface 29
and planar attachment surface 31. Edge 45 is shared between or
borders planar attachment surface 31 and planar attachment surface
33.
[0025] FIG. 6 shows a frontal view of one embodiment of a
triple-junction bracket 13 according to the invention. FIG. 7 shows
a top view of triple-junction bracket 13, and FIG. 8 shows a right
side view of triple-junction bracket 13. The formation, material
composition, and range of thickness for triple-junction bracket 13
may be similar or identical to that of double-junction bracket 11.
Triple-junction bracket 13 may be formed from a quadrilateral,
pentagonal, hexagonal, or other geometric shape. In the embodiment
shown, triple-junction bracket is formed from an irregular
heptagonal plate. A plurality of screw holes 39 may be cut or
drilled through planar attachment surfaces 47 and 49 to facilitate
fastening triple-junction bracket 13 to the frame members.
[0026] Triple-junction bracket 13 may form a first planar
attachment surface 47 and a second planar attachment surface 49. In
one embodiment, first planar attachment surface 47 may be angularly
offset from second planar attachment surface by an angle .beta.
between 0 and 180 degrees. Preferably, angle .beta. is about 90
degrees. In the embodiment shown, planar attachment surface 47
includes two frame member attachment lengths 51 and 53. These
lengths may extend away from the second planar attachment surface
49 and diverge, defining an angle .gamma. between frame member
attachment length 51 and frame member attachment length 53, as
shown. Preferably, angle .gamma. is an acute angle between 0 and 90
degrees.
[0027] In one embodiment of a gate kit according to the invention,
the obtuse angle .alpha. formed between second planar attachment
surface 31 and third planar attachment surface 33 of a
double-junction bracket 11 or 15 exceeds 90 degrees by a number of
degrees approximately equal to half of the acute angle .gamma.
formed between the frame member attachment lengths 51 and 52 of
triple-junction bracket 13. This design constraint allows gate kit
100 to align its brackets for attachment to frame members assembled
in an inverted capital Roman numeral V configuration. By supporting
the horizontal members 17 and 19 with two non-horizontal members 21
and 23 sloping in opposite directions, the invention provides a
stronger and more secure gate structure. Moreover, unlike the
conventional Z-frame gate, an inverted capital Roman numeral V is
far less susceptible to racking or collapse during assembly,
particularly with brackets 11, 13, and 15 already installed on the
horizontal members 17 and 19 in preparation to receive and fasten
to the non-horizontal members 21 and 23.
[0028] In one embodiment, frame member attachment lengths 51 and 53
form a notch 55 having an apex 57 displaced from planar attachment
surface 49 by a distance, D, that is less than a width, W, of
either of the frame member attachment lengths 51 and 53. The reason
for this dimensional constraint is to help the assembler center or
otherwise properly locate the triple-junction bracket 47 on the
surface of a horizontal member 17 or 19. The width W may be
approximately equal to the width of a non-horizontal member such as
a two-by-four (see FIG. 1). If a horizontal member having the same
width is used, for example, as horizontal member 17, then as long
as distance D is less than W, there will be a viewable area at apex
57 through which assembler may view a carpenter's mark or centering
line drawn onto the surface of horizontal member 17. In other
words, as long as the bracket area above the notch doesn't
completely cover the horizontal member, the assembler can see a
pencil mark for centering the bracket.
[0029] Another way to allow an assembler to view a carpenter's mark
is by providing a sight hole. This feature is also shown in FIG. 6.
Triple-junction bracket 13 may define a sight hole 59 that is
formed, drilled or stamped at any convenient location through
planar attachment surface 47. Sight hole 59 is preferably located
along a centerline to facilitate centering triple-junction bracket
13 on a horizontal member 17 or 19 that is marked for that
purpose.
[0030] FIG. 9 shows an isometric drawing of the triple-junction
bracket of FIG. 6. This drawing illustrates another embodiment
where common edges are shared between two planar attachment
surfaces. Edge 61 is shared between or borders planar attachment
surface 47 and planar attachment surface 49.
[0031] A gate building kit 100 according to the invention greatly
streamlines and simplifies the otherwise cumbersome process of
constructing a wooden gate. The construction process may be
completed in three easy phases. These phases are described below
for one example of a particular size of gate frame built from
common two-by-fours according to the invention.
[0032] In the first phase, the frame members are cut. The assembler
cuts two 42-inch two-by-fours to serve as the upper horizontal
member 17 and the lower horizontal member 19. The assembler then
cuts two 37 11/16'' (net) two-by-fours with a 72-degree angle at
each end. An edge of the double-junction bracket, such as edge 63,
may be conveniently used to mark each two-by-four for cutting the
72-degree angle. When cut, these two-by-fours serve as the
non-horizontal members 21 and 23.
[0033] In the second phase, brackets are attached to the frame
members. The assembler marks a vertical centerline on the upper
horizontal member 17 at its 21-inch center, and places the
triple-junction bracket 13 over the centerline. The centerline is
viewable through notch area 55 or sight hole 59. The assembler then
fastens the triple-junction bracket 13 to the top surface and front
surface of upper horizontal member 17 by driving wood screws
through holes 39.
[0034] The assembler then marks the lower horizontal member 19 with
a vertical line six inches from each end. The mirror-image
double-junction brackets (right-hand and left-hand) are then placed
at their respective ends, and aligned for fastening by lining up
one side of second portion 37 to its respective vertical line while
planar surface 33 rests on the upper side of lower horizontal
member 19. Wood screws are then used to fasten each double-junction
bracket to the lower horizontal member through holes 39 in second
portion 37 and holes in planar surface 33.
[0035] The assembler then places the upper and lower horizontal
members 17 and 19 (on the ground) in parallel relation separated by
about 36 inches. The assembler then installs non-horizontal members
21 and 23 into the brackets as shown in FIG. 1, and attaches them
through holes 39 using a corresponding number of wood screws. A
gate frame according to the invention
[0036] In the third and final phase, the assembler installs the row
of parallel planks 25 by fastening them to the sides of the frame
members that are opposite the brackets using nails or wood screws.
The assembler may complete the gate construction by adding a latch
and hinges, and fasten the hinges to a fence post to complete the
installation.
[0037] The invention has been disclosed in an illustrative style.
Accordingly, the terminology employed throughout should be read in
an exemplary rather than a limiting manner. Although minor
modifications of the present invention will occur to those well
versed in the art, it shall be understood that what is intended to
be circumscribed within the scope of the patent warranted hereon
are all such embodiments that reasonably fall within the scope of
the advancement to the art hereby contributed, and that that scope
shall not be restricted, except in light of the appended claims and
their equivalents.
* * * * *