U.S. patent application number 12/330099 was filed with the patent office on 2009-03-26 for pocket rail construction.
Invention is credited to Maurice G. Coen, Randal Heath, William McGinness.
Application Number | 20090078923 12/330099 |
Document ID | / |
Family ID | 39666925 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090078923 |
Kind Code |
A1 |
McGinness; William ; et
al. |
March 26, 2009 |
Pocket Rail Construction
Abstract
A rail structure for use as part of a fence construction. The
rail has a rigid support member enclosed by a sleeve, the sleeve
having a groove or channel extending along its longitudinal length
and a hollow chamber for receiving the support member therein. The
channel is dimensioned to receive a plurality of slats disposed in
spaced relation to one another such that when received in the
channels of opposed rails a fence section is formed. Various
modifications to the basic rail structure permit construction of a
privacy or containment fence section that may include a plurality
of vertical segments, including for example lattice work.
Inventors: |
McGinness; William; (PINSON,
AL) ; Heath; Randal; (US) ; Coen; Maurice
G.; (Orange Park, FL) |
Correspondence
Address: |
SMITH, GAMBRELL & RUSSELL
SUITE 3100, PROMENADE II, 1230 PEACHTREE STREET, N.E.
ATLANTA
GA
30309-3592
US
|
Family ID: |
39666925 |
Appl. No.: |
12/330099 |
Filed: |
December 8, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11699593 |
Jan 29, 2007 |
|
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12330099 |
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Current U.S.
Class: |
256/65.01 ;
256/59 |
Current CPC
Class: |
E04H 17/16 20130101 |
Class at
Publication: |
256/65.01 ;
256/59 |
International
Class: |
E04H 17/14 20060101
E04H017/14 |
Claims
1. A rail comprising an elongate rigid support member and an outer
sleeve; said outer sleeve comprising a chamber defined to receive
and enclose the elongate rigid support member and a channel defined
along a longitudinal length of the sleeve adjacent said chamber,
said channel defined by a pair of fingers extending outwardly from
said sleeve and separated by a fixed width, said fingers having an
outwardly facing wall, an inwardly facing wall, and a slot defined
in said inwardly facing wall; and, a spring clip having a base
commensurate with said fixed width, said spring clip seated within
said channel and held in compression by engagement of opposed ends
of said spring clip in said slots in said fingers, such that said
spring clip may retentively receive there within substantially
planar members of varying widths less than said fixed width.
2. The rail of claim 1, wherein said sleeve member comprises a
plurality of chambers, wherein each chamber is defined to receive
and enclose an elongate rigid support member.
3. The rail of claim 2, further comprising at least a second
elongate rigid support member, wherein each elongate support member
is received in and enclosed by a chamber.
4. The rail of claim 1, wherein said sleeve defines a plurality of
longitudinally extending channels.
5. A rail adapted to receive facing material of various
thicknesses, comprising: an outer sleeve enclosing an elongate
rigid support member, said outer sleeve defining an outwardly
opening longitudinal channel, said channel having a fixed width and
a first and second slot defined in opposed inner surfaces of said
channel; and a retaining clip selected from: a spring clip
captively received in said first and second slots retentively
receiving facing material of varying thickness; or a longitudinally
extending spring clip captively received in said first and second
slots and having defined therein a plurality of longitudinally
spaced apertures for insertion of a plurality of pickets forming
said facing material.
6. The rail of claim 5, wherein said retaining clip comprises a
base, a pair of legs extending from said base, and a retaining
flange formed on each of said legs, wherein said retaining flanges
engage said first and second slots.
7. The rail of claim 5 wherein said retaining clip has a length
substantially the same as a longitudinal length of said sleeve.
8. The rail of claim 5, wherein said retaining clip is comprised of
a plurality of discrete retaining clips.
9. The rail of claim 5, wherein said retaining clip has a base with
a width substantially equal to the width of said channel.
10. The rail of claim 5, wherein said legs of said clip are
arcuate.
11. The rail of claim 5, wherein sail legs of said clip are
flat.
12. The rail of claim 5, said retaining clip further comprising a
dust shield extending outwardly from an end of said leg to overlie
a surface of the sleeve adjacent to said channel opening.
13. A reinforced railing comprising, a rigid, elongated, structural
member formed optionally as a channel, tube or I-beam from a
material selected from a metallic or composite material having
suitable reinforcing and support characteristics, an outer sleeve
extruded from a durable polymer composition, said sleeve having a
length commensurate with said structural member and at least one
longitudinal chamber having an inner dimension such that said
structural member may be slidingly received therein in close
fitting relationship, said sleeve further defining an open
longitudinal channel along at least one side thereof.
14. A family of reinforcing railings in according to claim 13
wherein each of said rails have one or more chambers of identical
size for receiving said structural members therein.
15. A family of reinforcing railings as defined in claim 14 having
at least two parallel chambers for selectively receiving one or
more of said structural members therein.
16. A reinforced railing in accordance with claim 13, wherein said
channel is defined by a pair of fingers extending outwardly from
said sleeve and separated by a fixed width, a spring clip having a
base commensurate with said fixed width, said spring clip seated
within said channel and held in compression by engagement of
opposed ends of said spring clip in said fingers, such that said
spring clip may retentively receive there within substantially
planar members of varying widths less than said fixed width.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/699,593, filed on Jan. 29, 2007 and is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
fences and guard rails. More particularly, the invention relates to
containment and decorative fences having a vinyl covering. With
even greater particularity, the present invention relates to a
method of assembling and components for providing a vinyl covering
over a substrate support structure for a fence or guard rail.
BACKGROUND OF THE INVENTION
[0003] In the art of fences numerous materials and methods have
been employed to construct and design fences for various purposes
such as containment of livestock, pets, people and the like or for
the exclusion of the same. In other instances, fences may be
employed to add a decorative or aesthetic flourish to structures
and landscapes.
[0004] A commonly used fence configuration is a picket or slat
design, wherein the fence generally comprises horizontal support
members attached between vertical fence posts, and a plurality of
vertically aligned pickets or slats, attached to the horizontal
support members and spaced apart to varying amounts depending upon
the privacy or extent of containment desired. This common fence
configuration lends itself to construction with numerous materials,
depending upon the desired application. For example, a picket fence
may simply be constructed with materials such as treated lumber
utilizing 4''.times.4'' boards for the vertical posts,
2''.times.4'' boards for the horizontal support members, or rails,
and 1/2''.times.4'' planks selected for the vertical slats, or
facing material.
[0005] Added decorative features may be included, such as by
topping the fence with an additional facing material, such as a
lattice work, generally comprising a plurality of narrow strips of
lumber arranged in a crossed or woven pattern with the narrow
strips of lumber sized on the order of 1.5''.times.3/8''. The
strips are normally stapled or joined at their intersections to
create a lattice panel and are generally available in 4'.times.8'
panels and other convenient sizes. Typically, a groove may be cut
into the support members that will form a frame for the lattice.
The ends of the lattice panel are fitted into the groove around the
periphery of the panel, which provides a more rigid construction as
well as providing a more finished appearance to the fence
section.
[0006] A slatted fence panel may be constructed in a similar
manner, whereby the ends of the slats, or facing material are
inserted into grooves cut into the support members. As with the
picket fence, the slats may be spaced apart by varying amounts
depending upon the degree of privacy or containment desired.
Similarly, the slats may be placed in abutment with one another to
provide complete privacy or containment.
[0007] More recently, vinyl, plastics and similar such materials
have been found to be advantageous for fencing applications. These
materials provide convenience due to their ease of fabrication,
light weight, relative cost, and their ability to maintain an
attractive appearance, particularly for exterior fencing, where
weather may deteriorate the finish of wood or paints applied
thereto. However, a significant disadvantage of these materials is
that many building codes do not approve of their use in certain
applications requiring structural or protective support.
[0008] Similarly, the U.S. Department of Housing and Urban
Development (HUD) has also established standards for fence
constructions. For example, in hurricane prone areas HUD standards
require a fence to withstand 120 mph wind gusts, whereas in other
areas such fences should withstand 90 mph wind gusts. Accordingly,
the application of vinyl materials remains somewhat limited due to
these restrictions.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention solves many of the aforementioned
problems with existing fence materials and construction methods.
The invention is described as a pocket rail construction, with the
rail having an elongate rigid support member, and an outer pocketed
or channeled sleeve. The support member may be formed of a
metallic, composite, or other approved construction material, and
is preferably made of aluminum. The support member may be channel
shaped or alternatively tubular shaped, preferably having a
generally square or rectangular cross section.
[0010] The outer sleeve is preferably made of a vinyl, plastic,
composite or similar such materials. The outer sleeve has a first
side defined by a groove, or pocket, extending along the
longitudinal length of the sleeve and a chamber defined adjacent to
the pocket which also extends along the longitudinal length of the
sleeve.
[0011] The chamber is dimensioned such that the length of the
support member may be slidingly received in the chamber without
great difficulty, and should preferably have a slight interference
fit when the support member is fully inserted. The pocket or
channel should have a width sufficient to receive the ends of a
facing material, such as a plurality primary slats, to define a
fence section. Preferably the ends of the primary slats or facing
have a slight interference fit in the pocket. The pocket should
also have a depth sufficient to receive and retain the ends of the
primary slats or facing material.
[0012] The channel may also be adapted to receive a section of
lattice work, panels, or secondary slats having a thickness
considerably narrower than that of the primary slats. The
adaptation comprises a pair of slots defined along opposed inner
walls of the pocket and a retaining spring or clip that is inserted
into the pocket. The retaining spring is generally U or V shaped,
having a base and a pair of legs extending from opposed ends of the
base. The legs are shaped such that the spacing between an opposed
surface of the legs is narrower than the ends of the lattice,
panel, or secondary slats. Upon insertion of the ends of the
lattice, panel, or secondary slats between the clip's legs, opposed
ends of the clip are urged outwardly into the slots to captively
retain the clip in the pocket. The panel is pinched between the
inner walls of the clip's legs to retain it within the pocket.
[0013] For ease of assembly, the retaining spring will preferably
be a unitary elongate member, although a plurality of clips may be
inserted into the pocket at discrete points if care is exercised to
ensure that they are positioned at the points where the ends of the
lattice work panel extend into the pocket, rather than at the voids
created between adjacent slats of the lattice.
[0014] In an alternative embodiment of the invention, the spring
clip may also include a dust shield to prevent the accumulation of
dust, dirt and debris within the pocket of the fence rail. In this
instance, the spring clip is dimensioned such that the ends of the
spring clip will extend past edges of the pocket and will overlie
the surfaces of the rail adjacent the pocket. A retaining flange is
defined at an intermediate point along the legs of the spring clip.
Upon insertion of the lattice, panel, or secondary slats, the
retaining flange is urged outwardly and engage with the slots.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 is partial perspective view of a fence section having
a pocket rail construction.
[0016] FIG. 2 depicts a partial perspective view of a pocket rail
construction with a dust shield.
[0017] FIG. 3 depicts an end perspective view of a pocket rail
construction with an adapter clip.
[0018] FIG. 4 depicts an arcuate adapter clip.
[0019] FIG. 5 depicts a V-shaped adapter clip with dust shield.
[0020] FIG. 6 depicts an end view of an in-line splice pocket rail
construction.
[0021] FIG. 7 depicts an end view of a pocket rail construction
with a single hollow chamber.
[0022] FIG. 8 depicts an end view of a pocket rail construction
with dual hollow chambers.
[0023] FIG. 9 depicts an end view of a pocket rail construction
with triple hollow chambers.
[0024] FIG. 10 depicts a gate constructed with pocket rails.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to the drawings for a more complete description of
the invention, FIG. 1 depicts a fence section 1 constructed with an
pocket rail 10 constructed according to an embodiment of the
present invention. As may be seen rail 10 comprises an elongated
rigid substrate support member 20, which provides support and
structure for rail 10, and an outer sleeve 30 having at least one
groove or channel 31 defined along a longitudinal side of sleeve 30
and at least one chamber 32 defined to receive and enclose support
member 20 therein.
[0026] The support member 20 is comprised of a metallic, composite,
or other approved construction material according to applicable
building codes, and is preferably made of aluminum. It may be
formed as an I-beam, channel, or tubular construction so as to
provide the required structural strength and dimensioned to be
received within in chamber 32.
[0027] The outer sleeve 30 is preferably made of a vinyl, plastic,
composite or similar such materials, which may be readily extruded.
As may best be seen in reference to FIGS. 5 and 6-9, outer sleeve
30 has a first side portion that defines a groove, or channel 31,
extending along the longitudinal length of the sleeve 30. Sleeve 30
also has a chamber 32 defined adjacent to the groove 31 and
extending the longitudinal length of the sleeve 30.
[0028] Groove 31 is defined by a pair of parallel projections, or
fingers 33, which are preferably hollow extrusions. Each projection
33 has an inner wall 34 an outer wall 35 and may also include a
tapered tip 36. Outer wall 35 and tapered tip 36 may be
substantially flat, or may otherwise be provided with a decorative
surface ornamentation selected for the desired finished appearance
of the rail 10.
[0029] Chamber 32 is dimensioned such that the length of the
support member 20 may be slidingly received in the chamber 32
without great difficulty. Preferably, a slight interference fit
will allow the support member 20 to be fully inserted into chamber
32.
[0030] To form a fence section, a pair of rails 10 are disposed in
a generally parallel arrangement with their respective pockets 31
facing each other, as shown in FIG. 1. A plurality of primary slats
11 are usually vertically disposed between the respective opposed
pockets 31 and in spaced relation to one another, although they may
be laterally disposed between vertically disposed rails as well.
Slats 11 may be disposed in abutment with one another to provide
complete privacy or containment or as may be seen in FIG. 2, slats
11 may be spaced apart for partial privacy or containment. To
assist in maintaining the desired spacing between slats 11, a cover
25 may be utilized. Cover 25 is a substantially U-shaped elongate
extrusion that may be pre formed with receiving holes 26 at
predetermined points. Alternatively, cover 25 may be provided
without receiving holes 26, such that the receiving holes 26 may be
cut at an interval and spacing selected by the installer or
property owner and readily made with a router or similar cutting
tool or punch.
[0031] Channel 31 should have a width sufficient to receive the
ends of the slats 11, preferably with a slight interference fit.
Channel 31 should also have a depth sufficient to receive the ends
of the slats 11 so that the slats 11 are retained in the channels
31 between opposed rails 10 to define a fence section 1. Moreover,
because the slats 11 are subject to flexing and resultant
shortening, such as when encountering a wind gust, the channel 31
depth should be sufficient to accommodate the anticipated flex
while still permitting slats 11 to remain retained within the
channels 31.
[0032] As may be seen in reference to FIGS. 2, 8, 9, sleeve 30 may
further comprise a plurality of chambers 32. Preferably, the
additional chambers such as 32', 32'' as depicted, have the same
inner dimensions as the first chamber 32, such that the rail 10 may
be assembled with the support member 20 received in any of the
selected chambers 32, 32', 32'' to permit mounting to a support
structure at a desired height relative to the selected chamber.
Providing a plurality of chambers 32 to the sleeve 30, may also be
advantageous for aesthetic reasons, such as when it may desirable
to give the appearance of a wider, seemingly more robust rail, when
only utilizing a single support member 20. Alternatively,
additional support members 20', 20'' may be inserted in the
chambers 32, 32', 32'' to add greater structural strength to the
rail 10. Thus, the pocket rail assembly 10 of the present invention
lends itself to multiple design possibilities for creating a fence
of various structural strengths and aesthetic designs.
[0033] An additional feature of the pocket rail assembly 10 entails
adaptation of the channel 31 to receive a section of lattice work
12, panels 12, or alternative slats 12 having a thickness
considerably less than that of the primary slats 11. To accomplish
this a pair of slots 37 are defined along opposed inner walls 34 of
the projections 33. As depicted slots 37 have a pair sharply
defined edges, however, all that is necessary is that slot 37 have
a suitably defined inwardly facing edge 38, for engagement with a
retaining spring or clip 40.
[0034] As may be seen in reference to FIGS. 3-5, retaining spring
or clip 40 is generally U or V shaped, having a base or apex 41 and
a pair of legs 42 extending from opposed ends of the base 41. Legs
42 are shaped such that the spacing between opposed inner surfaces
43 of the legs 42 is dimensioned to receive the ends of the
lattice, panel, or secondary slats 12. In the preferred embodiment
shown in FIG. 4, the spacing between opposed inner surfaces 43 of
the legs 42 is narrower than the thickness of the lattice, panel,
or secondary slats 12. Upon insertion of the ends of the lattice,
panel, or secondary slats 12 between the clip's legs 42, the ends,
or retaining flanges 44 of the clip 40 are urged outwardly into the
slots 37 such that clip 40 is captured and retained within channel
31 by the engagement of retaining flanges 44 with inwardly facing
edge 38. The ends of the lattice, panel or secondary slats 12 are
pinched between an inner surface 43 of the clip's legs to retain it
within channel 31.
[0035] More preferably, the retaining flanges 44 of clip 40 are
spaced apart by a distance D that is slightly greater than the
width W of channel 31, so that ends 44 engage edge 38 without a
lattice, panel or secondary slat 12 being inserted in the clip 40.
This configuration permits clip 40 to be snap-fit into channel 31
and captively retained therein by the engagement of retaining
flanges 44 with edge 38. This aspect is particularly useful during
assembly of a fence section, especially for a downwardly or
laterally facing channel 31, where clip 40 would have a tendency to
fall out of pocket 31.
[0036] For ease of assembly, retaining spring 40 will preferably be
a unitary elongate member, although a plurality of clips 40 may be
inserted into the channel 31 at discrete points if care is
exercised to ensure that they are positioned at the points where
the ends of lattice work panel 12 extend into the channel 31,
rather than at the voids created between adjacent slats of the
lattice. For a solid panel 12, a plurality of discrete clips 40 may
be advantageous to conserve clip material though the panel 12 may
experience some flapping or flexure within channel 31 since it is
only retained within pocket 31 at discrete points.
[0037] In an alternative embodiment of the invention shown in FIG.
5, the spring clip 40 may also include a dust shield 46 to prevent
the accumulation of dust, dirt and debris within the channel 31 of
the fence rail 10. In this instance, the ends of the dust shield 46
have a spacing S that is greater than the width W of channel 31.
Legs 42 should be dimensioned such that a lower surface 47 of dust
shield 46 and will overlie the outer surface 39 of the rail 10
adjacent to the channel 31. In this embodiment, retaining flange 44
is defined at an intermediate point along the legs 42 of the spring
clip 40. As with the previous embodiment, the ends of retaining
flange 44 are preferably dimensioned to have a width greater than
that of pocket 31 so that spring clip 40 may be captively retained
in channel 31. Upon insertion of the lattice, panel, or secondary
slats 12, retaining flange 44 is urged further outwardly and engage
with the slots 37.
[0038] In each embodiment of clip 40 it base 41 is preferably
dimensioned to correspond to the width of channel 31 to facilitate
centering of clip 40 within channel 31, which will facilitate
centering of lattice, panel or secondary slats 12 within channel
31.
[0039] As may be seen in reference to the lower portion of FIG. 1,
a pair of rails 10 may be used to form a fence section 1, with
rails 10 in opposed relation and plurality of primary slats 11
spaced apart and extending between a first rail 14 and a second
rail 15. Slats 11 being usually vertically disposed and rails 14
& 15 usually being horizontally disposed. Fence or guardrail
section 1 may be attached to opposed walls of a structure, such as
in a balcony, or between posts, such as in a fence, or in an
combination thereof as is well known to those of skill in the
art.
[0040] As may be seen in reference to the center portion of FIGS. 1
and 10, and as depicted in FIG. 6, sleeve 30 may be provided with
an additional channel 31' adding greater versatility to the pocket
rail system. In the embodiment depicted, sleeve 30 is provided with
a second channel 31' to form an in-line splice. This configuration
permits the addition of an upper decorative portion to the fence
section, such as that shown in the upper half of FIG. 1, with the
upper portion being constructed of a lattice, panel or secondary
slats 12. Alternatively, this configuration of sleeve 30 can be
utilized to build a stronger fence section utilizing shorter
primary slats 11. It is also advantageous for applications
requiring a taller fence section such that a second course of
primary slats 11 may be positioned above a first course of primary
slats 11.
[0041] The versatility of the pocket rail of the present is further
demonstrated in reference to FIG. 10. In this case, rails 10 are
utilized to completely frame the slats 11 and panel 12 to construct
a gate 50. As may be seen, each of the corners 51 may be miter cut
and the rails 10 joined by application of a suitable adhesive. More
preferably, we have found that the materials may be suitably joined
by a sonic weld along corner 51 and will have sufficient strength
to withstand the rigors encountered during its employment as a gate
50. When utilizing the in-line splice to create a two part gate, as
an alternative to miter cutting, the fingers 33 may be removed or
partially removed from the vertical rails 10' at points adjacent to
the horizontal rails 10 to provide a complete pocketed frame around
the primary and/or secondary fence sections 1. Sonic welds may also
be utilized to join the intermediate horizontal rail section 10 to
the vertical rails 10'. Hinges 52 are affixed to one of the
vertical rails 10', and a handle 53 with associated latching
hardware installed on the opposite vertical rail 10'. In like
manner, a completely framed fence section 1 may be obtained by
adding vertical rails to the horizontal rails 10 of the fence
section 1 depicted in FIG. 1.
[0042] It should be understood that although examples of preferred
embodiments of the invention have been disclosed herein in some
detail, modifications and variations might be made without
departing from the spirit and scope of the invention. Accordingly,
all forms of the invention are claimed that come within the scope
of the appended claims.
* * * * *