Picket fence kit
A picket fence kit for a picket fence section includes an enclosure, a hollow post, a hollow top rail, a hollow bottom rail, and a plurality of pickets. The enclosure surrounds the post. The post surrounds the two rails and the plurality of pickets, and each rail surrounds a plurality of pickets. Pickets are axially aligned with each other in pairs, two rails are located side-by-side within the post, and two pairs of axially aligned pickets are positioned side-by-side within a rail. The post further surrounds a pair of axially aligned pickets not surrounded by a rail. The kit further includes a post cap, a shipping cap, a plurality of picket caps, a set of rail brackets and a set of self-tapping screws. A picket fence kit for a for a picket fence gate includes an enclosure, a hollow post, a first gate upright, a second gate upright, a hollow top rail, a hollow bottom rail, and a plurality of pickets. The enclosure surrounds the post. The post surrounds the first gate upright, the second gate upright, the hollow top rail, the hollow bottom rail, and the plurality of pickets.
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This application claims priority to co-owned, co-pending U.S. provisional application Ser. No. 60/898,033, filed Jan. 29, 2007.
TECHNICAL FIELDThis invention relates generally to the design and packaging of fence products for improved packing density. More specifically the invention relates to the design and packaging in kit form of a picket fence section or gate that includes a hollow post.
BACKGROUND OF THE INVENTIONA typical installed fence includes a single fence gate and a plurality of fence sections. Picket fences are available in a wide variety of decorative styles, and are typically assembled on site to custom requirements because each job site imposes its own unique requirements. Accordingly, the number of fence part types and configurations available is very large, and the number of part mixes needed to build the whole range of specific fences is much larger still.
Fence parts are typically shipped palletized in boxes of parts of the same type, or as a mix of a few types. Shipping packs in boxes of parts of the same type (e.g., posts, or rails, or pickets). This simplifies the manufacturers' packaging task. However, this generally results in a low packing density which increases shipping and storage costs. It also creates the need to repack parts at intermediate distribution points along the distribution chain. Opening boxes and repacking the parts exposes the parts to greater risk of damage or loss by theft, at a series of distribution points. Repacking and restocking parts at wholesale or retail sales outlets increases the number of product identification codes, requires new labeling, and adds costs associated with distribution clerical activities.
Shipping a custom package based on the requirements of each job offers an opportunity to achieve high packing density, but only at the added expense of custom packaging by the manufacturer. Shipping custom packages to match end-user requirements complicates the manufacturers' packaging task, thereby causing long delivery times or unexpected delays or both. Shipping custom packages to match end-user requirements also requires a degree of integration in the distribution chain that is largely non-existent in today's distributor-dominated, world-wide marketplace, thereby adding cost.
Further disadvantages are experienced by the installer or the end-user, at least one of whom is required to order parts from a potentially enormous catalog of parts.
The consequence of these shortcomings is that the whole fence industry, from manufacturer to retailer, suffers at least some of the above cost and convenience drawbacks.
The end-user would generally prefer to buy a fence in kit form. So boxed or bagged single-section fences in kit form are now being offered. (See advertisement for “Structure PVC Picket Fence”, now offered by W&E International, LLC). However, while kits such as this address the demand for stand-alone, single-section fences, they do not address the system problem presented by the far more typical situation where the need is for a multi-section fence.
SUMMARY OF THE INVENTIONThe invention provides a plurality of picket fence kits including picket fence section kits and picket fence gate kits. A given kit preferably includes all the parts needed to assemble a single picket fence section or a single picket fence gate. A typical installed fence includes a single fence gate and a plurality of fence sections. To support assembly of picket fences in a variety of styles, each picket fence gate kit is associated with a picket fence section kit of matching style.
Although most of the picket fences built from the kits are conventional picket fences, well known in the art, novel aspects of the kits provide significant commercial benefits.
A first group of novel aspects of the invention provides benefits in shipping, product tracking and stocking, to produce cost savings in a distribution chain. This first group of novel aspects involves multi-level nesting of fence section or fence gate parts. This multi-level nesting of pre-defined, size-related fence kit parts within a protective enclosure provides high packing density that reduces shipping costs. It also reduces the risk of damage or loss in shipping, and provides convenience in end-user transportation.
A second group of novel aspects of the invention provides kits for a wide variety of embodiments and configurations of picket fences based on a relatively small number of parts, each kit pre-packaged for point-of-sale retail display. The provision of a wide variety of embodiments and configurations involves the use of non-routed fence kit parts, rail brackets, and self-tapping screws for on-site customization, and a shipping enclosure designed for use in point-of-sale retail display.
A first preferred embodiment of a kit for a picket fence section, illustrated in
A first preferred embodiment of a kit for a picket fence gate, illustrated in
A first preferred embodiment of a picket fence section kit is shown at the top of
Enclosure 19, identified in the side and end views of kit 10, contains and protects all the parts of the kit. The side and end views of kit 10 show two heat-sealed end-tabs, end-tabs 26, of a preferred embodiment of enclosure 19. Enclosure 19 also contains, protects and displays label 29. Label 29 displays product identity data and other data useful for shelf display of the kit in a retailer's store.
Kit 10 is a packaged kit of parts for assembling a picket fence section 20. The structural parts contained in kit 10, from which picket fence section 20 is to be assembled, are designed and sized to achieve several benefits in shipping, distribution, sale and use. These benefits include high package density, low shipping costs, low number of different prefabricated part types to satisfy a wide range of fence configuration needs, low risk of parts loss or damage in distribution, and convenience in storage, point-of-sale display, and end-user transportation.
Kit 10 comprises a set of parts in an enclosure that contains the parts, protects the parts from loss, to a limited extent protects the parts from damage, and facilitates display of identification and other data needed in the distribution process.
The kit, as packaged, is designed to provide multiple distribution benefits, including reduction of distribution, stocking and sales-related costs, and better protection of the product in transit. Distribution benefits are achieved in part by nested placement of the prefabricated fence parts within the enclosure (i.e., the shipping container), and in part by definition of dimensional relationships among the prefabricated fence parts of the kit.
The kit is also designed to provide various convenience benefits for point-of-sale display. Point-of-sale display benefits are derived from the compact packaging of a kit in a shipping container suitable for retail point-of-sale display.
The kit is also designed to provide a degree of size and shape customization during on-site assembly. Customization is provided by the use of a bracket for mounting a rail to a post that does not require routing the post or providing pre-drilled holes in the post.
In a first preferred embodiment the kit includes an enclosure, a single hollow post, top and bottom hollow rails, a plurality of pickets, and hardware. The rails, the pickets, the brackets and miscellaneous hardware are all packed within the single hollow post.
For picket fence section 20 shown in
In a preferred embodiment, enclosure 19 is formed as a tough, transparent tubular sheet of plastic material sized to fit over the post. In one preferred embodiment, making the kit includes placing the rails, the pickets, the rail brackets and miscellaneous hardware inside the post, then pulling a tubular sheet over the post to cover both ends, and then sealing both ends of the sheet. Sealing the sheet includes flattening and folding the sheet, then heat-sealing the sheet to form end-tabs that close both ends of the enclosure. Enclosure 19 is not limited to this material or this method of construction. Alternatively, enclosure 19 include packing the kit in a cardboard box, or wrapping the kit in two shrink-wrap plastic sheets of electro-static wrap, one at each end of the post, or fixedly attaching a post cap at the top end of the post and a shipping cap at the bottom end of the post to form a rigid enclosure, or by providing a post cap fixedly attached to the top end of the post, and providing a removable shipping cap attached by adhesive tape to the bottom end of the post.
In a preferred embodiment, the kit also includes a label located between enclosure 19 and the post 11. In this embodiment, enclosure 19 includes a transparent region through which the label may be read.
In a preferred embodiment, post 11 includes a first post cap 15 attached at a first end of the post, preferably an internal cap fixedly attached to the post with glue, and a shipping cap 16 attached at the second end of the post. Shipping cap 16 may be a removable post cap to facilitate unpacking the rails and the pickets, or it may be attached with glue to better contain and protect the rails and the pickets during shipping. In the latter case, the end-user would cut the post just short of the shipping cap to allow the rails and the pickets to be unpacked. In a preferred embodiment, each picket includes a picket cap 17 attached to a top end of the picket.
In a preferred embodiment, each rail is preferably attached to its post by a rail bracket, as indicated in
Multi-level nesting of the elongated structural components in the fence section kit of
Dimensions associated with depth and width limitations are identified in
Limitations revealed in
1) The external depth 12-ED of rail 12 plus the external depth 14-ED of rail 14 must be less than the internal width 11-IW of post 11.
2) The external height 12-EH of rail 12 plus the external depth 13-ED of one picket must be less than the internal depth 11-ID of post 11.
3) The external depth 13-ED of one picket must be less than half the internal depth 12-ID of one rail.
Dimensions associated with height and length limitations are identified in
In a preferred embodiment of a fence section kit wherein the post has two attached internal post caps, and wherein the kit has post and rail dimensions as specified in Table 1 below, the two rails will not be a tight fit within the post. So the walls of the cap will not reduce the effective internal height of post 11. Accordingly, 11-IH, the effective internal height of the post (with its post cap 15 attached and with its shipping cap 16 attached) is equal to the height of post 11.
Limitations revealed in
1) The external length 12-TRL of rail 12 must be less than the internal height 11-IH of post 11.
2) The external height 13-EH of a pair of axially aligned pickets must be less than the internal height 11 Joanne-IH of post 11.
Table 1 gives selected dimensions of the main components of the first preferred embodiment of the picket fence section described above, and as shown in
A second embodiment of a picket fence section kit is illustrated in
A third embodiment of a picket fence section kit is illustrated in
In a variant of the fourth embodiment, the four brackets 48 are omitted and post 41 is a routed post.
Fifth Embodiment—Pool Code Picket Fence Section KitA first preferred embodiment of a picket fence gate kit is shown at the top of
Returning now to
The main structural parts of kit 110 are illustrated in perspective view in
Kit 110 also includes two upright caps 137 and 138, two hinges 141 and 142, one safety gate latch 144 having a gate stop 145 and a latch body 146, one striker, and miscellaneous hardware. The locations, in the assembled picket fence gate, of the upright caps, the hinges, and the latch are indicated in
Miscellaneous hardware includes white-cap self-tapping screws 149 for attaching the rail pockets to the uprights and a tube of PVC fence glue 148.
The upright caps are similar in shape to the post caps illustrated in
Rail pockets kit 140 includes a set of four rail pockets and a set of self-tapping screws.
Hinges 141 and 142 are conventional gate hinges. A suitable hinge is the Nationwide Industries NW096 Self-Closing Hinge. These hinges are available from Nationwide Industries at www.nationwideindustries.com.
Latch 144 is a conventional safety gate latch. A suitable latch is D & D Technologies Magna Latch, a safety gate latch. This latch is available from D & D Technologies at www.ddtechglobal.com.
Table 2 lists selected dimensions of the main components of the first preferred embodiment of the picket fence gate, as described above and as shown in
Claims
1. A picket fence kit comprising an enclosure, a hollow post, a hollow top rail, a hollow bottom rail, and a plurality of pickets;
- wherein the enclosure surrounds the post; and
- wherein the post surrounds the two rails and a plurality of pickets.
2. A picket fence kit according to claim 1 for a picket fence section, wherein at least one rail surrounds a plurality of pickets.
3. A picket fence kit according to claim 1 for a picket fence section, wherein two pickets are axially aligned with each other.
4. A picket fence kit according to claim 1 for a picket fence section, wherein the two rails are located side-by-side within the post.
5. A picket fence kit according to claim 1 for a picket fence section, wherein at least one rail surrounds two pairs of axially aligned pickets, and wherein the two pairs of axially aligned pickets are positioned side-by-side within the at least one rail.
6. A picket fence kit according to claim 1 for a picket fence section, wherein the post surrounds at least one picket not surrounded by a rail.
7. A picket fence kit according to claim 1 for a picket fence section, wherein the enclosure includes a protective sheet having at least one closed end.
8. A picket fence kit according to claim 7 for a picket fence section, further comprising a label, wherein the protective sheet includes a transparent region through which the label may be viewed.
9. A picket fence kit according to claim 1 for a picket fence section, further comprising a post cap attached to an end of the post.
10. A picket fence kit according to claim 9 for a picket fence section, further comprising a shipping cap, wherein the post cap and the shipping cap are fixedly attached to the post.
11. A picket fence kit according to claim 1 for a picket fence section, further comprising a plurality of picket caps, each picket cap attached to the top end of a picket.
12. A picket fence kit according to claim 1 for a picket fence section, further comprising a set of miscellaneous components located within the enclosure.
13. A picket fence kit according to claim 12, wherein the miscellaneous components include a set of rail brackets and a set of self-tapping screws.
14. A picket fence kit according to claim 1 for a picket fence section, wherein the post is a routed post.
15. A picket fence kit according to claim 1 for a picket fence section, wherein the top rail contains at least three pickets, and the bottom rail contains at least four pickets.
16. A picket fence kit according to claim 1 for a picket fence gate, further comprising a first gate upright and a second gate upright, wherein the post surrounds the first gate upright and the second gate upright.
17. A picket fence kit according to claim 16 for a picket fence gate, wherein the second gate upright is axially aligned with the first gate upright.
18. A picket fence kit according to claim 16 for a picket fence gate, wherein the first gate upright surrounds a first rail, and the second gate upright surrounds a second rail.
19. A picket fence kit according to claim 16 for a picket fence gate, wherein each rail surrounds at least one picket.
20. A picket fence kit according to claim 16 for a picket fence gate, wherein at least one gate upright surrounds at least one picket not surrounded by a rail.
21. A picket fence kit according to claim 16 for a picket fence gate, further comprising a brace, wherein the brace is surrounded by the post and is axially aligned with a picket.
22. A picket fence kit according to claim 16 for a picket fence gate, wherein the plurality of pickets is five pickets.
23. A picket fence kit according to claim 16 for a picket fence gate, further comprising two gate hinges and a latch, wherein the post surrounds the two gate hinges and the latch.
24. A picket fence kit according to claim 16 for a picket fence gate, further comprising a set of rail pockets and a set of self-tapping screws, both sets located within the enclosure.
25. A picket fence kit according to claim 16 for a picket fence gate, wherein the post is a routed post.
Type: Application
Filed: Dec 8, 2007
Publication Date: Jul 31, 2008
Applicant:
Inventor: Paul Mulgrew (Topsfield, MA)
Application Number: 11/999,904
International Classification: E04H 17/24 (20060101); E04H 17/16 (20060101);