CROSS REFERENCE TO RELATED APPLICATIONS 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 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.
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.
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 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.
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.
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 FIG. 1a is a side view of a section of a picket and rail fence in accordance with an embodiment of the present invention;
FIG. 1b is a sectional view of the picket and rail fence of FIG. 1a taken along the section A-A;
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;
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;
FIG. 2b is a perspective view of a rail grommet in accordance with an embodiment of the present invention;
FIG. 2c is a top view of a retaining bar in accordance with an embodiment of the present invention;
FIG. 2d is a side view of the retaining bar of FIG. 2c;
FIG. 2e is a top view of a rail in accordance with an embodiment of the present invention;
FIG. 2f is a cross sectional view of the rail of FIG. 2e;
FIG. 2g is a side view of the rail of FIG. 2e;
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 of FIG. 3a;
FIG. 3c is an expanded view of a joint including the top rail and one post of the fence shown in FIG. 3b;
FIG. 3d is an expanded view of a joint including the bottom rail and one picket of the fence shown in FIG. 3b;
FIG. 4a is a perspective view of a fence post in accordance with an embodiment of the present invention;
FIG. 4b is a perspective view of the opposite side of the fence post shown in FIG. 4a;
FIG. 4c is a front view of the fence post shown in FIG. 4a;
FIG. 4d is a side view of the fence post shown in FIG. 4a;
FIG. 4e is a rear view of the fence post shown in FIG. 4a;
FIG. 5a is a perspective view of a top rail in accordance with an embodiment of the present invention;
FIG. 5b is a side view of the rail shown in FIG. 5a;
FIG. 5c is an expanded view of one end of the rail shown in FIG. 5a;
FIG. 5d is a bottom view of the rail shown in FIG. 5a;
FIG. 6a is a perspective view of a bottom rail in accordance with an embodiment of the present invention;
FIG. 6b is a top view of the rail shown in FIG. 6a;
FIG. 6c is a side view of the rail shown in FIG. 6a;
FIG. 6d is an expanded view of one end of the rail shown in FIG. 6c;
FIG. 6e is an expanded view of one end of a bottom rail in accordance with an embodiment of the present invention;
FIG. 7a is a perspective view of a picket in accordance with an embodiment of the present invention;
FIG. 7b is a front view of the picket shown in FIG. 7a;
FIG. 7c is a side view of the picket shown in FIG. 7a;
FIG. 7d is an expanded view of the upper end of the picket shown in FIG. 7c;
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;
FIG. 8a is a perspective view of a picket grommet in accordance with an embodiment of the present invention;
FIG. 8b is a side view of the picket grommet shown in FIG. 8a;
FIG. 8c is a top view of the picket grommet shown in FIG. 8a;
FIG. 8d is a front view of the picket grommet shown in FIG. 8a;
FIG. 8e is a top sectional view taken along the section A-A of the picket grommet shown in FIG. 8d;
FIG. 8f is a perspective view of a small rail grommet in accordance with an embodiment of the present invention;
FIG. 9a is a perspective view of a post grommet in accordance with an embodiment of the present invention;
FIG. 9b is a front view of the post grommet shown in FIG. 9a;
FIG. 9c is a rear view of the post grommet shown in FIG. 9a;
FIG. 9d is a side sectional view taken along the section A-A of the post grommet shown in FIG. 9c;
FIG. 9e is a bottom view of the post grommet shown in FIG. 9a;
FIG. 10a is 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 rear view of the post bracket shown in FIG. 10a;
FIG. 11a is a top sectional view of a rail and a picket in accordance with an embodiment of the present invention;
FIG. 11b is a side sectional view of a post and a rail in accordance with an embodiment of the present invention;
FIG. 12a is a perspective view of a post grommet in accordance with another embodiment of the present invention;
FIG. 12b is a front view of the post grommet shown in FIG. 12a;
FIG. 12c is a rear view of the post grommet shown in FIG. 12a;
FIG. 12d is a side sectional view taken along the section A-A of the post grommet shown in FIG. 12c;
FIG. 12e is a bottom view of the post grommet shown in FIG. 12a;
FIG. 13a is a perspective view of a large rail grommet in accordance with another embodiment of the present invention;
FIG. 13b is a front view of the large rail grommet shown in FIG. 13a;
FIG. 13c is a rear view of the large rail grommet shown in FIG. 13a;
FIG. 13d is a side sectional view taken along the section A-A of the large rail grommet shown in FIG. 13c;
FIG. 13e is a bottom view of the large rail grommet shown in FIG. 13a;
FIG. 14a is a perspective view of a picket grommet in accordance with the embodiment of the large rail grommet shown in FIG. 11a;
FIG. 14b is a side view of the picket grommet shown in FIG. 14a;
FIG. 14c is a top view of the picket grommet shown in FIG. 14a;
FIG. 14d is a front view of the picket grommet shown in FIG. 14a;
FIG. 14e is a top sectional view taken along the section A-A of the picket grommet shown in FIG. 14d;
FIG. 14f is a perspective view of a small rail grommet in accordance with the embodiment of the post grommet shown in FIG. 10a;
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;
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
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 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.
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.
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.
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.
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).
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.
FIG. 1b is a sectional view of the picket and rail fence of FIG. 1a taken along the section A-A.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
FIGS. 12b-12e illustrate front, rear, side sectional and bottom views, respectively, of the post grommet of FIG. 12a.
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.
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.
FIGS. 13b-13e illustrate front, rear, side sectional and bottom views, respectively, of the large rail grommet of FIG. 13a.
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.
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.
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.
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.
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).
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.
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.
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.
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.
