Extruded Aluminum Rail
An integrally formed rail for use with a fence panel. The rail is formed to define a top platform, first and second side walls, and a bottom platform. The side walls extend from the top platform and past the bottom platform. The top platform and the bottom platform define the boundaries of a rail channel. The top platform and the bottom platform define picket openings. The rail is formed by extruding the platforms and side walls from an extrudable material such as aluminum. The picket openings can be formed by inserting a mandrel in the rail channel and stamping the openings. Fence pickets are inserted through the picket openings to construct the fence panel. A retaining rod is inserted in the rail channel and through openings in the pickets to retain the pickets in the panel.
The present invention relates generally to rails and more particularly to rails for use with picket fences.
SUMMARY OF THE INVENTIONThe present invention is directed to a rail for use with a fence. The rail is integrally formed and comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall. The first side wall and the second side wall extend from the top platform and past the bottom platform. The top platform and the bottom platform define boundaries of a rail channel.
In an alternative embodiment, the present invention is directed to a rail for use with a fence, wherein the rail comprises a channel element. The channel element comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall. The first side wall and the second side wall extend from the top platform and past the bottom platform. The top platform and the bottom platform define a rail channel and the bottom platform is characterized by a plurality of longitudinally spaced picket openings formed in the platform. The channel element is formed from extruded metal.
In yet another embodiment, the present invention is directed to a method of making a rail for use in a fence. The method comprising the step of forming a channel element by extrusion. The channel element comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall such that the first side wall and the second side wall extend from the top platform and past the bottom platform. The method further comprises the steps of inserting a mandrel in the channel element between the top platform and the bottom platform, and stamping a plurality of picket openings in the bottom platform.
With reference now to the drawings and to
Preferably, the posts 16 are of identical construction. Each of the posts 16 is securely anchored at its lower portion into a substrate 18, such as an underground mass of concrete. The substrates 18 are preferably disposed in spaced relationship, with a separate substrate preferably supporting each post 16. The posts 16 are situated along the boundary of the area to be enclosed by the fence 10, with a post spacing which is adequate to impart strength to the fence 10 and to securely anchor other fence components.
Distance between posts 16, as well as height, diameter, and cross-sectional design of the posts may be varied to suit the particular application of the fence 10. Design and construction of posts 16 will preferably be comparable to that described in commonly owned U.S. Pat. No. 6,969,051, the content of which is hereby incorporated in its entirety.
With continued reference to
Referring now to
The platforms 24 and 26 and side walls 32 and 34 define the boundaries of a rail channel 36. The first and second side walls 32 and 34 are preferably disposed in parallel planes, with each orthogonal to the planes of the platforms 24 and 26. The rail channel 36, as shown in
Referring now to
With continued reference to
Turning now to
The platforms 54 and 56 and side walls 58 and 60 define the boundaries of a rail channel 62. The rail channel 62, as shown in
As with the rail 20 of
Referring now to
Each picket 21 for use in the panel 70 preferably defines a plurality of parallel, longitudinally offset, retainer passages 72. The number of retainer passages 72 in each picket 21 preferably equals the number of rails 20 and 50 in the panel 70. The retainer passages 72 are positioned on the pickets 21 such that each retainer passage may be aligned with corresponding retainer channels 36 and 62 of the rails 20 and 50.
The panel 70 of the present invention further comprises a plurality of elongate retainer elements 74 (shown in
Pickets 21 are installed on the rails 20 and 50 by extending each picket through an aligned pair of picket openings 40 and 42 of a rail 20, until the retainer channel 36 of the rail is aligned with the retainer passage 72. With the pickets 21 in the rail 20 and the retainer passage 72 aligned in the retainer channel 36, the retainer element 74 is inserted into the channel and through the aligned retainer passages of each of the pickets. This procedure is repeated for each rail 20 and 50 to be used in a panel. Preferably, construction of the panel 70 will be comparable to that described in U.S. Pat. No. 6,969,051, previously incorporated by reference.
With reference again to
Various means and hardware for connecting fence panels 70 and rails 20 and 50 to posts 16 may be used. Additionally, other hardware components for protecting internal components of the fence 10 and fence panels 70 may be used as desired. Components and hardware suitable for use with the present invention are disclosed in previously mentioned U.S. Pat. No. 6,969,051.
Referring now to
The fence of the present invention may be assembled from, and the methods of the invention advantageously practiced with, a kit. The kit of the present invention preferably comprises a plurality of posts, preferably identical to the posts 16. The posts 16 are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.
The kit further comprises a plurality of rails 20, with each rail 20 including a channel element 22 and a retainer element 74. The rails 20 should be provided in the kit in a number sufficient to form the fence, or fence panels thereof, to be installed. The kit should further comprise a plurality of brackets and fasteners should for securing each rail 20 to an adjacent pair of posts 16. The brackets and fasteners are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.
The kit further comprises a plurality of pickets, preferably identical to the pickets 21, preferably in a number sufficient for the fence, or section thereof, to be installed.
Various modifications can be made in the design and operation of the present invention without departing from the spirit thereof. Thus, while the principal preferred construction and use of the invention have been explained in what is now considered to represent its best embodiments, it should be understood that the invention may be practiced otherwise than as specifically illustrated and described, and claimed in the following claims.
Claims
1. A rail for use with a fence, the rail comprising:
- a top platform having opposed first and second lateral edges;
- a first side wall which depends from the first lateral edge of the platform;
- a second side wall which depends from the second lateral edge of the platform; and
- a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform;
- wherein the top platform and the bottom platform define boundaries of a rail channel; and
- wherein the rail is integrally formed.
2. The rail of claim 1 further comprising:
- a first flange at an end of the first side wall remote from the top platform; and
- a second flange at an end of the second side wall remote from the top platform.
3. The rail of claim 1 wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein.
4. The rail of claim 1 wherein the top platform defines a plurality of longitudinally spaced picket openings formed therein; and
- wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein;
- such that each picket opening of the top platform is aligned with a corresponding picket opening in the bottom platform.
5. A fence panel comprising a plurality of rails as defined in claim 4, and further comprising:
- a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails.
6. The rail of claim 4 further comprising an elongate retainer element receivable within the rail channel.
7. A fence panel comprising a plurality of rails as defined in claim 6, and further comprising:
- a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails; and
- wherein each picket defines at least one retainer passage; the retainer element of each rail positioned within the rail channel such that it passes through the retainer passages of the pickets.
8. A fence comprising a plurality of fence panels as defined in claim 7, and further comprising:
- a plurality of vertically disposed posts, each adjacent pair of posts supporting opposite ends of a plurality of rails.
9. A kit comprising a plurality of rails as defined in claim 1, and further comprising: a plurality of posts; and a plurality of pickets.
10. A kit comprising a plurality of rails as defined in claim 4, and further comprising: a plurality of posts; and a plurality of pickets.
11. A method of making a rail as defined in claim 1, comprising: forming the rail from an extrudable material by an extrusion process.
12. A method of making a rail as defined in claim 4, comprising the steps of:
- forming the rail from an extrudable material by an extrusion process;
- inserting a mandrel into the rail channel;
- stamping the plurality of picket openings in the top platform; and
- stamping the plurality of picket openings in the bottom platform.
13. The method of claim 12 in which the extrudable material comprises aluminum.
14. A method of making a rail as defined in claim 2, comprising the steps of:
- forming the rail from an extrudable material by an extrusion process;
- inserting a mandrel into the rail channel; and
- stamping the plurality of picket openings in the bottom platform.
15. The method of claim 14 in which the extrudable material comprises aluminum.
16. A fence comprising a plurality of rails, including at least one rail as defined in claim 15, and further comprising: a plurality of vertically disposed posts, with each adjacent pair of posts supporting the opposite ends of a plurality of rails; and a plurality of pickets, with each picket being laterally traversed by at least one retainer passage; in which the retainer element is positioned within the retainer channel such that it passes through the aligned retainer passages of the pickets.
17. A rail for use with a fence, the rail comprising:
- a channel element comprising:
- a top platform having opposed first and second lateral edges;
- a first side wall which depends from the first lateral edge of the platform;
- a second side wall which depends from the second lateral edge of the platform; and
- a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform;
- wherein the top platform and the bottom platform define a rail channel; and
- wherein the bottom platform is characterized by a plurality of longitudinally spaced picket openings formed therein; and
- wherein the channel element is formed from extruded metal.
18. The rail of claim 1 further comprising:
- a first flange at an end of the first side wall remote from the top platform; and
- a second flange at an end of the second side wall remote from the top platform.
19. The rail of claim 1 wherein the top platform is characterized a plurality of longitudinally spaced picket openings formed therein.
20. A method of making a rail for use in a fence, the method comprising the steps of:
- forming a channel element by extrusion, the channel element comprising: a top platform having opposed first and second lateral edges; a first side wall which depends from the first lateral edge of the platform; a second side wall which depends from the second lateral edge of the platform; and a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform;
- inserting a mandrel in the channel element between the top platform and the bottom platform;
- stamping a plurality of picket openings in the bottom platform.
21. The method of claim 18 further comprising stamping a plurality of picket openings in the top platform.
Type: Application
Filed: Apr 30, 2009
Publication Date: Nov 4, 2010
Inventor: Edward L. Gibbs (Tulsa, OK)
Application Number: 12/433,517
International Classification: E04H 17/00 (20060101); E04H 17/14 (20060101); B21C 23/00 (20060101);