Fence Panel and Method for Assembly

Abstract

A fence panel has a first fence post and a second fence post spaced from the first post, each post having a face oriented toward the other post. An upper tab and lower clip are mounted on each post. Each upper tab is fixed, and each lower clip is movable during assembly relative to the associated post between a lower position and a higher position. A top rail is assembled onto the upper tabs, a bottom rail is assembled onto the lower clips, and at least one fence picket is inserted between the rails. During assembly the bottom rail and pickets are moved upward together relative to the posts and toward the top rail to an assembled position for retaining each picket between the rails. The lower clips are moved to the higher position for retaining the bottom rail and pickets in the assembled position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part application of U.S. patent application Ser. No. 14/685,232 filed 13 Apr. 2015.

BACKGROUND

1. Field of the Invention

The present application relates in general to fences and in particular to component fence systems.

2. Description of Related Art

Fences are typically constructed with pre-built panels, and these are usually made of wood or metal. With pre-built panels, the choice of which side to have facing the owner is made during installation, but adjacent neighbors may be dissatisfied with having the other side facing them. Also, adjacent neighbors may disagree on what type of fence to erect, what color to use, and what details should be used on the fence.

Pipe fences are constructed with components, but they often have few custom options available. One advantage to a pipe fence is that adjacent neighbors have similar views of the fence, as pipe fences tend to be symmetrical along their length. However, this does not eliminate disagreement concerning color or other details of the fence.

Although great strides have been made in fence systems, considerable shortcomings remain.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the subject matter of this application are set forth in the appended claims. However, the subject matter itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a fence panel assembled form an embodiment of a fence system according to the present application;

FIG. 2 is an exploded side view of the fence panel of FIG. 1;

FIG. 3 is a front view of a post of the fence panel of FIG. 1;

FIG. 4 is a detailed view of an upper portion of the post of FIG. 3;

FIG. 5 is a detailed view of a lower portion of the post of FIG. 3;

FIG. 6 is a side view of a top rail of the fence panel of FIG. 1;

FIG. 7 is a bottom view of an end portion of the top rail of FIG. 6;

FIG. 8 is an end view of the top rail of FIG. 6;

FIG. 9 is a side view of a bottom rail of the fence panel of FIG. 1;

FIG. 10 is a top view of an end portion of the bottom rail of FIG. 9;

FIG. 11 is an end view of the bottom rail of FIG. 9,

FIG. 12 is a perspective view of an end portion of the bottom rail of FIG. 9;

FIG. 13 is a front view of a clip of the fence panel of FIG. 1;

FIG. 14 is a side view of the clip of FIG. 13;

FIG. 15 is a perspective view of the clip of FIG. 13 installed on a fence post of the fence panel of FIG. 1;

FIG. 16 is a cross-section side view of the clip of FIG. 13 installed on a fence post of the fence panel of FIG. 1;

FIGS. 17A through 17D are top and side views of embodiments of pickets for the fence panel system of the present application;

FIG. 18 is a flowchart of a method according to the present application;

FIG. 19 is an end view of the top and bottom rails and a picket of the fence panel of FIG. 1 and illustrating steps of assembly of the fence panel;

FIG. 20 shows side and end views of an alternative embodiment of a clip for use with the fence panel of FIG. 1;

FIG. 21 is a cross-section side view of the clip of FIG. 20 installed on a fence post of the fence panel of FIG. 1;

FIGS. 22 through 24 are side views illustrating an alternative embodiment of a fence panel according to the present application;

FIG. 25 is an oblique exploded view of an alternative embodiment of an attachment system for assembling and installing a fence panel according to the present application;

FIG. 26 is an oblique view of the assembled system of FIG. 25;

FIG. 27 is an oblique view of the assembled system of FIG. 25;

FIG. 28 is an oblique exploded view of another alternative embodiment of an attachment system for assembling and installing a fence panel according to the present application;

FIG. 29 is an oblique view of the assembled system of FIG. 28;

FIG. 30 is an oblique view of the assembled system of FIG. 28;

FIGS. 31 illustrates side and end views of a lower clip of the system of FIG. 28, the clip being in a lower position;

FIG. 32 illustrates side and end views of the lower clip of FIG. 31, the clip being in a higher position;

FIG. 33 is an end view of a fence post and template assembly;

FIG. 34 illustrates end and top views of steps for using the template of FIG. 33;

FIG. 35 is an oblique exploded view of an alternative embodiment of an attachment system for assembling and installing a fence panel according to the present application;

FIG. 36 is an oblique view of the assembled system of FIG. 35;

FIG. 37 is a block diagram showing a method of installation and assembly of the systems of FIGS. 25, 28, and 35.

While the apparatus, system, and method of the present application are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the application to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Illustrative embodiments of the preferred embodiment are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.

There is a need for a simple and inexpensive component fence system that allows for ease of assembly and customization. The fence system is preferably a minimum-fastener or no-fastener system.

FIG. 1 illustrates a fence panel 11 assembled from embodiments of components according to the present application and using a method according to the present application, and FIG. 2 shows an exploded view of panel 11. FIGS. 3 through 17D illustrate the components in detail, and FIGS. 18 and 19 illustrate a method of assembly.

FIG. 1 is a perspective view of panel 11, and FIG. 2 is an exploded side view of panel 11. Panel 11 comprises fence posts 13, 15 longitudinally spaced form each other, and top rail 17 and bottom rail 19 extend between posts 13, 15, forming a generally planar structure. Pickets 21, illustrated in FIGS. 1 and 2 as wood panels 21A and square metal-tubing pickets 21B, are installed between rails 17, 19, and the top and bottom ends of pickets 21 are retained within rails 17, 19 for creating panel 11. A clip 23 is installed in each post 13, 15 below bottom rail 19 for retaining rail 19 and pickets 21 in a raised position, as described below. In the exploded view of FIG. 2, the upper and lower ends of pickets 21 are visible.

FIGS. 3 through 5 illustrate details of fence posts 13, 15. Posts 13, 15 are constructed in a similar manner and only post 13 is shown, though details of post 13 also apply to post 15. In the embodiment shown, post 13 is formed from square metal tubing, though post 13 may have another cross-sectional shape and may be formed from appropriate alternative materials. Post 13 has at least one inner face 25 with top rail slot 27 and bottom rail slot 29 both formed therein. Additional inner faces 25 with slots 27, 29 formed on other sides of post 13 allow for additional panels to be assembled using the same post 13.

Top rail slot 27 is shown in detail in FIG. 4 and is formed as an upside-down U-shaped opening in inner face 25, slot 27 defining tab 31 centered within slot 27. Slot 27 is sized to receive an outer end of top rail 17, which is described in detail below. FIG. 5 shows details of bottom rail slot 29, which is formed as a U-shaped opening in inner face 25, slot 29 defining a tab 33 centered within slot 29. Slot 29 is sized to receive an outer end of bottom rail 19, which is described in detail below. Unlike top rail slot 27, lower edge 34 of bottom rail slot 29 is spaced a significant distance from tab 33, creating an extended portion 35 and allowing for bottom rail 19 to move vertically within slot 29 and relative to post 13. Optional fastener holes 37 may be used to retain clip 23 to post 13, as described in detail below.

Top rail 17 is shown in detail in FIGS. 6 through 8. As shown, rail 17 is formed from square, U-shaped channel stock and may be formed of metal or an appropriate alternative material. Rail 17 comprises horizontal panel 39 and vertical panels 41. A hole 43, shown in FIG. 7, is located at each end of rail 17 and allows for a retaining pin or rod to be inserted through hole 43 to retain rail 17 in slot 27 of post 13 during assembly of panel 11. Alternatively, a tab or similar feature may be formed in the end of rail 17 to retain rail 17 in post 13. Top rail 17 is sized to fit into slot 27 with minimum clearance, limiting vertical and lateral movement of rail 17 relative to post 13 while allowing for rail 17 to slide in a longitudinal direction through slot 27 relative to post 13. Though shown as having a generally square cross-sectional shape, top rail 17 may be formed to have other open cross-sectional shapes, such as an open V or a semicircle, and slot 27 would be formed to accommodate the alternative shape of rail 17.

Bottom rail 19 is shown in detail in FIGS. 9 through 12. As shown, rail 19 is formed from square, U-shaped channel stock and may be formed of metal or an appropriate alternative material. Rail 19 comprises horizontal panel 45 and vertical panels 47, and horizontal panel 45 has a downward-facing lower surface 49. A hole 51, shown in FIG. 7, is located at each end of rail 19 and allows for a retaining pin or rod to be inserted through hole 51 to retain rail 19 in slot 29 of post 13 during assembly of panel 11. Alternatively, a tab or similar feature may be formed in the end of rail 19 to retain rail 19 in post 13. Bottom rail 19 is sized to fit into slot 29 with minimum lateral clearance, limiting lateral movement of rail 19 relative to post 13 while allowing for rail 19 to slide in a longitudinal direction through slot 29 relative to post 13. Also, extended portion 35 of slot 29 allows rail 19 to move vertically a limited amount relative to post 13, and clip 23 is used to retain rail 19 in a raised position relative to post 13, as described in detail below. As stated for top rail 17, bottom rail 19 may be formed to have other open cross-sectional shapes, such as an open V or a semicircle, and slot 29 would have a corresponding shape with an enlarged area for vertical movement of rail 19.

Because bottom rail 19 opens upward, rail 19 may fill with water from rain or irrigation. To alleviate this problem, bottom rail 19 preferably has multiple drain holes 53 formed in horizontal panel 45 and spaced along the length of rail 19. In the preferred embodiment, a spacer, such as optional tube 55, is installed within rail 19 and adjacent panel 45 for spacing pickets 21 above panel 45 and increasing stiffness of rail 19. Tube 55 is preferably formed from ¾″ metal square tubing and is large enough to keep pickets 21 above water accumulating within rail 19 prior to draining through holes 53. Tube 55 is also wide enough to provide a ledge for 1×n pickets 21 to not fall between tube 55 and vertical panels 47. Alternatively, a large ridge or other raised platform may be formed or installed in rail 19 to also act as a spacer and perform the same functions as tube 55. Tube 55 is preferably fastened to rail 19 with fasteners 56 along the length of tube 55, allowing tube 55 to be removed when the length of rail 19 is shortened for use in a particular location, tube 55 being shortened a similar amount and then reinstalled on rail 19.

FIGS. 13 through 16 illustrate details of clip 23 and the installation of clip 23 on fence post 13. Clip 23, as shown, is preferably formed from thin metal sheet and comprises a back plate 57 and a ledge plate 59. As shown, back plate 57 is generally square, having a front surface 61, upper surface 63, and optional fastener holes 65. As shown, ledge plate 59 is generally rectangular and has an upper surface 67 and a lower surface 69. Ledge plate 59 is preferably formed as a separate piece that is attached to an upper portion of front surface 61 of back plate 57 by welding or other means, though ledge plate 59 may be formed as an integral part of back plate 57 to form clip 23. Ledge plate 59 has a horizontal width sized for plate 59 to fit closely within slot 29 of post 13, whereas back plate 57 has a horizontal width that is wider than slot 29. Ledge plate 59 is preferably horizontally centered on back plate 57, with upper surfaces 63, 67 of both plates 57, 59 being aligned.

Referring now specifically to FIGS. 15 and 16, clip 23 is used to retain bottom rail 19 in a raised position relative to post 13. As described in detail below, during assembly of fence panel 11 (FIG. 1) bottom rail 19 is inserted into slot 29 and then raised toward top rail 17 relative to fence post 13. To retain rail 19 in the raised position, which is the position shown in FIGS. 15 and 16, ledge plate 59 of clip 23 is inserted into enlarged area 35 (shown in FIG. 5) of slot 29, and this assembled configuration is show in cross-section in FIG. 16. When clip 23 is installed, front surface 61 of back plate 57 is adjacent inner face 25 of post 13, and lower surface 69 of ledge plate 59 rests atop lower edge 34 of slot 29. Upper surfaces 63, 67 are in contact with lower surface 49 of bottom rail 19 and cooperate to support rail 19. Ledge plate 59 has a vertical height that fills enlarged area 35 of slot 29 and retains rail 19 in the raised position within slot 29. In the embodiment shown, fasteners 71 extend through holes 65 in back plate 57 and into holes 37 (FIG. 5) of post 13 for retaining clip 23 in position relative to post 13. In another embodiment, to assist in retaining clip 23 in slot 29 with or without fasteners, bottom surface 69 of ledge plate 59 may be formed to have an angle, forming a back cut, or may have a notch formed on surface 69, the angle or notch being configured to engage lower edge 34 of slot 29.

As shown in FIG. 1, pickets 21 are inserted into rails 17, 19 during assembly, allowing for customization of panel 11 in any desired configuration. To allow for proper lateral location of pickets 21 within rails 17, 19, rails 17, 19 are preferably formed to have a selected lateral width, such as 1.6 or 1.7 inches. This particular width allows for pickets 21 having a lateral width of 1.5 in to be inserted within rails 17, 19. This allows, for example, boards having a cross-section of the common “2×n” (actual is 1.5 in×n) measurement to be used as pickets 21 in fence panel 11. Also, boards having a cross-section of the common “1×n” (actual is 0.75 in×n) measurement may be oriented back-to-back or overlapped to achieve the 1.5 in lateral width needed to locate pickets 21 within rails 17, 19. Alternatively, pickets 21 having less than the required lateral width may have flanges or be shimmed. Any configuration of pickets 21 achieving the necessary lateral width may be used, and these may include, for example, boards, privacy or non-privacy panels, screen panels, metal tubing, or decorative panels (e.g., scenery, promotional, Christmas). Pickets 21 may be made, for example, from metal, plastic, composites, masonry, or any other appropriate material.

FIGS. 17A through 17D illustrate examples of pickets 21 and an example assembly configuration. FIG. 17A shows I-beam versions of pickets 21, illustrated by picket 21 C, each comprising a web 73 and flanges 75 perpendicular to web 73. Web 73 may be any desired longitudinal length, and flanges 75 have a lateral width of approximately 1.5 in. FIG. 17B shows picket 21B (shown in FIGS. 1 and 2), which is formed from square metal tubing 77 and 1.5 in-wide flanges 79 on upper and lower ends of tubing 77. FIG. 17C illustrates “2×n” boards of various width, including intermediate picket 21A (shown in FIGS. 1 and 2), whereas FIG. 17D shows use of “1×n” pickets 21D, which are overlapped to achieve the desired 1.5 in lateral width required for rails 17, 19. The ability to overlap or stack pickets 21 allows for use of different pickets 21 on each side of fence panel 11 for providing a different aesthetic to each side of panel 11.

FIGS. 18 and 19 illustrate a method 81 of assembling panel 11 of FIG. 1. FIG. 18 is a flowchart that begins with step 83 of placing the first fence post, such as post 13, and affixing the post in its final position, which may include the common step of using concrete to affix the post. Step 85 follows, in which the next post, such as post 15, is also placed in its position and affixed in its final position, such as with concrete, and then top rail 17 and bottom rail 19 are inserted into slots 27, 29, respectively, of posts 13, 15 in step 87. Alternatively, step 85 may be repeated to place and affix some or all of the remaining posts of the fence prior to performing step 87 for each panel of the fence. Step 87 requires that one end of each rail 17, 19 is inserted into a corresponding slot 27, 29 of one post 13, 15 a sufficient amount to allow the other end of rail 17, 19 to clear inner face 25 of the other post 13, 15. Step 89 is inserting pickets 21 between (and within) rails 17, 19, so that rails 17, 19 loosely retain pickets 21 in position. Step 91 is lifting bottom rail 19 and pickets 21 toward top rail 17 and relative to posts 13, 15, and step 93 is inserting clips 23 in slot 29 of each post 13, 15 to retain bottom rail in the raised position and complete assembly of panel 11. Step 93 may also include installing fasteners, such as fasteners 71 of FIG. 15, to retain clips 23 in position on posts 13, 15. After completing step 93, the next adjacent panel 11 may be assembled by returning to step 85, as shown by arrow 95, and placing and affixing the next post. Step 91 of lifting bottom rail 19 and pickets 21 may be accomplished through use of straps or similar devices to pull rail 19 upward toward top rail 17. The straps would be tightened until rail 19 is in the raised position, clips 23 are installed, and then the straps are loosened and removed. The positions of pickets 21 may be shifted relative to each other and/or to rails 17, 19 before and/or after rail 19 is moved to the raised position.

FIG. 19 is pictorial illustration of steps 91 through 95. Part A of the figure shows an upper end of picket 21 inserted into top rail 17 by lifting picket 21 in the direction shown by arrow 101. In part B, a lower end of picket 21 is moved in the direction of arrow 103 to position the lower end over bottom rail 19. In part C, picket 21 is moved downward in the direction of arrow 105, positioning the lower end of picket 21 within rail 19, a small portion of the upper end of picket 21 still being located within top rail 17, thereby retaining picket 21 between and within both rails 17, 19. Part D shows bottom rail 19 and picket 21 having been lifted toward rail 17 in the direction of arrow 107, and part E shows clip 23 installed to retain bottom rail 19 and picket 21 in the raised position.

FIGS. 20 and 21 show an alternative clip 109 for retaining bottom rail 19 in the raised position. Clip 109 has a body 111 having an upper surface 113 and a notch 115 formed in a lower portion of body 111. Clip 109 is preferably formed from metal, though it may be formed from any appropriate material. As shown in FIG. 21, when clip 109 is installed, notch 115 engages lower edge 34 of slot 29 in post 13, and lower surface 49 of rail 19 rests on upper surface 113 of clip 109.

FIGS. 22 through 24 illustrate a fence panel 117, panel 117 having components that serve to prevent objects from moving under panel 117. As shown, panel 117 comprises fence posts 13, 15, top rail 17, and bottom rail 19. Pickets include boards 119, which are like pickets 21A in FIG. 17C, and tubing pickets 121. Tubing pickets 121 are constructed similarly to picket 21B of FIG. 17B, but each picket 121 has an extended portion 123 extending below lower flange 125, as shown in FIG. 23. Bottom rail 19 has additional holes in horizontal panel 45 for allowing extended portion 123 to pass through rail 19 and extend below rail 19. This allows for the same method of assembly as for panel 11 to be used for panel 117 and provides additional fencing below rail 19, preventing animals, children, or objects from passing under rail 19.

Referring to FIG. 24, when using boards 119, or other pickets without pieces that can protrude below rail 19, guard 127 provides another option for providing fencing below rail 19. Guard 127 comprises a flange 129 that sits under other pickets, such as boards 119, and flange 129 may have holes to allow extended portions 123 of tubing pickets 121 to pass through flange 129. Depending from flange 129 are tubes 131, which cooperate with pickets 121 when assembled in panel 117 to provide fencing under rail 19. Though shown with only a few tubes 131, guard 127 may have tubes along its length, allowing for use of, for example, only boards 119 or use of pickets 21 B.

FIGS. 25 through 37 illustrate alternative embodiments for a modular fence system and methods of assembly according to this patent application. These embodiments allow for installation of a customizable fence panel, similar to panel 11 of FIG. 1, and utilize a method similar to method 61 described above and shown in FIG. 18. However, the following embodiments do not require any rail slots 27, 29 or other features to be provided on the fence posts, allowing unmodified, typical tubing stock to be used for the fence posts.

FIGS. 25 through 27 illustrate an alternative embodiment of an attachment system 133 for assembly and installation of a modular fence panel, similar to panel 11, on fence post 135. Post 135 has four faces 137, though post 135 may have more or fewer faces 137 and may have a different cross-sectional shape, such as cylindrical. Components may require a particular configuration for adaptation to other shapes of post 135, such as a saddle shape for attachment to cylindrical posts.

Rather than forming holes, such as rail slots 27, 29, in post 135, system 133 utilizes a plate 139 for locating an upper clip 141 and for movably locating and retaining a lower clip 143. Plate 139 and clips 141, 143 are preferably formed from metal, though other appropriate materials may be used. In the embodiment shown, plate 139 is an elongated, planar rectangular plate formed from, for example, 2-inch wide bar stock. A rectangular aperture 145 is formed in an upper end portion of plate 139, and a downward-opening rectangular notch 147 is formed in a lower end portion of plate 139. An inner surface 149 of plate 139 is configured to be placed against face 137 of post 135. A stop plate 151 is mounted to outer surface 153 of plate 139, stop plate 151 enclosing the end portion of notch 147. Two holes 155 are formed in plate 139 and located between aperture 145 and notch 147, and a fastener 156 extends through each hole 155 and into post 135 for retaining plate 139 to post 135.

In the embodiment shown, clips 141, 143 are preferably identical and L-shaped, each having a rail-support tab 157 and a perpendicular mounting tab 159. A hole 161 is formed in each mounting tab 159, and a fastener 163 extends through each hole 161 and into post 135 for retaining clip 141, 143 to post 135. Each rail-support tab 157 has an upward-facing rail-support surface 165 for supporting either top rail 167 or bottom rail 169, as shown in FIG. 27. A downward-facing inner surface 171 of upper rail 167 rests on surface 165 of upper clip 141, and a downward-facing outer surface 173 of bottom rail 169 rests on surface 165 of lower clip 143.

To install a fence panel according to this patent application on post 135 in system 175, the user first aligns plate 139 at the desired height on post 135, with inner surface 149 of plate 139 against face 137 of post 135. To retain plate 139 in this position, fasteners 157 are installed through holes 155 and extend into post 135. Upper clip 141 is installed by placing mounting tab 159 into aperture 145 of plate 139, and then a fastener 163 is installed through hole 161 and extends into post 135 to retain upper clip 141 in a fixed position relative to plate 139. Lower clip 143 is installed in a first position, shown in FIG. 26, by placing mounting tab 159 of lower clip 143 into notch 147 of plate 139. At this point, lower clip 143 is free to slide vertically within notch 147, and gravity pulls lower clip 143 downward until support tab 157 rests against stop plate 151. In this position, mounting tab 159 is located between face 137 of post 135 and stop plate 151, removably capturing lower clip 143 in the lower, first position shown in FIG. 26.

This installation is repeated on a corresponding face 137 of a next post 135, and then top rail 167 is installed on upper tabs 141 and bottom rail 169 is installed on lower tabs 143 while tabs 143 are in the first position. Pickets (not shown), such as those shown in FIGS. 2 and 17A through 17D, are inserted in the same manner as described above and shown in FIG. 19, and then bottom rail 169 and the installed pickets are lifted toward top rail 167 to the raised, assembled position shown in Figure 27. Lower clip 143 is then moved upward within notch 147 to the higher second position shown in FIG. 27, and fastener 163 is installed through hole 161 and into post 135 for retaining lower clip 143 in the second position. Thus, lower clip 143 supports bottom rail 169 and pickets in the raised position.

In the preferred embodiment, aperture 145 of plate 139 positions upper tab 141 so that the outer edges of the end of top rail 167 align with the outer edges of plate 139, providing for an aesthetically pleasing, finished appearance. Also, bottom rail 169 may be fastened or otherwise attached to lower clip 143, so that they move in unison when being moved to the raised position. Another alternative configuration of system 133 includes installing fasteners through rails 167, 169 and the installed pickets.

In an alternative embodiment, plate 139 may be provided in two pieces, with an upper piece and a lower piece. Also, another embodiment includes only the bottom, notch portion of plate 139 (and stop plate 151) with a bare upper clip 141.

FIGS. 28 through 32 illustrate an alternative embodiment of an attachment system 175 for assembly and installation of a modular fence panel, similar to panel 11, on fence post 135. As with system 133 described above, post 135 may have more or fewer faces 137, may have a different cross-sectional shape, and may require a particular configuration for adaptation to other shapes of post 135.

Rather than utilizing an attached plate 139, system 175 uses a removable template 177 for determining the mounting locations of upper clip 141 and lower clip 179. Template 139 and clips 141, 179 are preferably formed from metal, though other appropriate materials may be used. In the embodiment shown, template 177 is an elongated, planar rectangular plate formed from, for example, 2-inch wide bar stock. A rectangular aperture 181 is formed in an upper end portion of template 177, and a lower rectangular aperture 183 is formed in a lower end portion of template 177. An inner surface 185 of template 177 is configured to be placed against face 137 of post 135.

In the embodiment shown, upper clip 141 is identical to clips 141, 143 used in system 133, as described above, and clip 141 has rail-support tab 157 and perpendicular mounting tab 159. Likewise, lower clip 179 is also L-shaped, clip 179 having a rail-support tab 187 and an elongated, perpendicular mounting tab 189. An elongated, open-bottom slot 191 is formed in mounting tab 189 and is sized for receiving fasteners 193, which extend through slot 191 and into post 135 for retaining clip 179 to post 135. Rail-support tab 187 has an upward-facing rail-support surface 195 for supporting bottom rail 169, as shown in FIG. 30, with downward-facing inner surface 171 of upper tail 167 resting on surface 165 of upper clip 141 and downward-facing outer surface 173 of bottom rail 169 resting on surface 195 of lower clip 179.

To install a fence panel according to this patent application on post 135 in system 175, it is preferred that the user first determine where upper clip 141 should be located on the first post 135 and install upper clip 141. The user can then locate the desired location on subsequent posts using any appropriate method, such as with a string line, and install upper clips 141 on other posts 135. The user can then hang template 177 on upper clip 141 of each post 135 to show the location for lower clip 179. If desired, template 177 may be temporarily retained in position on post 135 using any appropriate means, such as, for example, fasteners or adhesive tape, or the user may apply pressure to hold template 177 against post 135. The user may then trace or otherwise mark the locations of aperture 183 on face 137 and then remove template, leaving marks indicating the mounting locations for clip 179. Alternatively, either or both of clips 141, 179 may be installed while template 177 is adjacent face 137 by placing mounting tabs 159, 189 into the corresponding aperture 181, 183 of template 177.

A fastener 163 is installed through hole 161 and into post 135 to retain upper clip 141 in a fixed position relative to template 177. Lower clip 179 is installed in a lower, first position, shown in FIG. 29, by installing the lower two of three vertically spaced fasteners 193 through the upper portion of slot 191 and into post 135. At this point, template 177 can be removed, and then lower clip 179 is free to slide vertically relative to fasteners 193, though the two installed fasteners maintain clip 179 in a vertical orientation. Gravity pulls lower clip 179 downward until the upper end of slot 191 rests against the upper fastener 193, as shown in FIGS. 29 and 31.

This installation is repeated on a corresponding face 137 of a next post 135, and then top rail 167 is installed on upper clips 141 and bottom rail 169 is installed on lower clips 179 while clips 179 are in the first position. Pickets (not shown), such as those shown in FIGS. 2 and 17A through 17D, are inserted in the same manner as described above and shown in FIG. 19, and then bottom rail 169 and the installed pickets are lifted toward top rail 167 to the raised position shown in FIG. 30. Lower clip 179 is then moved upward relative to post 135 to the higher second position shown in FIGS. 30 and 32, and the upper fastener 193 is installed through the upper end of slot 191 and into post 135 for retaining lower clip 179 in the second position. Thus, lower clip 179 supports bottom rail 169 and pickets in the raised position.

Alternatively, instead of aperture 183, holes (not shown) for marking the position of the lower two of fasteners 193 may be formed in the lower portion of template 177, allowing installation of the lower two of fasteners 193 after removal of template 177. Then lower clip 179 is installed in the lower position by sliding slot 191 over the installed fasteners 193. Another alternative is that open-ended slots (not shown) sized for receiving the lower two of fasteners 193 may be formed in the lower portion of template 177, allowing installation of the lower two fasteners 193 prior to removal of template 177. Lower clip 179 can then be installed in the lower position on these fasteners.

FIGS. 33 and 34 show another embodiment of a template 197 and steps for use of template 197 while installing clips 141, 179. FIG. 33 is an end view looking toward face 137 of post 135, and FIG. 34 shows steps A though E from the end view and top view for each step. As shown, template 197 has an L-shaped cross-section and comprises template plate 199 and perpendicular alignment plate 201. Alternatively, template 197 may comprise only template plate 199. Template 197 is preferably formed from metal, though any appropriate material may be used. Template plate 199 has a side-opening, horizontal clip slot 203 on an upper portion of plate 199 and a pair of side-opening, horizontal fastener slots 205 in a vertical arrangement on a lower portion of plate 199. Clip slot 203 is sized in height for receiving upper clip 141, allowing template 197 to be placed adjacent post 135 and be supported by upper clip 141, with the top edge of clip slot 203 resting against rail-support surface 165 of tab 157 of clip 141. As template 197 hangs from clip 141, template plate 199 lies adjacent face 137 of post 135, and alignment plate 201 (if present) lies adjacent side face 207 of post 135. Fastener slots 205 are sized in height to receive fasteners 193 and preferably sized in horizontal length for placing the closed end of slot 203 at the horizontal center of face 137 of post 135 when alignment plate 201 is adjacent face 207 of post 135. Hanging template 197 from upper clip 141 provides for the ability to install (or mark the locations) at the proper vertical and horizontal position of the lower two fasteners 193 for lower clip 179. Slots 203, 205 allow for template 197 to be removed after installation of fasteners 193 by sliding template 197 sideways.

FIG. 34 shows the steps of installation of clips 141, 179 using template 197. As shown in step A of the figure, after post 135 is affixed in a final position, upper clip 141 is installed on face 137 of post 135 at a desired height. In step B, template 197 is placed adjacent post 135 and hung by clip slot 203 from clip 141, with template plate 199 adjacent face 137 and alignment plate 201 adjacent face 207. Step B also includes installing two fasteners 193 (or marking the position for subsequent installation), one in each fastener slot 205. After installation of fasteners 193, template is removed in step C, and in step D lower clip 179 is installed onto the lower two fasteners 193, as shown and described above. Step E shows moving clip 179 upward to the raised position to support bottom rail 169 (not shown) in the raised position, as shown and described above. Though not a preferred method, clips 141, 197 may optionally be installed on post 135 prior to emplacement of post 135.

FIGS. 35 and 36 illustrate another alternative embodiment of an attachment system 209 for assembly and installation of a modular fence panel, similar to panel 11, on fence post 135. Post 135 has four faces 137, though post 135 may have more or fewer faces 137 and may have a different cross-sectional shape, such as cylindrical. Components may require a particular configuration for adaptation to other shapes of post 135, such as a saddle shape for attachment to cylindrical posts.

Like systems 133 and 175, described above, system 209 does not require rail slots formed in fence posts 135, system 209 utilizing a plate 211 that has an integral upper rail-support tab 213 and a vertically movable lower clip 179. Plate 209 and clip 179 are preferably formed from metal, though other appropriate materials may be used. In the embodiment shown, plate 211 is an elongated, planar rectangular plate formed from, for example, 1.5-inch wide bar stock. Rail-support tab 213 is formed as a flat, rectangular protrusion extending perpendicularly from the upper end of plate 211, and tab 213 has an upward-facing rail-support surface 215. An inner surface 217 of plate 211 is configured to be placed against face 137 of post 135. Mounting holes 219 are formed in plate 211 and sized to receive fasteners 163, which extend through each hole 219 and into post 135 for retaining plate 211 to post 135. Three fastener holes 221 are formed in a spaced vertical arrangement in a lower portion of plate 211 and are sized for receiving fasteners 193. The lower two of fasteners 193 movably retain lower clip 179 adjacent plate. 211, whereas the upper fastener 193 affixes clip 179 in an upper raised position, as shown and described above for system 175. Alternatively, only the lower two of holes 221 are formed in plate 211, with the top hole 221 being formed, such as by a self-drilling fastener, after clip 179 is moved upward to the raised position during assembly.

To install a fence panel according to this patent application on post 135 in system 209, the user first aligns plate 211 at the desired height on post 135, with inner surface 217 of plate 211 against face 137 of post 135. To retain plate 211 in this position, fasteners 163 are installed through holes 219 and extend into post 135. The lower two of fasteners 193 are installed through the lower two of holes 221 and extend into post 135 to movably retain lower clip 179 adjacent plate 211. At this point, lower clip 179 is free to slide vertically relative to plate 211 and post 135, and gravity pulls lower clip 179 downward until the top of slot 191 rests against middle fastener 193.

This installation is repeated on a corresponding face 137 of a next post 135, and then top rail 167 is installed on upper tabs 213 and bottom rail 169 is installed on tabs 187 of lower clips 179 while clips 179 are in the lower first position. Pickets (not shown), such as those shown in FIGS. 2 and 17A through 17D, are inserted in the same manner as described above and shown in FIG. 19, and then bottom rail 169 and the installed pickets are lifted toward top rail 167 to the raised, assembled position shown in FIG. 36. Lower clip 179 is then moved upward relative to plate 211 to the higher second position shown in FIG. 36, and then top fastener 193 is installed through the top hole 221 and into post 135 for retaining lower clip 179 in the raised second position. Thus, lower clip 179 supports bottom rail 169 and pickets in the raised position. Also, bottom rail 169 may be fastened or otherwise attached to lower clip 179, so that they move in unison when being moved to the raised position. Another alternative configuration of system 209 includes installing fasteners through rails 167, 169 and the installed pickets.

FIG. 37 illustrates a method 223 of assembling and installing a fence panel according to this patent application using systems 133, 175, or 209. Method 223 is similar to method 61, as shown in FIGS. 18 and 19. FIG. 37 is a flowchart that begins with step 225 of placing the first fence post, such as post 135, and affixing the post in its final position, which may include the common step of using concrete to affix the post. Step 227 follows, in which the next post, is also placed in its position and affixed in its final position, such as with concrete, and then upper clips 141 (or plate 211 with integral upper tab 213) and lower clips 143 or 179 are installed on posts 135 in step 229. Alternatively, step 227 may be repeated to place and affix some or all of the remaining posts of the fence prior to performing step 229 for each panel of the fence. Step 229 may be accomplished using plate 139 or templates 177, 197 and requires that each upper clip 141 is affixed to post 135, whereas each lower clip 143 or 179 is installed so that it is movable between a lower position and a higher position. In step 231, a top rail 167 is placed on upper clips 141 or integral tabs 213, and a bottom rail 169 is placed on lower clips 143 or 179. Step 233 is inserting pickets, such as pickets 21, between (and within) rails 167, 169, so that rails 167, 169 loosely retain the pickets in position. Step 235 is lifting bottom rail 169 and the pickets toward top rail 167 and relative to posts 135, and step 237 is affixing lower clips 143 or 179 in a higher position relative to each post 135 to retain bottom rail in the raised position and complete assembly of the fence panel. Step 237 optionally includes installing fasteners in rails 167, 169 and the pickets. After completing step 237, the next adjacent fence panel may be assembled by returning to step 227, as shown by arrow 239, and placing and affixing the next post. The positions of the pickets may be shifted relative to each other and/or to rails 167, 169 before and/or after rail 169 is moved to the raised position.

Step 235 of lifting bottom rail 169 and the pickets may be accomplished through use of straps or similar devices to pull rail 169 upward toward top rail 167. The straps would be tightened until rail 169 is in the raised position and clips 143 or 179 are affixed in their higher position, and then the straps are loosened and removed. Another alternative order includes affixing clips 141, 143, 179 prior to emplacing posts 135.

It should be noted that, where appropriate, additional clips may be used in any of the described systems for accommodating additional rails, and the clips may be fixed or movable. It should also be noted that the systems and methods, though only described above with the bottom rail moving relative to the fence posts, could also be implemented with a fixed bottom rail and a top rail that is movable vertically in an enlarged slot of the fence posts. This configuration has the advantage of eliminating the need to lift the weight of the bottom rail and all of the pickets, but it has the disadvantage of having clips on an upper, more visible portion of the fence panel and, for some embodiments, also eliminates the advantage of the weight of the bottom rail and pickets tending to secure the clip in place.

It will be evident to those skilled in the art that several additional features may be used with the fence system. For example, panels may incorporate various decorative details, such as finials or scalloped edges, and panels may include electrical components. In addition, it should be noted that certain embodiments are retrofit onto existing fence posts by forming slots for top and bottom rails in the fence posts or by affixing additional parts that include slots. Also, a middle rail can used to add further customization to the fence system.

The present application provides several significant advantages, including: (1) providing for ease of assembly of a fence panel; and (2) providing for ease of customization of a fence panel.

The particular embodiments disclosed above are illustrative only, as the application may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. It is apparent that subject matter with significant advantages has been described and illustrated. Although the present application includes embodiments having a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.

Claims

1. A fence panel, comprising:

a first fence post and a second fence post spaced from the first post, each post having a face oriented toward the other post;

a fixed upper tab on the face of each post, corresponding upper tabs on adjacent posts forming a pair;

a lower clip on the face of each post, each lower clip having a tab, corresponding lower clips on adjacent posts forming a pair, each lower clip being movable relative to the associated post during assembly;

at least one fence picket;

a top rail assembled onto one pair of upper tabs and having a cross-sectional shape configured for receiving an upper end of each picket; and

a bottom rail assembled onto one pair of lower clips and having a cross-sectional shape configured for receiving a lower end of each picket;

wherein during assembly the bottom rail and the at least one picket are moved upward together relative to the posts and toward the top rail to an assembled position for retaining each picket between the rails.

2. The fence panel of claim 1, wherein the upper end of each picket is inserted into the top rail from below the top rail.

3. The fence panel of claim 1, wherein the lower end of each picket is inserted into the bottom rail from above the bottom rail.

4. The fence panel of claim 1, wherein during assembly the lower clips are moved from a lower position to a higher position and affixed in the higher position to retain the bottom rail and the at least one picket in the assembled position.

5. The fence panel of claim 1, wherein each upper tabs is located on an upper clip.

6. The fence panel of claim 1, wherein each lower clip has a mounting tab and a rail-support tab extending generally perpendicular from to the mounting tab.

7. The fence panel of claim 1, wherein the lower tab has an elongated slot.

8. The fence panel of claim 1, wherein the upper tab is integral to a plate that serves as a template for installation of the lower clip.

9. A fence panel, comprising:

a first fence post and a second fence post spaced from the first post, each post having a face oriented toward the other post;

a fixed upper tab on the face of each post, corresponding upper tabs on adjacent posts forming a pair;

a lower clip on the face of each post, corresponding lower clips on adjacent posts forming a pair, each lower clip being movable relative to the associated post during assembly;

at least one fence picket;

a top rail assembled onto one pair of upper tabs and having a cross-sectional shape configured for receiving an upper end of each picket; and

a bottom rail assembled onto one pair of lower clips and having a cross-sectional shape configured for receiving a lower end of each picket;

wherein during assembly the bottom rail and the at least one picket are moved upward together relative to the posts and toward the top rail to an assembled position for retaining each picket between the rails, and the lower clips are moved from a lower position to a higher position and affixed in the higher position to retain the bottom rail and at least one picket in the assembled position.

10. The fence panel of claim 9, wherein the upper end of each picket is inserted into the top rail from below the top rail.

11. The fence panel of claim 9, wherein the lower end of each picket is inserted into the lower rail from above the lower rail.

12. The fence panel of claim 9, wherein each upper tabs is located on an upper clip.

13. The fence panel of claim 9, wherein each lower clip has a mounting tab and a rail-support tab extending generally perpendicular from to the mounting tab.

14. The fence panel of claim 9, wherein the upper tab is integral to a plate that serves as a template for installation of the lower clip.

15. A method of constructing a fence panel, the steps comprising:

(a) affixing a first fence post in a final position;

(b) affixing a second fence post in a final position spaced from the first fence post;

(c) installing a fixed upper tab on each post, corresponding upper tabs on adjacent posts forming a pair;

(d) installing a movable lower clip on each post, corresponding lower clips on adjacent posts forming a pair, each lower clip being movable relative to the associated post during assembly between a lower position and a higher position;

(e) assembling a top rail onto one pair of upper tabs;

(f) assembling a bottom rail onto one pair of lower clips;

(g) inserting pickets between the rails; and

(h) moving the bottom rail and the pickets upward together toward the top rail, thereby capturing the pickets between the rails.

16. The method of claim 15, further comprising:

(i) moving the lower clips from the lower position to the higher position and affixing the clips in the higher position to retain the bottom rail and the pickets in the assembled position.

17. The method of claim 15, wherein step (d) comprises using a template to indicate an installation location for each lower clip.

18. The method of claim 15, wherein step (d) comprises using a template to indicate an installation location for each lower clip, the template having a template portion and a perpendicular alignment portion.

19. The method of claim 15, wherein step (c) comprises using a plate with an integral upper tab, the plate also indicating an installation location for each lower clip.

20. The method of claim 15, wherein step (h) comprises using straps to pull the bottom rail toward the top rail.