US20080179581A1 - Picket fence kit - Google Patents
Picket fence kit Download PDFInfo
- Publication number
- US20080179581A1 US20080179581A1 US11/999,904 US99990407A US2008179581A1 US 20080179581 A1 US20080179581 A1 US 20080179581A1 US 99990407 A US99990407 A US 99990407A US 2008179581 A1 US2008179581 A1 US 2008179581A1
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- United States
- Prior art keywords
- post
- picket
- picket fence
- rail
- gate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- RLLPVAHGXHCWKJ-IEBWSBKVSA-N (3-phenoxyphenyl)methyl (1s,3s)-3-(2,2-dichloroethenyl)-2,2-dimethylcyclopropane-1-carboxylate Chemical compound CC1(C)[C@H](C=C(Cl)Cl)[C@@H]1C(=O)OCC1=CC=CC(OC=2C=CC=CC=2)=C1 RLLPVAHGXHCWKJ-IEBWSBKVSA-N 0.000 title claims abstract description 217
- 238000010079 rubber tapping Methods 0.000 claims abstract description 10
- 230000001681 protective effect Effects 0.000 claims description 4
- 238000004806 packaging method and process Methods 0.000 description 6
- 238000012856 packing Methods 0.000 description 5
- 230000000149 penetrating effect Effects 0.000 description 5
- 230000035515 penetration Effects 0.000 description 5
- 239000003292 glue Substances 0.000 description 4
- 241000237509 Patinopecten sp. Species 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 235000020637 scallop Nutrition 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 239000003351 stiffener Substances 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000012857 repacking Methods 0.000 description 2
- 239000002390 adhesive tape Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000002372 labelling Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H17/00—Fencing, e.g. fences, enclosures, corrals
- E04H17/14—Fences constructed of rigid elements, e.g. with additional wire fillings or with posts
- E04H17/1413—Post-and-rail fences, e.g. without vertical cross-members
- E04H17/1417—Post-and-rail fences, e.g. without vertical cross-members with vertical cross-members
- E04H17/1426—Picket fences
- E04H17/1439—Picket fences with separate pickets going through the horizontal members
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B11/00—Means for allowing passage through fences, barriers or the like, e.g. stiles
- E06B11/02—Gates; Doors
Abstract
A picket fence kit for a picket fence section includes an enclosure, a hollow post, a hollow top rail, a hollow bottom rail, and a plurality of pickets. The enclosure surrounds the post. The post surrounds the two rails and the plurality of pickets, and each rail surrounds a plurality of pickets. Pickets are axially aligned with each other in pairs, two rails are located side-by-side within the post, and two pairs of axially aligned pickets are positioned side-by-side within a rail. The post further surrounds a pair of axially aligned pickets not surrounded by a rail. The kit further includes a post cap, a shipping cap, a plurality of picket caps, a set of rail brackets and a set of self-tapping screws. A picket fence kit for a for a picket fence gate includes an enclosure, a hollow post, a first gate upright, a second gate upright, a hollow top rail, a hollow bottom rail, and a plurality of pickets. The enclosure surrounds the post. The post surrounds the first gate upright, the second gate upright, the hollow top rail, the hollow bottom rail, and the plurality of pickets.
Description
- This application claims priority to co-owned, co-pending U.S. provisional application Ser. No. 60/898,033, filed Jan. 29, 2007.
- This invention relates generally to the design and packaging of fence products for improved packing density. More specifically the invention relates to the design and packaging in kit form of a picket fence section or gate that includes a hollow post.
- A typical installed fence includes a single fence gate and a plurality of fence sections. Picket fences are available in a wide variety of decorative styles, and are typically assembled on site to custom requirements because each job site imposes its own unique requirements. Accordingly, the number of fence part types and configurations available is very large, and the number of part mixes needed to build the whole range of specific fences is much larger still.
- Fence parts are typically shipped palletized in boxes of parts of the same type, or as a mix of a few types. Shipping packs in boxes of parts of the same type (e.g., posts, or rails, or pickets). This simplifies the manufacturers' packaging task. However, this generally results in a low packing density which increases shipping and storage costs. It also creates the need to repack parts at intermediate distribution points along the distribution chain. Opening boxes and repacking the parts exposes the parts to greater risk of damage or loss by theft, at a series of distribution points. Repacking and restocking parts at wholesale or retail sales outlets increases the number of product identification codes, requires new labeling, and adds costs associated with distribution clerical activities.
- Shipping a custom package based on the requirements of each job offers an opportunity to achieve high packing density, but only at the added expense of custom packaging by the manufacturer. Shipping custom packages to match end-user requirements complicates the manufacturers' packaging task, thereby causing long delivery times or unexpected delays or both. Shipping custom packages to match end-user requirements also requires a degree of integration in the distribution chain that is largely non-existent in today's distributor-dominated, world-wide marketplace, thereby adding cost.
- Further disadvantages are experienced by the installer or the end-user, at least one of whom is required to order parts from a potentially enormous catalog of parts.
- The consequence of these shortcomings is that the whole fence industry, from manufacturer to retailer, suffers at least some of the above cost and convenience drawbacks.
- The end-user would generally prefer to buy a fence in kit form. So boxed or bagged single-section fences in kit form are now being offered. (See advertisement for “Structure PVC Picket Fence”, now offered by W&E International, LLC). However, while kits such as this address the demand for stand-alone, single-section fences, they do not address the system problem presented by the far more typical situation where the need is for a multi-section fence.
- The invention provides a plurality of picket fence kits including picket fence section kits and picket fence gate kits. A given kit preferably includes all the parts needed to assemble a single picket fence section or a single picket fence gate. A typical installed fence includes a single fence gate and a plurality of fence sections. To support assembly of picket fences in a variety of styles, each picket fence gate kit is associated with a picket fence section kit of matching style.
- Although most of the picket fences built from the kits are conventional picket fences, well known in the art, novel aspects of the kits provide significant commercial benefits.
- A first group of novel aspects of the invention provides benefits in shipping, product tracking and stocking, to produce cost savings in a distribution chain. This first group of novel aspects involves multi-level nesting of fence section or fence gate parts. This multi-level nesting of pre-defined, size-related fence kit parts within a protective enclosure provides high packing density that reduces shipping costs. It also reduces the risk of damage or loss in shipping, and provides convenience in end-user transportation.
- A second group of novel aspects of the invention provides kits for a wide variety of embodiments and configurations of picket fences based on a relatively small number of parts, each kit pre-packaged for point-of-sale retail display. The provision of a wide variety of embodiments and configurations involves the use of non-routed fence kit parts, rail brackets, and self-tapping screws for on-site customization, and a shipping enclosure designed for use in point-of-sale retail display.
- A first preferred embodiment of a kit for a picket fence section, illustrated in
FIGS. 1 , 3-6, and 10, includes an enclosure, a hollow post, a hollow top rail, a hollow bottom rail, and a plurality of pickets, wherein the enclosure surrounds the post, the post surrounds the two rails and a plurality of pickets, and at least one rail surrounds a plurality of pickets. In this first embodiment two pickets are axially aligned with each other, two rails are located side-by-side within the post, and two pairs of axially aligned pickets are positioned side-by-side within a rail. The post also surrounds at least one picket not surrounded by a rail. The enclosure includes a protective sheet having two closed ends and a transparent region through which a label may be viewed. The kit further includes a post cap attached to one end of the post, a shipping cap attached at the other end of the post, a plurality of picket caps, each picket cap attached to a top end of a picket, and a set of miscellaneous components, including a set of rail brackets and a set of self-tapping screws, located within the enclosure. - A first preferred embodiment of a kit for a picket fence gate, illustrated in
FIGS. 37-46 , includes an enclosure, a hollow post, a first gate upright, a second gate upright, a hollow top rail, a hollow bottom rail, and a plurality of pickets, wherein the enclosure surrounds the post, wherein the post surrounds the first gate upright and the second gate upright, each gate upright surrounds a rail and a plurality of pickets, each rail surrounds at least one picket, two pickets are axially aligned, and the brace is axially aligned with a picket. -
FIG. 1 is a line drawing showing a first embodiment of a fence section kit in side view and in end view, and showing a single fence section constructed from the kit. -
FIG. 2 (prior art) is a line drawing showing a portion of an installed multi-section fence, the fence including a fence section constructed from the kit ofFIG. 1 . -
FIG. 3 is a line drawing locating cross section A-A of the kit ofFIG. 1 . -
FIG. 4 is a cross section view along the long axis of the post of the kit ofFIG. 1 , illustrating multi-level nesting layout of rails and pickets within the post. -
FIG. 5 is a cross section view transverse to the long axis of the post, at cross section B-B, of the kit ofFIG. 4 . -
FIG. 6 is a cross section view transverse to the long axis of the post, at cross section C-C, of the kit ofFIG. 4 . -
FIG. 7 (prior art) is a side view of the post cap ofFIG. 1 . -
FIG. 8 (prior art) is a top view of the post cap ofFIG. 1 . -
FIG. 9 (prior art) is a bottom view of the post cap ofFIG. 1 . -
FIG. 10 shows greater detail ofFIG. 5 in the region of the post cap. -
FIG. 11 (prior art) is a front view of a portion of the fence section ofFIG. 1 , showing attachment of top and bottom rails to the post using rail brackets, and showing penetration of pickets into the bottom rail and through the top rail. -
FIG. 12 (prior art) is a front view of a portion of a fence section having a routed post, showing attachment of top and bottom rails to the post by penetration of top and bottom rails into the post. -
FIG. 13 (prior art) is a perspective view showing penetration of a picket through the center of the top surface of the top rail. -
FIG. 14 is a diagram that identifies directions used for identifying post and picket dimensions in the several fence section embodiments and fence gate embodiments. -
FIG. 15 is a diagram that identifies directions used for identifying rail dimensions in the several fence section embodiments and in fence gate embodiments. -
FIG. 16 (prior art) illustrates attachment of a rail to a post by a prior art rail bracket, the rail bracket supporting a rail. -
FIG. 17 (prior art) is a front view, in partial cross section, of the bracket ofFIG. 16 . -
FIG. 18 (prior art) is a side view of the base of the bracket ofFIG. 16 . -
FIG. 19 (prior art) is a front view of the base of the bracket ofFIG. 16 . -
FIG. 20 identifies post, rail and picket dimensions in a view corresponding to the view displayed inFIG. 4 . -
FIG. 21 identifies rail and picket dimensions in a view corresponding to the view displayed inFIG. 5 . -
FIG. 22 identifies post dimensions in a view corresponding to the view displayed inFIG. 6 . -
FIG. 23 shows a layout of rails and pickets within the post that is an alternative to the layout ofFIG. 4 . -
FIG. 24 is a perspective line drawing showing one end of the kit ofFIG. 1 with the enclosure and the post cap removed. -
FIG. 25 is a partial cross section view transverse to the long axis of the body of an 8-picket fence section kit, illustrating the layout of rails and pickets. -
FIG. 26 is a partial cross section view transverse to the long axis of the body of a 12-picket fence section kit, illustrating the layout of rails and pickets. -
FIG. 27 (prior art) is a line drawing showing a portion of an installed multi-section scalloped fence. -
FIG. 28 is a cross section view of a fence section kit for assembling the scalloped fence ofFIG. 27 , the kit including axially aligned pairs of short and long pickets. -
FIG. 29 (prior art) is a partially cut-away line drawing of one section of a multi-section pool code fence assembled from a kit having 10 pickets per section. -
FIG. 30 is a cross section view transverse to the long axis of a pool code fence section kit associated with the pool code fence ofFIG. 29 , illustrating the general layout of rails and pickets within the post. -
FIG. 31 (prior art) is a partially cut-away line drawing of a portion of a Deluxe pool code fence assembled from a kit having 25 pickets per section, that uses a bracket for attaching a rail to a post. -
FIG. 32 (prior art) is a partially cut-away line drawing of a portion of a Deluxe pool code fence assembled from a kit having 25 pickets per section, that uses a routed post for attaching a rail to a post. -
FIG. 33 is a cross section view transverse to the long axis of a Deluxe pool code fence section kit associated with each of the Deluxe pool code fences ofFIGS. 31 and 32 , illustrating the general layout of rails and pickets within the post. -
FIG. 34 (prior art) is a line drawing in perspective view of a top rail bracket included in a Deluxe pool code fence kit that uses brackets for attaching a rail to a post. -
FIG. 35 (prior art) is a line drawing in perspective view of a bottom rail bracket included in a Deluxe pool code fence kit that uses a bracket for attaching a rail to a post. -
FIG. 36 (prior art) is a line drawing in perspective view of a portion of the Deluxe pool code fence ofFIG. 31 with the post cap removed, illustrating the shape of the top rail, and showing the rail penetrating the routed post. -
FIG. 37 is a line drawing showing a first embodiment of a picket fence gate kit in side view and in end view, and showing a single gate constructed from the kit. The picket fence gate ofFIG. 37 includes a post, two uprights and five pickets, the two uprights and the five pickets each having a height of less than half the height of the post. (The first embodiment of a picket fence gate kit is a seventh embodiment of the picket fence kit.) -
FIG. 38 is a perspective line drawing of the main structural components of the picket fence gate kit ofFIG. 37 . -
FIG. 39 locates cross sections A-A and B-B of the picket fence gate kit ofFIG. 37 . -
FIG. 40 is a partial cross section view of the picket fence gate kit ofFIG. 37 at A-A ofFIG. 39 . -
FIG. 41 is a partial cross section view of the picket fence gate kit ofFIG. 37 at B-B ofFIG. 39 . -
FIG. 42 is a cross section view of a first end of the picket fence gate kit ofFIG. 37 . -
FIG. 43 is a cross section view of a second end of the picket fence gate kit ofFIG. 37 . -
FIG. 44 illustrates attachment of a picket fence gate rail to a picket fence gate upright using one of the four picket fence gate rail pockets identified inFIG. 37 . -
FIG. 45 is a partially cut-away front view of a picket fence gate rail pocket attached to a post in the assembled picket fence gate ofFIG. 37 . -
FIG. 46 is a side view of a picket fence gate rail pocket attached to a post in the assembled picket fence gate ofFIG. 37 . - A first preferred embodiment of a picket fence section kit is shown at the top of
FIG. 1 , in side view and in end view, as picketfence section kit 10. A picket fence section built fromkit 10, and having ten pickets, is illustrated at the bottom ofFIG. 1 aspicket fence section 20. Picketfence section kit 10 is one component of a fence parts distribution system. -
Enclosure 19, identified in the side and end views ofkit 10, contains and protects all the parts of the kit. The side and end views ofkit 10 show two heat-sealed end-tabs, end-tabs 26, of a preferred embodiment ofenclosure 19.Enclosure 19 also contains, protects and displayslabel 29.Label 29 displays product identity data and other data useful for shelf display of the kit in a retailer's store. -
FIG. 2 shows assembledfence section 20 as one section of an installed multi-section fence, each fence section having ten pickets. Fence section post 11 has a height of approximately eight feet. The bottom end ofpost 11 is shown encased inconcrete footing 31, which is buried inearth 32. -
Kit 10 is a packaged kit of parts for assembling apicket fence section 20. The structural parts contained inkit 10, from whichpicket fence section 20 is to be assembled, are designed and sized to achieve several benefits in shipping, distribution, sale and use. These benefits include high package density, low shipping costs, low number of different prefabricated part types to satisfy a wide range of fence configuration needs, low risk of parts loss or damage in distribution, and convenience in storage, point-of-sale display, and end-user transportation. -
Kit 10 comprises a set of parts in an enclosure that contains the parts, protects the parts from loss, to a limited extent protects the parts from damage, and facilitates display of identification and other data needed in the distribution process. - The kit, as packaged, is designed to provide multiple distribution benefits, including reduction of distribution, stocking and sales-related costs, and better protection of the product in transit. Distribution benefits are achieved in part by nested placement of the prefabricated fence parts within the enclosure (i.e., the shipping container), and in part by definition of dimensional relationships among the prefabricated fence parts of the kit.
- The kit is also designed to provide various convenience benefits for point-of-sale display. Point-of-sale display benefits are derived from the compact packaging of a kit in a shipping container suitable for retail point-of-sale display.
- The kit is also designed to provide a degree of size and shape customization during on-site assembly. Customization is provided by the use of a bracket for mounting a rail to a post that does not require routing the post or providing pre-drilled holes in the post.
- In a first preferred embodiment the kit includes an enclosure, a single hollow post, top and bottom hollow rails, a plurality of pickets, and hardware. The rails, the pickets, the brackets and miscellaneous hardware are all packed within the single hollow post.
- For
picket fence section 20 shown inFIG. 1 ,kit 10 includesenclosure 19, onehollow post 11, one hollowtop rail 12, onehollow bottom rail 14, a plurality ofpickets 13,rail brackets - In a preferred embodiment,
enclosure 19 is formed as a tough, transparent tubular sheet of plastic material sized to fit over the post. In one preferred embodiment, making the kit includes placing the rails, the pickets, the rail brackets and miscellaneous hardware inside the post, then pulling a tubular sheet over the post to cover both ends, and then sealing both ends of the sheet. Sealing the sheet includes flattening and folding the sheet, then heat-sealing the sheet to form end-tabs that close both ends of the enclosure.Enclosure 19 is not limited to this material or this method of construction. Alternatively,enclosure 19 include packing the kit in a cardboard box, or wrapping the kit in two shrink-wrap plastic sheets of electro-static wrap, one at each end of the post, or fixedly attaching a post cap at the top end of the post and a shipping cap at the bottom end of the post to form a rigid enclosure, or by providing a post cap fixedly attached to the top end of the post, and providing a removable shipping cap attached by adhesive tape to the bottom end of the post. - In a preferred embodiment, the kit also includes a label located between
enclosure 19 and thepost 11. In this embodiment,enclosure 19 includes a transparent region through which the label may be read. - In a preferred embodiment, post 11 includes a
first post cap 15 attached at a first end of the post, preferably an internal cap fixedly attached to the post with glue, and ashipping cap 16 attached at the second end of the post.Shipping cap 16 may be a removable post cap to facilitate unpacking the rails and the pickets, or it may be attached with glue to better contain and protect the rails and the pickets during shipping. In the latter case, the end-user would cut the post just short of the shipping cap to allow the rails and the pickets to be unpacked. In a preferred embodiment, each picket includes apicket cap 17 attached to a top end of the picket. -
FIG. 4 shows a multi-level nesting layout ofrails post 11 of a first preferred embodiment of 10-picketfence section kit 10.FIG. 4 also shows a bag ofmiscellaneous components 28, andproduct identifier label 29. The bag of miscellaneous components contains fourrail brackets FIG. 4 is a view along the long axis of the post, at cross section A-A ofFIG. 3 . -
FIG. 5 shows a multi-level nesting layout ofrails post 11 of a first preferred embodiment of 10-picketfence section kit 10.FIG. 5 is a view transverse to the long axis of the post, at cross section B-B ofFIG. 4 .FIG. 5 further shows pairs ofpickets 13 aligned lengthwise end-to-end, two pairs enclosed withinrail 12, and two pairs enclosed withinrail 14. -
FIG. 6 shows a multi-level nesting layout ofrails post 11 of a first preferred embodiment of 10-picketfence section kit 10.FIG. 6 is a view transverse to the long axis of the post, at cross section C-C ofFIG. 4 .FIG. 6 further shows one pair ofpickets 13 enclosed within the post but not enclosed within a rail. -
FIGS. 7-9 show detail ofpost cap 15.FIG. 7 is a side view.FIG. 8 is a top view.FIG. 9 is a bottom view. -
FIG. 10 shows greater detail ofFIG. 5 in the region ofpost cap 15.FIG. 10 shows detail ofenclosure 19 fitted around an end ofpost 11 and shows detail of one folded and sealed end-tab 26. -
FIG. 11 is a front view of a portion of the fence section ofFIG. 1 . The end oftop rail 12 and the end ofbottom rail 14 are shown attached to post 11 by priorart rail brackets Bottom end 23 ofpicket 13 is shown penetrating into, but not completely through,bottom rail 14.Picket 13 is shown passing completely through the upper and lower surfaces oftop rail 12. -
FIG. 12 is a front view of a portion of a prior art fence section having a routedpost 27, showing attachment of top and bottom rails to the post by penetration of top and bottom rails into the post. The top and bottom rails are supported byends post 11. -
FIG. 13 is a perspective view showing penetration of a picket through the upper surface of the top rail.FIGS. 14 and 15 are first and second diagrams that specify letter codes used for coding post, rail, and picket dimensions in the several fence section embodiments and fence gate embodiments.FIGS. 14 and 15 also specify letter codes used for coding directions, as understood from the perspective drawing ofFIG. 13 , of the elongated structural parts. - In a preferred embodiment, each rail is preferably attached to its post by a rail bracket, as indicated in
FIGS. 1 , 2 and 11. Each of the four rail brackets, 21, 22, 33 and 34 ofFIGS. 1 and 2 , is adapted to attach to a post using a rail bracket.FIG. 16 showsrail bracket 21 attached to post 11 by bracket attachment screws 53 and 54, andtop rail 12 attached to railbracket 21 byrail locking screw 55 passing throughholes FIG. 17 is a front view offirst rail bracket 21, showingtop rail 12 supported byfirst rail bracket 21.FIG. 18 is a cross section view ofbracket 21, showingholes FIG. 19 is a front view offirst rail bracket 21 showing inwardly taperedperipheral edge 59. Suitable rail brackets are disclosed in U.S. Pat. No. 5,788,224, issued Aug. 4, 1998. U.S. Pat. No. 5,788,224 is hereby incorporated herein by reference. - Multi-level nesting of the elongated structural components in the fence section kit of
FIG. 1 imposes dimensional limitations on the depth, width, height, and length of these components. For the discussion below of these limitations,FIGS. 20-22 identify dimensions associated with the several limitations. - Dimensions associated with depth and width limitations are identified in
FIG. 20 .FIG. 20 identifies selected dimensions of the post, the two rails and the pickets in a view corresponding to the view displayed inFIG. 4 . InFIGS. 20-22 (and also inFIG. 23 ) “H” denotes height, “D” denotes depth, “W” denotes width, “L” denotes length, “E” denotes external dimension for post, rail and picket, and “I” denotes internal dimensions ofpost 11, rails 12 and 14, and pickets 13. - Limitations revealed in
FIG. 20 , limitations associated with depth and width, are as follows. - 1) The external depth 12-ED of
rail 12 plus the external depth 14-ED ofrail 14 must be less than the internal width 11-IW ofpost 11. - 2) The external height 12-EH of
rail 12 plus the external depth 13-ED of one picket must be less than the internal depth 11-ID ofpost 11. - 3) The external depth 13-ED of one picket must be less than half the internal depth 12-ID of one rail.
- Dimensions associated with height and length limitations are identified in
FIGS. 21 and 22 .FIG. 21 identifies picket external height 13-EH and rail length 12-EL in a view corresponding to the view displayed inFIG. 5 .FIG. 22 identifies post internal height dimension 11-IH, in a view corresponding to the view displayed inFIG. 6 . In a preferred embodiment of a fence section kit wherein each picket has an attached internal picket cap, the external height 13-EH ofpicket 13 is equal to the height ofpicket 13 plus the added height of the external portion ofpicket cap 17. - In a preferred embodiment of a fence section kit wherein the post has two attached internal post caps, and wherein the kit has post and rail dimensions as specified in Table 1 below, the two rails will not be a tight fit within the post. So the walls of the cap will not reduce the effective internal height of
post 11. Accordingly, 11-IH, the effective internal height of the post (with itspost cap 15 attached and with itsshipping cap 16 attached) is equal to the height ofpost 11. - Limitations revealed in
FIGS. 21 and 22 , limitations associated with height and length, are as follows. - 1) The external length 12-TRL of
rail 12 must be less than the internal height 11-IH ofpost 11. - 2) The external height 13-EH of a pair of axially aligned pickets must be less than the
internal height 11 Joanne-IH ofpost 11. -
FIG. 23 shows kit 30 having a layout of rails and pickets within the post that is an alternative to the layout ofFIGS. 4 and 20 . The width/depth orientation of the post inFIG. 23 is at 90° to its orientation inFIGS. 4 and 20 . -
FIG. 24 is a perspective line drawing showing one end of the kit ofFIG. 1 with the enclosure and the post cap removed. - Table 1 gives selected dimensions of the main components of the first preferred embodiment of the picket fence section described above, and as shown in
FIGS. 1-20 . -
TABLE 1 Item Item Dimension Height Width Depth Wall Name No. Qty. ID Inches Inches Inches Inches Post 11 1 11-EH 84 5 5 0.150 with 2 caps Top rail 12 1 12-TRL 3.5 35.75 2 0.110 Picket 13 10 13-EH 34 3 7/8 0.070 w/ spade cap Bottom 14 1 14-BRL 3.5 35.75 2 0.110 rail - A second embodiment of a picket fence section kit is illustrated in
FIG. 25 as picketfence section kit 37 having eight pickets.FIG. 25 is a partial cross section view transverse to the long axis of the body ofkit 37 The eight pickets are aligned lengthwise end-to-end in four pairs. - A third embodiment of a picket fence section kit is illustrated in
FIG. 26 as picketfence section kit 38 having twelve pickets aligned lengthwise end-to-end in six pairs.FIG. 26 is a partial cross section view transverse to the long axis of the body of a twelve picket fence section kit, illustrating the layout of the rails and pickets within the post.FIG. 26 shows post 11,top rail 12,bottom rail 14, and six of the twelve pickets 13. -
FIG. 27 shows a portion of a prior art multi-sectionscallop picket fence 40.Fence 40 includes a row of ten scallop pickets including short pickets and long pickets. -
FIG. 28 shows, in cross section view, scallop picketfence section kit 50 for constructingfence 40.Kit 50 includespost 41,top rail 42,bottom rail 43, ten pickets includingshort picket 51 andlong picket 52,post cap 45 andpicket cap 47.Kit 40 includes axially aligned pairs of pickets, each pair having one short picket axially aligned with one long picket. Inkit 40 such axially aligned pairs of pickets are located within the top and bottom rails.Kit 50 further includes fourrail brackets 48. - In a variant of the fourth embodiment, the four
brackets 48 are omitted and post 41 is a routed post. -
FIG. 29 shows a pool codepicket fence section 60 having ten pickets. Pool codepicket fence section 60 is built from a fifth embodiment of the pool code fence section kit.FIG. 30 is a cross section view of the kit, transverse to its long axis.FIG. 30 shows the major structural parts of the kit, including onehollow post 61, one hollowtop rail 62, onehollow bottom rail 64, a plurality ofpickets 63, and an aluminum J-channel stiffener 68.Kit 60 further includes twotop rail brackets 66 and twobottom rail brackets 67. In a variant of the fifth embodiment, the four brackets are omitted and post 61 is a routed post. -
FIG. 31 shows a Deluxe pool codepicket fence section 70 having twenty-five pickets.Fence section 70 is built from a sixth embodiment of the picket fence section kit.FIG. 33 is a cross section view of the Deluxe pool code picket fence section kit of the sixth embodiment, transverse to its long axis.FIG. 33 shows the major structural parts of the kit, including onehollow post 71, one hollowtop rail 72, onehollow bottom rail 74, a plurality ofpickets 73, a firstinternal stiffener 81, a secondinternal stiffener 82, and a structural beam 83 (preferably an aluminum H-channel). The Deluxe pool code picket fence section kit further includes twotop rail brackets 77 and twobottom rail brackets 78.Top rail bracket 77 andbottom rail bracket 78 are illustrated inFIGS. 34 and 35 respectively. -
FIG. 36 illustrates a variant of the kit of the sixth embodiment, for constructing a Deluxe pool code picket fence section wherein the four brackets are omitted and post 71 is a routed post.FIG. 36 provides a perspective view of the top of thefence section 90 with its post cap removed to reveal the top of routedpost 91,top rail 92 penetrating the post, and the shape of the top rail. The cross section view ofFIG. 33 remains applicable to this variant of the sixth embodiment. - A first preferred embodiment of a picket fence gate kit is shown at the top of
FIG. 37 , in side view and in end view, as picketfence gate kit 110. Apicket fence gate 120 built fromkit 110 is shown at the bottom ofFIG. 37 as having five pickets and a brace. Picketfence gate kit 110 is a second component of a fence parts distribution system. A complete fence may be assembled using a plurality of fence section kits according to any of the above-described six embodiments and one or more fence gates using variations of the seventh embodiment. - Returning now to
FIG. 37 ,enclosure 119, identified in the side and end views ofkit 110, contains and protects all the parts of the kit. The side and end views ofkit 110 show two heat-sealed end-tabs, end-tabs 128, of a preferred embodiment ofenclosure 119.Enclosure 119 also displayslabel 129.Label 129 presents product identity data and other data useful for shelf display of the kit in a retailer's store. -
FIG. 37 showsgate 120 having top andbottom rails uprights FIG. 37 also shows pickets 121-125 penetrating intotop rail 114 andbottom rail 115. - The main structural parts of
kit 110 are illustrated in perspective view inFIG. 38 . The main structural parts arepost 111, gate uprights 112 and 113, top andbottom rails brace 126. Also shown inFIG. 38 are four rail pockets 131-134,post cap 135, andshipping cap 136. -
Kit 110 also includes twoupright caps hinges safety gate latch 144 having agate stop 145 and alatch body 146, one striker, and miscellaneous hardware. The locations, in the assembled picket fence gate, of the upright caps, the hinges, and the latch are indicated inFIG. 37 . - Miscellaneous hardware includes white-cap self-tapping
screws 149 for attaching the rail pockets to the uprights and a tube ofPVC fence glue 148. - The upright caps are similar in shape to the post caps illustrated in
FIGS. 7-9 , but are sized to fituprights -
Rail pockets kit 140 includes a set of four rail pockets and a set of self-tapping screws. -
Hinges -
Latch 144 is a conventional safety gate latch. A suitable latch is D & D Technologies Magna Latch, a safety gate latch. This latch is available from D & D Technologies at www.ddtechglobal.com. -
FIG. 38 is a perspective line drawing of the main structural components of the picket fence gate kit ofFIG. 37 . As noted above, the main structural parts arepost 111, gate uprights 112 and 113, top andbottom rails brace 126. Also shown inFIG. 38 are four rail pockets 131-134,post cap 135, andshipping cap 136.Shipping cap 136 is not shown inFIG. 37 because an installed fence post does not usually include a bottom cap. -
FIG. 39 locates cross sections A-A and B-B of the picketfence gate kit 110 ofFIG. 37 . -
FIG. 40 is a partial cross section view of the picket fence gate kit ofFIG. 37 at A-A ofFIG. 39 .FIG. 40 shows a multi-level nesting layout ofupright 112,rail 114 and pickets 121-123 withinpost 111 of the picket fence gate kit ofFIG. 37 .FIG. 40 also shows upright 112, onepicket 121 withinpost 111 but not within a rail, and twopickets post 111 and withinrail 114. -
FIG. 41 is a partial cross section view of the picket fence gate kit ofFIG. 37 at B-B ofFIG. 39 .FIG. 41 shows a multi-level nesting layout ofupright 113,rail 115, pickets 124-125, and brace 126, withinpost 111 of the picket fence gate kit ofFIG. 37 .FIG. 41 also shows upright 113, onepicket 124 withinpost 111 but not within a rail, and onepicket 125 and onebrace 126 withinpost 111 and withinrail 115. -
FIG. 42 is a cross section view showing a first end of the picket fence gate kit ofFIG. 37 , the end corresponding toFIG. 40 .FIG. 42 , likeFIG. 40 , shows a multi-level nesting layout ofgate upright 112,rail 114 and pickets 121-123 withinpost 111.Enclosure 119 is shown surroundingpost 111, and closing the first end of the kit at first heat-sealed end-tab 127.Post cap 135 is shown fitted to the top end ofpost 111.Gate upright 112 is axially aligned withgate upright 113. Upright 113 is shown inFIG. 43 . Returning toFIG. 42 , the end ofpicket 122 is shown protruding beyond the end of each ofpickets Picket 122 is protruding becausepicket 122 is axially aligned withbrace 126, and becausebrace 126 in the embodiment shown inFIG. 37 , is necessarily longer than a picket. -
FIG. 43 is a cross section view showing a second end of the picket fence gate kit ofFIG. 37 , the end corresponding toFIG. 41 .FIG. 43 , likeFIG. 41 , shows a multi-level nesting layout ofgate upright 113,rail 115, pickets 124-125 andbrace 126, withinpost 111. The end ofbrace 126 is protruding beyond the end of each ofpickets brace 126 is axially aligned with picket 122 (shown inFIG. 42 ), and brace 126 is a little longer than a picket.Enclosure 119 is shown surroundingpost 111, and closing the second end of the kit at second heat-sealed end-tab 128.Shipping cap 136 is shown fitted to the bottom end ofpost 111.FIG. 43 also showsrail pockets kit 140, hinges andlatch kit 143 and tube ofglue 148 enclosed byenclosure 119.Rail pockets kit 140 includes a pair of such hinges and a set of self-tapping screws. Hinges andlatch kit 143 includes twohinges safety gate latch 144, a striker (not shown), and a set of self-tapping screws. -
FIG. 44 illustrates attachment ofgate rail 114 toupright 112 ofFIG. 37 by means ofgate rail pocket 131 and five self-tappingscrews 149.FIG. 45 is a partially cut-away front view ofgate rail pocket 131 attached toupright 112.FIG. 46 is a side view of the gate rail pocket ofFIG. 45 . - Table 2 lists selected dimensions of the main components of the first preferred embodiment of the picket fence gate, as described above and as shown in
FIGS. 37-46 . -
TABLE 2 Di- Wall men- Height/ Thick- Item Item sion Length Width Depth ness Name No. Qty. ID Inches Inches Inches Inches Post w/ cap 111 1 84 5 5 0.150 Gate Upright 112 1 37.75 4 4 0.135 Hinge end Gate Upright 113 1 37.75 4 4 0.135 Latch end Top rail 114 1 3.5 35.75 2 0.110 Bottom rail 115 3.5 35.75 2 0.110 Pickets 121- 5 0.070 w/ spade cap 125 Brace 126 1 126- 39 3 7/8 0.070 BL
Claims (25)
1. A picket fence kit comprising an enclosure, a hollow post, a hollow top rail, a hollow bottom rail, and a plurality of pickets;
wherein the enclosure surrounds the post; and
wherein the post surrounds the two rails and a plurality of pickets.
2. A picket fence kit according to claim 1 for a picket fence section, wherein at least one rail surrounds a plurality of pickets.
3. A picket fence kit according to claim 1 for a picket fence section, wherein two pickets are axially aligned with each other.
4. A picket fence kit according to claim 1 for a picket fence section, wherein the two rails are located side-by-side within the post.
5. A picket fence kit according to claim 1 for a picket fence section, wherein at least one rail surrounds two pairs of axially aligned pickets, and wherein the two pairs of axially aligned pickets are positioned side-by-side within the at least one rail.
6. A picket fence kit according to claim 1 for a picket fence section, wherein the post surrounds at least one picket not surrounded by a rail.
7. A picket fence kit according to claim 1 for a picket fence section, wherein the enclosure includes a protective sheet having at least one closed end.
8. A picket fence kit according to claim 7 for a picket fence section, further comprising a label, wherein the protective sheet includes a transparent region through which the label may be viewed.
9. A picket fence kit according to claim 1 for a picket fence section, further comprising a post cap attached to an end of the post.
10. A picket fence kit according to claim 9 for a picket fence section, further comprising a shipping cap, wherein the post cap and the shipping cap are fixedly attached to the post.
11. A picket fence kit according to claim 1 for a picket fence section, further comprising a plurality of picket caps, each picket cap attached to the top end of a picket.
12. A picket fence kit according to claim 1 for a picket fence section, further comprising a set of miscellaneous components located within the enclosure.
13. A picket fence kit according to claim 12 , wherein the miscellaneous components include a set of rail brackets and a set of self-tapping screws.
14. A picket fence kit according to claim 1 for a picket fence section, wherein the post is a routed post.
15. A picket fence kit according to claim 1 for a picket fence section, wherein the top rail contains at least three pickets, and the bottom rail contains at least four pickets.
16. A picket fence kit according to claim 1 for a picket fence gate, further comprising a first gate upright and a second gate upright, wherein the post surrounds the first gate upright and the second gate upright.
17. A picket fence kit according to claim 16 for a picket fence gate, wherein the second gate upright is axially aligned with the first gate upright.
18. A picket fence kit according to claim 16 for a picket fence gate, wherein the first gate upright surrounds a first rail, and the second gate upright surrounds a second rail.
19. A picket fence kit according to claim 16 for a picket fence gate, wherein each rail surrounds at least one picket.
20. A picket fence kit according to claim 16 for a picket fence gate, wherein at least one gate upright surrounds at least one picket not surrounded by a rail.
21. A picket fence kit according to claim 16 for a picket fence gate, further comprising a brace, wherein the brace is surrounded by the post and is axially aligned with a picket.
22. A picket fence kit according to claim 16 for a picket fence gate, wherein the plurality of pickets is five pickets.
23. A picket fence kit according to claim 16 for a picket fence gate, further comprising two gate hinges and a latch, wherein the post surrounds the two gate hinges and the latch.
24. A picket fence kit according to claim 16 for a picket fence gate, further comprising a set of rail pockets and a set of self-tapping screws, both sets located within the enclosure.
25. A picket fence kit according to claim 16 for a picket fence gate, wherein the post is a routed post.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/999,904 US20080179581A1 (en) | 2007-01-29 | 2007-12-08 | Picket fence kit |
PCT/US2008/000668 WO2008094414A1 (en) | 2007-01-29 | 2008-01-18 | Picket fence kit |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US89803307P | 2007-01-29 | 2007-01-29 | |
US11/999,904 US20080179581A1 (en) | 2007-01-29 | 2007-12-08 | Picket fence kit |
Publications (1)
Publication Number | Publication Date |
---|---|
US20080179581A1 true US20080179581A1 (en) | 2008-07-31 |
Family
ID=39666926
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/999,904 Abandoned US20080179581A1 (en) | 2007-01-29 | 2007-12-08 | Picket fence kit |
Country Status (2)
Country | Link |
---|---|
US (1) | US20080179581A1 (en) |
WO (1) | WO2008094414A1 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090140227A1 (en) * | 2007-12-04 | 2009-06-04 | Robert Cantatore | Ornamental fencing system and method for assembling the same |
US20130126811A1 (en) * | 2011-11-18 | 2013-05-23 | Flange, Inc. | Wood railing connectors |
US8713853B2 (en) | 2011-01-11 | 2014-05-06 | Azek Building Products, Inc. | Adjustable gate |
US9470041B2 (en) | 2012-02-29 | 2016-10-18 | Gary W. Ash | Rail and post assembly and method of use |
US9784031B2 (en) | 2014-10-16 | 2017-10-10 | Dee Volin | Adjustable gate, having multiple guttering systems, multiple impact-absorbing systems, multiple anti-warping systems, multiple anti-sagging systems, multiple personal-injury-eliminating systems, and self-centering angle-locking safety truss |
US20180135330A1 (en) * | 2016-11-16 | 2018-05-17 | Innovative Fencing Products | Methods and Systems for Providing an Accessible Fence Gate with Efficient Separability of Fencing Railing from Support Posts |
US10253524B2 (en) * | 2016-06-10 | 2019-04-09 | Barrette Outdoor Living, Inc. | Combination bracket and rail for mounting a deck board |
US11002002B2 (en) * | 2013-09-30 | 2021-05-11 | Drew P. HENRY | Hollow connector sleeve with interlocking components |
US20220389759A1 (en) * | 2016-09-13 | 2022-12-08 | Barrette Outdoor Living, Inc. | Fence gate assembly, fence gate kit, system and methods of manufacturing thereof |
US11596227B2 (en) * | 2019-08-23 | 2023-03-07 | Jungheinrich Aktiengesellschaft | Stacking storage arrangement |
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US20090140227A1 (en) * | 2007-12-04 | 2009-06-04 | Robert Cantatore | Ornamental fencing system and method for assembling the same |
US8713853B2 (en) | 2011-01-11 | 2014-05-06 | Azek Building Products, Inc. | Adjustable gate |
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US10253524B2 (en) * | 2016-06-10 | 2019-04-09 | Barrette Outdoor Living, Inc. | Combination bracket and rail for mounting a deck board |
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US11596227B2 (en) * | 2019-08-23 | 2023-03-07 | Jungheinrich Aktiengesellschaft | Stacking storage arrangement |
Also Published As
Publication number | Publication date |
---|---|
WO2008094414A1 (en) | 2008-08-07 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: NORTHEASTERN FENCE & SUPPLY CORPORATION, MASSACHUS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MULGREW, PAUL;REEL/FRAME:020363/0304 Effective date: 20071206 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |