Two-part rail with internal picket connection

A two-part rail is formed from a channel element which includes internal runners and stops which form a tray holder. A separate tray element may slide into the channel element, where it is supported on and confined by the tray holder. The tray element and channel element define boundaries of a retainer channel. Pickets traversed by alignable retainer passages are inserted through registering picket openings in the channel and tray elements of a rail. The pickets are secured to the rail by inserting a rod-like retaining element into the retainer channel of the rail and through the aligned retainer passages of the pickets.

FIELD OF THE INVENTION

The present invention relates generally to rails, and more particularly to rails used in fences and other barriers.

SUMMARY OF THE INVENTION

The rail of the present invention comprises a channel element which features a platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, and a second side wall which depends from the second lateral edge of the platform. The platform and the first and second side walls define boundaries of a rail channel. The channel element further comprises a tray holder adapted to slidably support a tray element within the rail channel, while restricting its movement toward or away from the platform. The rail may further comprise a tray element supportable on the tray holder in an installed position within the channel element, with the tray element and the channel element defining boundaries of a retainer channel.

The present invention further comprises a fence comprising a plurality of the above-described rails and a plurality of vertically disposed posts. Each adjacent pair of posts supporting the opposite ends of a plurality of rails. The fence further comprises a plurality of pickets, with each picket being laterally traversed by at least one retainer passage. The fence further comprises an elongate retainer element which is positioned within the retainer channel such that it passes through the aligned retainer passages of the pickets.

The present invention further comprises a kit comprising a plurality of the above-described rails, and further comprising a plurality of posts and a plurality of pickets.

The present invention further comprises a method of making the above-described rail, comprising forming the channel element from an extrudable material by an extrusion process, and forming the tray element from an extrudable material by an extrusion process.

The present invention further comprises a method of assembling the above-described fence, comprising installing a plurality of pickets into a rail, such that their retainer passages are aligned. A retainer element is then inserted into the retainer channel, and through the aligned retainer passages of the installed pickets. These steps are repeated for each additional rail which will support the pickets. Each rail is then secured at its opposite ends to an adjacent pair of posts.

DETAILED DESCRIPTION

With reference toFIG. 1, the present invention comprises a fence, generally designated by reference numeral10. The fence10preferably comprises a plurality of adjacent sections, such as the sections12and14. Each section comprises a pair of adjacent vertical posts16. Preferably, the fence10is configured so that the same single post16may be shared by two adjacent sections, as shown inFIG. 1.

Preferably, the posts16are of identical construction. Each of the posts16is securely anchored at its lower portion into a substrate18, such as an underground mass of concrete. The substrates18are preferably disposed in spaced relationship, with a separate substrate preferably supporting each post16. The posts16are situated along the boundary of the area to be enclosed by the fence10, with a post spacing which is adequate to impart strength to the fence10and to securely anchor other fence components. In one preferred embodiment, adjacent posts comprising a section are separated by a distance of no greater than 8 feet.

The above-ground height of each post16, in its installed configuration, is preferably sufficient to impede or deny access by a human or other intruder. In preferred embodiments, the above-ground height of each post16is between 3 and 10 feet. The upper end of each post16may be provided with a round top, as shown inFIG. 1. Alternately, a flat post top may be used, or a top which has been formed into pointed or sharpened configuration, such as a spear or spike.

Each of the posts16is preferably formed from a strong and durable material, and more preferably from a material which is relatively lightweight and extrudable as well. Preferred materials include aluminum, aluminum alloys, and plastics such as polyvinyl chloride. One particularly preferred material is 6005-T5 aluminum alloy. Preferably, the post16is formed in a die by an extrusion process. After the post16has been formed, a polyester powder coating is preferably provided in order to enhance corrosion resistance of the post.

The post16is tubular in construction, and preferably is characterized by a rectangular, and more preferably, a square cross-section. The post16may be hollow, or may include a core or other structure to increase its strength. In a preferred embodiment, the post16is characterized by an internal wall which interconnects two opposing side walls of the post16, thereby defining a double box cross-sectional structure. In a preferred embodiment, the side walls of the post16are characterized by a thickness of 0.06 inches or more, and a width of between 2.5 and 4 inches.

With continued reference toFIG. 1, each section of the fence10further comprises a plurality of elongate rails20. Each rail20is preferably formed from two separate and discrete components: a channel element26, shown inFIGS. 2 and 3; and a tray element28, shown inFIGS. 4 and 5. Each of these components of the rail20is preferably formed from a strong and durable material, and more preferably from a material which is relatively lightweight and extrudable as well. Preferably, each component of the rail20is separately formed in a die by an extrusion process. After a rail component has been formed, a polyester powder coating is preferably provided in order to enhance the component's corrosion resistance.

The present invention is well-adapted to rails formed from materials which are not readily susceptible to conventional roll forming, such as aluminum and its alloys. Preferred materials for the rail20include aluminum, aluminum alloys, and plastics such as polyvinyl chloride. Particularly preferred materials are 6005-T5 aluminum alloy (for channel elements) and 6063-T5 aluminum alloy (for tray elements).

With reference toFIGS. 2 and 3, the channel element26comprises an elongate structure having a generally U-shaped cross section. The channel element26is characterized by a elongate planar platform30having a first lateral edge32and an opposed second lateral edge34. A plurality of collinear, longitudinally spaced, picket openings35are formed in the platform30.

A first side wall36depends from the first lateral edge32, and a second side wall38depends from the second lateral edge34. The platform30and side walls36and38define boundaries of a rail channel40. The first and second side walls36and38are preferably disposed in parallel planes, with each orthogonal to the plane of the platform30. Preferably, the base of each of the side walls36and38is provided with an inturned flange section42positioned within the rail channel40. Each flange section42is preferably characterized by a L-shaped cross section, and functions to enhance the strength of the channel element26.

As best shown inFIG. 3, the channel element26further comprises a tray holder44adapted to slidably support a tray element28within the rail channel40. The tray holder44preferably comprises a first runner element46projecting within the rail channel40from the first side wall36, and a second runner element48projecting within the rail channel40from the second side wall38. The runner elements are adapted to slidably receive and support a tray element28within the rail channel40, and further function to restrain movement of the tray element28away from the platform20towards the mouth50of the rail channel40.

Each of the runner elements46and48preferably each comprises an elongate flange having a L-shaped cross section. Each such flange preferably extends continuously and linearly along substantially the entire length of the channel element26. Alternately, either or both of the runner elements46and48may comprise a series of spaced collinear flanges, rather than a single elongate flange. The first and second runner elements46and48should be equidistant from the platform20.

With continued reference toFIG. 3, the tray holder44preferably further comprises a first stop element52projecting within the rail channel40from the first side wall36, and a second stop element54projecting within the rail channel40from the second side wall38. The stop elements52and54function to restrain movement of the tray element28toward the platform20.

Each of the stop elements52and54preferably comprises an elongate rib which extends continuously and linearly along substantially the entire length of the channel element26, in spaced relationship to an adjacent runner element. Alternately, either or both of the stop elements may comprise a series of spaced collinear ribs, rather than a single elongate rib. The stop elements52and54should be equidistant from the platform20, with each stop element situated nearer the platform20than its adjacent runner element.

The runner elements46and48, and the stop elements52and54cooperate to define a cage within which a tray element28may be slidably received and supported. While permitting easy insertion or withdrawal of the tray element28from the channel element26, this cage restricts movement by a received tray element28either toward or away from the platform20.

With reference toFIGS. 4 and 5, the tray element28comprises an elongate planar platform56having a first lateral edge58and an opposed second lateral edge60. The length of the platform56is preferably substantially the same as that of the platform30of channel element26, while its width should permit the platform56to be clearingly received within the rail channel40.

A plurality of collinear, longitudinally spaced, picket openings62are formed in the platform56. The picket openings62are preferably disposed so that, when the tray element28is installed in the channel element26, the center of each picket opening62is aligned with the center of a corresponding picket opening35formed in the channel element26, such that the line of alignment between the two centers is orthogonal to the planes of the platform30and platform56.

As shown inFIG. 5, the tray element58further comprises a first leg64, which depends from the first lateral edge58of the platform56, and a second leg66which depends66from the second lateral edge60. The first and second legs64and66are preferably disposed in parallel planes, with each orthogonal to the plane of the platform56. As shown inFIG. 6, the platform56and first and second legs64and66are sized to be clearingly received within the rail channel40, and within the cage defined by the runner elements46and48and stop elements52and54.

In one preferred embodiment of the rail20, the channel element26is characterized by a substantially square profile, with the platform20, first side wall36and second side wall38each having a width of 1.75 inches. The typical wall thickness of the tray element28in this embodiment is 0.12 inches. In the same embodiment, the width of the platform56of the tray element26is 1.481 inches, while the overall height of the tray element26, comprising the distance between the upper surface of the platform56and the base of either of the legs64and66, is 0.25 inches. The typical wall thickness of the tray element28in this embodiment is 0.08 inches.

With continued reference toFIG. 6, the rail20is assembled by sliding the tray element28into the tray holder44of the channel element26, until the entire length of the tray element28is within the rail channel40. In this installed position of the tray element28, the platform56of tray element28, and the platform30of channel element26, define boundaries of a retainer channel68. The retainer channel68is situated within the rail channel40, and extends along the length thereof adjacent the platform30. The portion of each of the side walls36and38which extends between the platforms30and56forms an additional boundary for the retainer channel68.

In an installed position, each of the assembled rails20extends between an adjacent pair of posts16comprising a section of the fence10, as shown inFIG. 1. Two brackets22are used to connect the respective ends of a rail20to a pair of adjacent posts16. Each bracket22is connected to the rail20by a fastener (not shown), such as a bolt or a screw. This fastener preferably extends through an aperture (not shown) in the bracket22, and through a registering aperture70formed in a side wall of the rail20, as shown inFIG. 7.

At least two rails20extend between each adjacent pair of posts16. While any plural number of rails may be provided for each section, either two rails, as shown inFIG. 1, or three rails, as shown inFIG. 9, are preferred. The length of each rail20should be sufficient to fully span the distance between the adjacent of pair of posts16which will support that rail20. A rail length of either 6 feet or 8 feet is preferred.

The rails20which extend between a given pair of posts are preferably disposed in parallel relationship. The incline of each rail20with respect to horizontal should substantially equal the incline of the terrain24on which pair of posts16supporting that rail20are installed. Thus, when a section12is positioned on horizontal terrain, as shown inFIG. 1, the rails20will be disposed substantially horizontally.

With continued reference toFIGS. 1 and 2, each section of the fence10further comprises a plurality of vertically disposed pickets72, preferably of identical construction. Each picket72is preferably formed from a strong and durable material, and more preferably from a material which is relatively lightweight and extrudable as well. Preferred materials include aluminum, aluminum alloys, and plastics such as polyvinyl chloride. One particularly preferred material is 6063-T6 aluminum alloy. Preferably, the picket72is formed in a die by an extrusion process. After the picket72has been formed, a polyester powder coating is preferably provided in order to enhance corrosion resistance.

Each picket72is tubular in construction, and preferably is characterized by a rectangular or, most preferably, a square cross-section. The picket72may be hollow, or may include a core or other structure to increase its strength. The cross-sectional dimensions of the picket72should permit it to be clearingly received through the picket openings35and62. In a preferred embodiment, the side walls of picket72are characterized by a thickness of 0.05 inches, and a width of 0.75 inches. As shown inFIGS. 1 and 7, the upper end of each picket72may be provided with a pointed or sharpened top, such as a spear or spike, as shown inFIG. 1. Alternately, each picket72may be provided with a flat or rounded top.

The length of each picket72is preferably approximately equal to the vertical above-ground height of the posts16. In preferred embodiments, each picket will have a length between 45 inches and 72 inches. In an installed position, the base of each picket72should preferably be situated no more than a small distance above the terrain24supporting the fence10, in order to prevent an intruder from traversing the gap between the base of the picket72and the terrain72.

The pickets72are preferably oriented in parallel relationship, with a separation distance between adjacent pickets72and between each post16and its adjacent picket72, which is sufficiently small to prevent an intruder from traversing the gap. In one preferred embodiment, the separation distance between the centers of adjacent pickets72, and between each post16and its adjacent picket72, is 4 inches or less. Between adjacent pairs of posts16, pickets72should be provided in sufficient number to assure that the separation distance between adjacent pickets72, or between a post16and an adjacent picket72, does not exceed the requisite distance.

With reference toFIG. 7, each picket72to be installed in a section of the fence10should be laterally traversed by a plurality of parallel, longitudinally offset, retainer passages74. The number of retainer passages74in each picket72preferably equals the number of rails20in the section. The relative position, orientation and size of each of the retainer passages74in each of the pickets72should be identical.

Each retainer passage74should cross the longitudinal axis of symmetry of the picket72, preferably along a path which is perpendicular to, and interconnects, two opposed sides of the picket72. The retainer passages74should be positioned on the picket72such that each retainer passage74may be aligned with a corresponding retainer channel68of a rail20in the section of fence10. The retainer passages74of a plurality of linearly aligned pickets72should be linearly alignable.

The present invention further comprises an elongate retainer element76, shown inFIG. 7, which connects a plurality of pickets72to a rail20. The retainer element76preferably comprises a rod formed from a strong a durable material, such as galvanized steel. The length of the retainer element76should be equal to, or slightly less than, the length of the rail20. In one preferred embodiment, the length of the retainer element76is between 0.75 inches and 2.00 inches less than the length of the rail20. The cross-sectional dimensions of the retainer element76should permit it to be clearingly received within the retainer channel68, and clearingly received within the retainer passage74of each picket72. In a preferred embodiment, the retainer element76is characterized by a circular cross-section, and a diameter of 0.125 inches.

Pickets72are installed on a rail20by extending the picket72through an unoccupied picket opening62of the tray element28, and through the aligned picket opening35, if any, in the channel element26, until the retainer channel38of the rail20is aligned with the retainer passage74. This step is repeated for each additional picket72to be installed on the rail20. The pickets72should be positioned on the rail20such that the retainer passages74of the pickets72are in linear alignment, as shown inFIG. 7. Once all pickets72have been positioned as required, a retainer element76is inserted into the retainer channel68and passed through the aligned retainer passages74of each of the pickets72to be installed on the rail20.

As shown inFIG. 7, the fence10preferably comprises a plurality of grommets78, which protect internal components of the fence10from water damage and corrosion. Each grommet78is seated in a picket openings35, and fills the region between the platform30and the picket72. The grommets78are preferably formed from a strong, flexible and water-resistant polymer, such as polyvinyl chloride, and are provided in a number equal to the number of picket openings35in the section. The grommets78are preferably installed by seating them in the picket openings of each rail20before installation of the pickets72into that rail. The final seated placement of a grommet78in the assembled fence10is shown at the right-hand picket ofFIG. 7.

After the pickets72comprising a section of fence10have been installed on a first rail20, as described above, the same steps should be repeated for each additional rail20which will support the same pickets72. The result of this series of steps is a rail-picket framework. This rail-picket framework is then formed into a section of fence by securing each rail20of the framework at its opposite ends to an adjacent pair of posts16, as shown inFIG. 1. Additional sections of the fence10may be formed and installed by repeating these steps.

As shown inFIGS. 2 and 4, the length of each picket opening62formed in the tray element28preferably exceeds the length of the adjacent picket opening35with which it registers. The greater length of the picket openings62permits the pickets72to be positioned in a vertical orientation, even when the rails20are not horizontal, as may occur when the fence10is installed on non-horizontal terrain.

The picket-rail attachment in the fence10of the present invention is situated within the rail channel40, and thus is not exposed to the external environment. In addition to its aesthetic advantages, this internal connection promotes security, by denying an intruder or vandal any practical way of prying a picket72away from the rails20. At the same time, the retainer elements76and retainer channels68function much like latches, and prevent the pickets72from being forcibly withdrawn from the picket openings35and62. Because it is not exposed to the elements, the internal picket-rail connection is also less susceptible to corrosion and water damage.

FIG. 8shows another embodiment of the fence of the present invention, generally designated by reference number100. Much as with the embodiment described with reference toFIGS. 1–7, each section of the fence100is formed a pair of adjacent vertical posts102, which support a plurality of parallel rails therebetween. The fence100comprises at least an upper rail104and a lower rail106. Preferably, the fence100further comprises an intermediate rail108, situated between upper rail104and lower rail106. The lower rail106and intermediate rail108are identical in construction to the rail20described with reference toFIGS. 1–7.

The upper rail104is formed from a channel element110and a tray element (not shown). The channel element110is identical to the channel element26, except that its platform112is unperforated, with no picket openings formed therein, as shown inFIG. 9. Because of absence of picket openings in the platform112, the pickets114of the fence100terminate within the rail channel of the upper rail104, as shown inFIG. 8, and no grommets are used. In contrast, in the fence10shown inFIG. 1, the pickets72terminate above the upper rail20. Other aspects of the construction and assembly of the upper rail104, including the tray element, and fence100, are identical to those described with reference to rail20and fence10.

The fence of the present invention may be assembled from, and the methods of the invention advantageously practiced with, a kit. The kit of the present invention preferably comprises a plurality of posts, preferably identical to the posts16. The posts16are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.

The kit further comprises a plurality of rails20, with each rail20including a channel element26, a tray element28and a retainer element76. The rails20should be provided in the kit in a number sufficient to form the fence, or section thereof, to be installed. The kit should further comprise a plurality of brackets22and fasteners should for securing each rail20to an adjacent pair of posts16. The brackets and fasteners are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.

The kit further comprises a plurality of pickets, preferably identical to the pickets72, preferably in a number sufficient for the fence, or section thereof, to be installed.

Changes may be made in the construction, operation and arrangement of the various parts, elements, steps and procedures described herein without departing from the spirit and scope of the invention as defined in the following claims.