Ornamental bridge kit

An ornamental bridge kit includes a frame having a first and second side beams (10, 12) of a length that may fit within a shipping container. The frame further includes a plurality of transverse braces (16) spanning between the internal surface of the first side beam (10) and the internal surface of the second side beam (12). The frame also includes a plurality of lateral stiffeners (18) and at least one longitudinal stiffener (20) secured to the plurality of transverse braces (16). A plurality of boards or planks (52) may further be arranged transversely and extending from the first side beam (10) to the second side beam (12) and secured to the top edge of the first side beam (12).

FIELD OF THE INVENTION

The present invention relates generally to an ornamental bridge, and more particularly, to an ornamental bridge kit that may be conveniently packaged and shipped to the purchaser for assembly.

BACKGROUND OF THE INVENTION

Ornamental bridges are commonly used in gardens and parks for both decorative and functional purposes. They can be used as a walkway over a stream or pond, or they can be added simply for visual pleasure.

To serve a functional purpose, a bridge must be well constructed to withstand a significant amount of pressure and force, and also durable such that it may last for an extended period of time. Such a reliable, sturdy bridge may not be accessible to a consumer who wishes to assemble the bridge without professional assistance. Moreover, many sturdy designs are not normally broken down into smaller components to allow for the packaging and delivery of an ornamental bridge kit to a residence, place of business, park, or elsewhere. For instance, the United Parcel Service™ requires that all packages be limited in length to 108 inches, or 9 feet. If the package is not limited to 9 feet, the shipper will incur extra costs to send the package. Thus, it is desirable that the kit parts be limited in length to conform to this requirement.

It is also desirable that the kit be conveniently transportable from a retail store to the consumer's home, for example in an SUV, a station wagon, or a pickup.

Based on the foregoing, there exists a need for an ornamental bridge kit that is shippable via standard shipping methods, and a kit that allows for fast, simple assembly of a reliable bridge.

SUMMARY OF THE INVENTION

One embodiment of an ornamental bridge kit formed in accordance with the present invention comprises a frame that includes a first side beam of a length that may fit within a shipping container. The first side beam has an internal surface, an external surface, a top edge, and a bottom edge. The frame also includes a second side beam of a length that may fit within a shipping container. The second side beam likewise has an internal surface, an external surface, a top edge, and a bottom edge. The frame further includes a plurality of transverse braces spanning between the internal surface of the first side beam and the internal surface of the second side beam. In addition, a plurality of stiffeners may be secured to the first and second side beams and the plurality of transverse braces. A plurality of deck boards are also arranged transversely on the frame, extending from the first side beam to the second side beam and secured to the top edges of the first and second side beams.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIGS. 1–4, one embodiment of the present invention is provided. Referring toFIG. 1, a complete ornamental bridge assembly8is shown. The ornamental bridge assembly8consists of an underlying frame, an external covering for the frame, and a plurality of boards or planks arranged transversely across the frame to form the bridge platform. The bridge is configurable in numerous sizes, including in lengths of, for example, 4, 8, 10, 12, 14, and 16 feet. For ease of illustration and clarity, the bridge and bridge components are shown in a substantially horizontal orientation, although it may be suitably shown in any orientation, such as vertical. Therefore, the terminology “vertical”, “horizontal”, “top”, “bottom”, etc., should be construed as descriptive and not limiting.

Referring now toFIG. 2, the underlying frame of the ornamental bridge is shown. The frame includes at least a first side beam10and a second side beam12disposed in a spaced parallel relationship to each other. The side beams10and12are preferably arched in shape and symmetrical about a longitudinal center axis14. The side beams10and12may taper near the end of the beam, however, to provide a substantially flat surface on which the bridge may rest. In order that the bridge kit be shippable to purchasers by standard methods, the first side beam and the second side beam components should be limited in length. For instance, the United Parcel Service™ (UPS) requires that all packages be limited in length to 108 inches, or 9 feet, without incurring additional costs for shipment. Thus, the bridge kit components, including the side beams10and12, should be limited in length to fit within a 9-foot container for shipment by UPS, or other maximum length prescribed by the shipper.

The first side beam10is joined to the second side beam12with a plurality of transverse braces16interspersed between the two side beams10and12. The transverse braces16may consist of a foamed plastic that is lightweight, yet strong and durable. Although foamed plastic is the preferred material, other materials may also be used. The first edge of the transverse braces16secure to the internal surface of the first side beam10and the second edge of the transverse braces16secure to the internal surface of the second beam12. Thus, the transverse braces16may be mounted such that they are oriented at substantially perpendicular position to both the first beam10and second side beam12. The braces16may be attached with fasteners, such as screws, bolts, or nails17. Depending on the length of the bridge, an appropriate number of transverse braces16may be used. For instance, the 4-foot bridge would likely need 2 transverse braces16to provide sufficient support, whereas a 16-foot bridge may use 7 transverse braces16for adequate support. An 8-foot bridge, therefore, may use 3 braces, a 10-foot bridge 3 braces, a 12-foot bridge 5 braces, and a 14-foot bridge may use 7 braces. However, fewer or more braces16may also be used. Moreover, braces16that are smaller in height may be used near the tapered end of the beams10and12.

Still referring toFIG. 2, a plurality of lateral stiffeners18may be secured to the bottom edges of the transverse braces16. The lateral stiffeners18may be made of metal, preferably a 16 gauge hot dip galvanized steel. The plurality of lateral stiffeners18may be arranged such that each lateral stiffener extends diagonally from the first side beam10to the second side beam12. Each stiffener may be arranged in this fashion, so as to create a criss-cross diagonal pattern within the plurality of lateral stiffeners18. The lateral stiffeners18are then secured to the transverse braces16to cooperatively form a more rigid frame. The lateral stiffeners18may be secured to the transverse braces16with fasteners, such as screws, bolts, or nails.

In addition to the plurality of lateral stiffeners18, a longitudinal stiffener20may be secured to the top edges of the plurality of transverse braces16. The longitudinal stiffener20may be positioned along the longitudinal center axis14such that it extends between the first side beam10and the second side beam12. The longitudinal stiffener20may be secured to the top edges of the transverse braces16with fasteners, such as screws, bolts, or nails.

Still referring toFIG. 2, a detailed illustration of the side beams10and12is shown. The first side beam10may be composed of multiple layers to provide greater strength. The layers may include a first external side rail22, a first internal side rail24, and a first plate26. The first external side rail22, a first internal side rail24, and a first plate26should be limited in length such that they may fit within a standard shipping container. The first external side rail22and the first internal side rail24may be formed with a foamed plastic material to provide the first side beam10with substantial strength while remaining lightweight. The plate26may be made of metal, and preferably a 16 gauge hot dip galvanized steel. After disposing the first plate26between the first external side rail22and the first internal side rail24, the layers may be secured together to form the complete first side beam10. The layers may be secured together with fasteners, such as screws, bolts, or nails.

The second side beam12may similarly be composed of multiple layers. The layers may include a second external side rail28, a second internal side rail30, and a second plate32. The second external side rail28, second internal side rail30, and second plate32should also be limited in length such that they may fit within a standard shipping container. The second external side rail28and second internal side rail30may be similarly formed from a foamed plastic, and the second plate32may be formed from metal. The second plate32may be disposed between the second external side rail28and the second internal side rail30, and fasteners may be used to secure the layers to one another.

The first side beam10and second side beam12may be composed of a plurality of longitudinal components to enable efficient packaging and shipping of the ornamental bridge kit. Thus, for a 16-foot bridge, the first side beam10may be broken down into smaller components such that the kit may be packaged and shipped in a standard shipping container. For simplicity and for illustration only, only the first side rail components34A and34B will be described in detail. However, the second side rail may have similar components. Referring toFIG. 3, the first external side rail22and first internal side rail24may be composed of at least two first side rail components34A and34B that mate together to form one longitudinal side rail22or24. The first side rail components34A and34B may be formed such that they mate together at a joint36, a mortise and tenon joint. Other types of joints may also be used to mate the components, such as dovetail joint or a dowel joint. The components may then be further secured with fasteners, such as nails, bolts, or screws. Depending on the length of the bridge, the side rails22and24may be composed of several components that similarly mate together or merely two components that mate together. Moreover, the side rails22and24need not contain identical components. Rather, the components may be of different lengths to create joints in different locations along the side rails22or24. Furthermore, a small bridge may include side rails22or24that comprise only a single component of foamed plastic. Regardless, each individual component should be limited in length such that it may fit within a standard shipping container. Thus, it is preferable that each component be less than 9 feet in length.

The first plate26may also be broken into smaller components to enable the plate to fit within a standard shipping container. Referring toFIG. 4, the first plate26may be composed of at least two first plate components38A and38B that mate together. Each first plate component38A and38B should be limited in length to fit within a standard shipping container. Thus, it is preferable that each first plate component38A and38B be less than 9 feet in length. The first plate components may be joined with a scab plate40, which overlaps the adjacent ends of each plate38A and38B and secures to each first plate component38A and38B. The scab plate40may be secured to the first plate components38A and38B by fasteners, such as nails or screws. The scab plate40joins the first plate components38A and38B to form the first plate26.

Now referring toFIG. 5, a cross sectional view of the first side beam10and second side beam12joined with a transverse brace16is shown. Preferable, the layers of the first side beam10are secured to the transverse brace16with a bolt that passes, in the following order, through the first external side rail22, the first plate26, and the first internal side rail24, and then through a hole in the outer edge of the transverse brace16to receive a nut. The second side beam12may be secured to the transverse brace16in a similar fashion. Although the preferred method includes passing a bolt through the first side beam10and the transverse brace16, other methods of fastening may also be used. Also secured to the transverse brace16is a lateral stiffener18. The lateral stiffener18may be secured to the transverse brace16with a screw; however, other fasteners may also be used.

Referring back toFIG. 1, the complete bridge is shown. The frame may be concealed with a wood covering to create a pleasing aesthetic image. The first side beam10may be covered with a first side covering42, and the second side beam12may be covered with a second side covering44. Although wood is preferred, the side coverings may consist of a synthetic material, such as plastic. Regardless, each side covering42and44may also be composed of smaller components for shipping purposes. Thus, it would be preferable that each component be no greater in length than 9 feet. The side coverings42and44may be secured to the side beams10and12with fasteners, such as nails, screws, or bolts. The same bolt may be used to secure the coverings42and44to the external side rails22and28, the plates26and32, the internal side rails24and30, and the transverse brace16. In the alternative, separate fasteners may be used to secure the coverings42and44to the side beams10and12.

Rather than using side coverings42and44, the exteriors of the first and second side beams may not be covered; rather, the side beams may be left exposed. To this end, the exterior side rails of the side beams may be textured to simulate wood grain or other design.

Still referring toFIG. 1, a first end covering46may be secured to the end of the frame to enclose the end openings. The first end covering46may extend transversely from the first end of the first side beam10to the first end of the second side beam12. The first end covering46may then be secured to the first end of the first side beam10and the first end of the second side beam12with fasteners, such as screws, nails, or bolts. A second end covering50may similarly be secured to the second end of the first side beam10and the second end of the second side beam12.

A plurality of boards or planks52may be arranged transversely across the frame, extending from the first side beam10to the second side beam12. The plurality of boards52may be secured to the top edge of the first side beam10and the second side beam12with fasteners, such as screws, nails, or bolts. The plurality of boards52form the bridge platform or deck to complete the bridge.

Handrails may be further added to the bridge if the user so desires. The handrails include posts or risers54having their lower ends mounted to the first and second side coverings44and46with fasteners such as screws, nails, or bolts. In the alternative, the handrails may be directly mounted to the first and second side beams10and12and then first and second side covering components may later be added to the side beams10and12. Upper railings56may extend along the tops of the risers54preferably at a height that may be readily grasped by one walking across the bridge.