Abstract:
A fence system including fence sections including singular blow-molded pickets that engage with fence rails using no additional parts and wherein the pickets show no external signs of functional engagement between the pickets and fence rails (e.g., pickets having substantially planar surfaces common to traditional wooden picket fence designs).

Description:
FIELD 
       [0001]    This disclosure relates generally to fencing systems. More particularly, this disclosure relates to a picket fence system including singular blow-molded pickets. 
       BACKGROUND 
       [0002]    The present disclosure relates to fence systems. Traditional wood picket fences have a desirable planar picket surface. When polymer or similar materials have been used to make construct similar fences due to, inter alia, the lighter and more robust characteristics of such materials and manufacturing techniques (e.g., extruding and/or blow-molding), a consistent problem encountered in the art has been the inability to achieve a traditional planar picket surface using polymer-based materials and related techniques. This problem is based at least in part on the external appearance of functional features in such polymer-based fences wherein such appearance does not correspond with the traditional look of similar fences made of wood. In particular, the pickets included in traditional picket fence designs have substantially planar surfaces of various widths and thicknesses, and often a particular repeating feature on the top of each picket. Picket fences made using blow molding techniques and/or extrusion have not been able to reproduce such a look and often require multiple parts per picket that must be attached together. 
         [0003]    What is needed therefore is a simplified picket fence system that provides a picket fence with a traditional picket fence look but wherein the parts of the fence are minimal and are made using blow molding and extrusion technologies. 
       SUMMARY 
       [0004]    The disclosure relates to a fencing system having a first singular blow-molded picket, a first substantially hollow rail, and a second substantially hollow rail. 
         [0005]    The first singular blow-molded picket includes a plurality of interference members defined along a first face of the first picket and at least one interference member defined along a second face of the first picket. The first picket is shaped according to a first predefined blow-molding pattern. The first substantially hollow rail includes a first aperture and a second aperture aligned on a common axis on opposing sides of the first rail and configured to tightly receive the first picket therethrough. A first interference member is located directly adjacent a lower rim of the first aperture. The second substantially hollow rail includes a third aperture and a fourth aperture aligned on a common axis on opposing sides of the second rail and configured to tightly receive the first picket therethrough. A second interference member is located directly adjacent a lower rim of the third aperture. A third interference member is located directly adjacent an upper rim of the second aperture or an internal upper rim of the fourth aperture. 
         [0006]    In some examples, the first interference member is located directly adjacent an internal lower rim of the first aperture, the second interference member is located directly adjacent an internal lower rim of the third aperture, and the third interference member is located directly adjacent an internal upper rim of the second aperture or an internal upper rim of the fourth aperture. 
         [0007]    In other examples, the first interference member is defined along the first face of the first picket and the second interference member is defined along the second face of the first picket. Additionally, a fourth interference member is defined along the second face of the first picket, directly across from the first interference member, located directly adjacent an internal lower rim of the first aperture. Also, a fifth interference member is defined along the first face of the first picket, directly across from the second interference member, located directly adjacent an internal lower rim of the third aperture. 
         [0008]    In still other examples, the first interference member is defined along the first face of the first picket and the second interference member is defined along the first face of the first picket. Additionally, a fourth interference member is defined along the second face of the first picket, directly across from the first interference member, located directly adjacent an internal lower rim of the first aperture. Lastly, a fifth interference member is defined along the second face of the first picket, directly across from the second interference member, located directly adjacent an internal lower rim of the third aperture. 
         [0009]    In certain other examples, a second singular blow-molded picket including a second plurality of interference members is defined along a first face of the second picket. Also, at least one interference member is defined along a second face of the second picket, wherein the second picket is shaped according to a second predefined blow-molding pattern. Additionally, the first substantially hollow rail includes a fifth aperture and a sixth aperture that are aligned on a common axis on opposing sides of the first rail and are configured to tightly receive the second picket. A fourth interference member is located directly adjacent an internal lower rim of the fifth aperture. Also, the second substantially hollow rail includes a seventh aperture and an eighth aperture that are aligned on a common axis on opposing sides of the second rail and are configured to tightly receive the second picket. A fifth interference member is located directly adjacent an internal lower rim of the seventh aperture. Lastly, a sixth interference member is located directly adjacent an internal upper rim of the sixth aperture or an internal upper rim of the eighth aperture. 
         [0010]    In certain other examples, each of the interference members of the plurality of interference members includes a bulge. Each bulge includes at least one sloped edge. 
         [0011]    In other embodiments, a sixth interference member is defined along the second face of the first picket, directly across from the third interference member and is located directly adjacent an internal upper rim of the second aperture. Also, a seventh interference member is defined along the second face of the first picket and is located directly adjacent an internal upper rim of the fourth aperture. Lastly, an eighth interference member is defined along the first face of the first picket, directly across from the seventh interference member and is located directly adjacent an internal upper rim of the fourth aperture. 
         [0012]    In some examples, the first pre-defined blow-molding pattern is the same as the second pre-defined blow-molding pattern. 
         [0013]    In some examples, the first pre-defined blow molding pattern has an average picket width of X and the second pre-defined blow molding pattern has an average picket width of X×Y, wherein X and Y are variables representing different numbers with each number provided in units of length. 
         [0014]    In some examples, the first pre-defined blow molding pattern has an average picket depth of X and the second pre-defined blow molding pattern has an average picket depth of X×Y, wherein X and Y are variables representing different numbers with each number provided in units of length. 
         [0015]    In some examples, the first pre-defined blow molding pattern has an average picket length of X and the second pre-defined blow molding pattern has an average picket length of X×Y, wherein X and Y are variables representing different numbers with each number provided in units of length. 
         [0016]    In a second set of examples, the disclosure relates to a kit of picket fence parts including a plurality of singular blow-molded pickets, a first substantially hollow rail and a second substantially hollow rail. Each picket includes a plurality of interference members defined along a first face of each picket. Also, each picket includes at least one interference member defined along a second face of each picket. At least a first portion of the plurality of pickets are shaped according to a first predefined blow-molding pattern. The first substantially hollow rail includes a first plurality of apertures spaced in a repeating pattern along a first edge of the first rail and a second plurality of apertures spaced in the repeating pattern along a second edge of the first rail. The second edge of the first rail is disposed opposite the first edge of the first rail such that the first rail includes repeating first pairs of apertures. Each pair of apertures is configured for tightly receiving one of the plurality of pickets therethrough. The second substantially hollow rail includes a third plurality of apertures spaced in the repeating pattern along a first edge of the second rail and a fourth plurality of apertures spaced in the repeating pattern along a second edge of the second rail. The second edge of the second rail is disposed opposite the first edge of the second rail such that the second rail includes repeating second pairs of apertures. Each pair of apertures is configured for tightly receiving one of the plurality of pickets therethrough. 
         [0017]    Additionally, the pickets are configured to be fixedly attached to the first rail by sliding each of the plurality of pickets partially through the first pairs of apertures along the first rail such that at least one interference member per picket is located directly adjacent a respective lower rim of a respective aperture of the first rail. Additionally, the pickets are configured to be fixedly attached to the second rail by sliding each of the plurality of pickets partially through the second pairs of apertures along the second rail such that at least one interference member per picket is located directly adjacent a respective lower rim of a respective aperture of the second rail. Sliding each of the plurality of pickets partially through the first pairs of apertures along the first rail and partially through the second pairs of apertures along the second rail also causes at least one interference member per picket to be located directly adjacent a respective upper rim of a respective aperture of either the first rail or the second rail. 
         [0018]    In some embodiments, the pickets are configured to be fixedly attached to the first rail and the second rail by first sliding each of the plurality of pickets partially through the first pairs of apertures along the first rail such that at least one interference member per picket is located directly adjacent a respective internal lower rim of a respective aperture of the first rail. Additionally, the pickets are configured to be fixedly attached to the first rail and the second rail such that the pickets are provided load-bearing support along each respective lower rim. Lastly, the pickets are configured to be fixedly attached to the first rail and the second rail by sliding each of the plurality of pickets partially through the second pairs of apertures along the second rail such that at least one interference member per picket is located directly adjacent a respective internal lower rim of a respective aperture of the second rail, providing load bearing support for each respective picket along each respective lower rim. 
         [0019]    In certain other embodiments, each picket of the plurality of singular blow-molded pickets includes a plurality of interference members defined along a first face of each picket and at least one interference member defined along a second face of each picket. At least a second portion of the plurality of pickets are shaped according to a second predefined blow-molding pattern. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    Further advantages of the disclosure are apparent by reference to the detailed description in conjunction with the figures, wherein elements are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein: 
           [0021]      FIG. 1A  is a perspective view of a fence section according to a fence system described in the disclosure;  FIG. 1B  is an exploded view thereof; and  FIG. 1C  is a cross-sectional side view thereof. 
           [0022]      FIGS. 2A-2C  are perspective views of a rail component of the system of  FIGS. 1A-1C . 
           [0023]      FIG. 3  is a perspective view of picket components of the system of  FIGS. 1A-1C . 
           [0024]      FIGS. 4A-4C  and  5 A- 5 C show picket components of the system of  FIGS. 1A-1C . 
           [0025]      FIG. 6A  is a perspective view of a fence section according to another embodiment of the fence system described in the disclosure, and  FIG. 6B  is an exploded view thereof. 
           [0026]      FIG. 7A  is a perspective view of a fence section according to yet another embodiment of the fence system described in the disclosure, and  FIG. 7B  is an exploded view thereof. 
           [0027]      FIG. 8A  is a perspective view of a fence section according to a still further embodiment of the fence system described in the disclosure;  FIG. 8B  is a cross-sectional side view thereof; and  FIGS. 8C and 8D  are exploded views thereof 
           [0028]      FIGS. 9A-9C  are perspective views of a rail component of the system of  FIGS. 8A-8D . 
           [0029]      FIGS. 10A-10C  show a picket component of the system of  FIGS. 8A-8D . 
           [0030]      FIG. 11  shows an interference fit of a picket and a rail according to the disclosure. 
           [0031]      FIG. 12  shows relative dimensions of components of a picket and a rail according to the disclosure. 
           [0032]      FIG. 13  shows an exemplary partial cut-away side view of a picket and rails engaged with the picket. 
           [0033]      FIG. 14  shows another exemplary partial cut-away side view of a picket and rails engaged with the picket. 
           [0034]      FIG. 15  shows yet another exemplary partial cut-away side view of a picket and rails engaged with the picket. 
           [0035]      FIG. 16  shows still another exemplary partial cut-away side view of a picket and rails engaged with the picket. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Referring to the  FIGS. 1-16 , the disclosure relates to a fencing system including, for example, a fence section  10  including a plurality of pickets  12 , a first rail  14 , and a second rail  16 . Each of the pickets  12  are formed as a single (or “singular”) piece by blow molding in a single molding step and are, therefore, formed based on one or more predefined blow-molding patterns. The first rail  14  is preferably substantially hollow and includes a plurality of first apertures  18  along two opposing sides of the first rail  14 , forming a pattern of pairs of first apertures  18  along the first rail  14 . Each pair of the first apertures  18  is configured to tightly receive one of the pickets  12  therethrough. Similarly, the second rail  16  is also preferably substantially hollow and includes a plurality of second apertures  20  along two opposing sides of the second rail  16 , forming a pattern of pairs of second apertures  20  along the second rail  16 . Each pair of the second apertures  20  is configured to tightly receive one of the pickets  12  therethrough. 
         [0037]    With reference to  FIGS. 13-16 , each of the pickets  12  includes a plurality of interference members  22  defined thereon. At least two of the interference members ( 22 A and  22 C) for each picket are defined along a first face  24  of each picket as well as at least one interference member ( 22 B) defined along a second face  26  of each picket. For each picket, at least one interference member ( 22 B) is located directly adjacent a lower rim  28  of one of the first apertures  18 , at least one interference member ( 22 C) is located directly adjacent a lower rim  30  of one of the second apertures  20 , and at least one interference member ( 22 A) is located directly adjacent either an upper rim  32  of one of the first apertures  18  or an upper rim  34  of one of the second apertures  20 . 
         [0038]    The interference member  22 B is preferably located as shown in  FIG. 13  directly adjacent a lower rim  28  of one of the first apertures  18  from an internal position (internal of the first rail  14 ), thereby providing load bearing support function for the applicable picket. Similarly, the interference member  22 C is preferably located directly adjacent a lower rim  30  of one of the second apertures  20  from an internal position (internal of the second rail  16 ), thereby providing load bearing support function for the applicable picket. Preferably, each picket includes at least four interference members  22  at every rail interface  36  as shown in  FIG. 14  wherein the internal height “H” of each rail ( 14 ,  16 ) is approximately the same as the distance “D” between outer edges  38  of the interference members  22  located on the same face of a picket between a rail. 
         [0039]      FIG. 15  shows an example of a picket that includes three interference members  22  per rail interface  36 .  FIG. 16  shows an example of a picket wherein some of the interference members  22  are located at locations external from the first rail  14  and the second rail  16 . However, internal location of interference members is preferred so as to preserve the look of a traditional picket fence with pickets made of wood or otherwise having substantially smooth and flat, panel-like exterior surfaces. 
         [0040]    As shown by comparing  FIG. 1A ,  FIG. 6C ,  FIG. 7A , and  FIG. 8A , the style of picket can vary, which, in turn, can vary the size and/or shape of apertures in the various rail designs to accommodate for the different sizes of the variously styled pickets.  FIG. 1A  through  FIG. 3  show an example of a picket fence section  40  wherein the style of picket varies according to a repeating pattern along the fence section  40 . Because the style and size of picket varies according to a particular pattern, the size of the respective apertures  18  in the first rail  14  and the size of the respective apertures  20  in the second rail  16  also vary accordingly as shown, for example, in  FIGS. 2A-2C . 
         [0041]      FIGS. 6A-6B  show another example of a fence section  42  including pickets  44  all made from a first predefined blow-molding pattern along with an upper rail  46  and a lower rail  48 , wherein both rails include apertures  50  configured for receiving the pickets  44 .  FIGS. 7A-7B  show yet another example of a fence section  52  including pickets  54  made from a second predefined blow-molding pattern along with an upper rail  56  and a lower rail  58 , wherein both rails include apertures  60  configured for receiving the pickets  54 . A plurality of interference members  62  are defined along widthwise surfaces  64  of the pickets  54  in this example.  FIGS. 8A-10C  show a third example of a fence section  66  including pickets  68  all made from a third predefined blow-molding pattern along with an upper rail  70  and a lower rail  72 , wherein both rails include apertures  74  configured for receiving the pickets  68 . A plurality of interference members  76  are defined along the depthwise surfaces  78  of the pickets  68  in this example. 
         [0042]    The size of various components of the fence system described herein can vary based on various factors including, for example, customer need, although traditional fence picket heights, widths, and lengths are often preferable. The plurality of fence pickets and associated rails are preferably made of polyvinyl chloride (PVC), high density polyethylene, polypropylene or other similar polymer, copolymer, and/or combinations thereof The rails are preferably made using an extrusion process. Fences are preferably formed in sections (e.g., the fence section  10  shown in  FIG. 1A ) prior to shipment to dealers or customers. However, kits of picket fence components are also contemplated wherein the fence components are shipped unattached.  FIG. 8C  shows an example of a fence kit  80  including the plurality of pickets  68 , the upper rail  70 , and the lower rail  72  used to form the fence section  66  shown in  FIG. 8A . End posts may be included in fence kits wherein the upper rail  70  and the lower rail  72  are attached to the end posts in any manner known to person having ordinary skill in the art. 
         [0043]    The previously described examples of the present disclosure have many advantages, including providing traditionally styled picket fence sections made from recyclable and/or recycled material, the whole of which is lighter than wood and more impervious to the elements than traditional wood picket fences. Another advantage is the traditional appearance of painted wooden picket fence pickets with substantially planar surfaces with little or no functional features appearing on the outside surfaces of the various parts of each fence section. 
         [0044]    The foregoing descriptions of preferred embodiments for this disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the disclosure and its practical application, and to thereby enable one of ordinary skill in the art to utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the disclosure as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.