Abstract:
A fencing assembly is adapted to be positioned between a pair of posts and mounted to the posts. The fencing assembly includes a plurality of pickets and a plurality of rails extending transverse to the pickets. Optionally, sliding covers are provided for concealing the connection between the pickets and the rails.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to fencing and method of producing fencing. 
       BACKGROUND OF THE INVENTION 
       [0002]    Fencing has existed for hundreds of years. Typical fencing comprises a series of vertical pickets that are attached to horizontal rails. In some types of fencing, the rails have holes through which the pickets extend therethrough, which are then connected using fasteners such as screws or by a welding. As these fasteners tend to wear over time, the durability of the fence can be dependant on the fastener. 
         [0003]    Accordingly, there is always a need for improved fence systems or assemblies. This invention is directed to this need, among others. 
       SUMMARY 
       [0004]    Briefly, one specific embodiment of this invention includes a fencing assembly adapted to be positioned between a pair of posts and mounted to the posts. The fencing assembly includes a plurality of pickets and a plurality of rails extending transverse to the pickets. The rails have a plurality of openings for receiving the pickets therethrough. The rails can be coupled or pivotally connected to the pickets by a protuberance in the rail and a recess in the picket so as to form a connection between the picket and the rail; the interconnection between the protuberance and the recess result is a connection between the rail and the picket. Sliding covers can be provided over the protuberances to conceal the connection between the pickets and the rails. For example, a sliding strip can be slidably mounted onto the rails and are captured therein. In some examples, the fence may be constructed without the use of screws or bolts. 
         [0005]    In some embodiments, the recesses may be a dimples (or apertures) formed in the pickets and the protuberances may be formed in the rails. Optionally, the recesses comprise dimples or may include apertures. Alternatively, the dimples could be formed in the rails and the protuberances formed in the pickets. Instead of or in addition to the dimples and protuberances, other connections can be employed between the pickets and the rails. For example, a series of holes could be drilled in the pickets for receiving nubs or the like formed on the rails. 
         [0006]    In one embodiment, the connection between a rail and the pickets is not readily visible, after the fencing assembly has been assembled. 
         [0007]    In one specific embodiment, the recesses or dimples may be formed in the pickets and the protuberance may be formed in the rails using a press tool. For example, a tool may be appropriately positioned over a rail then pressed forcibly against the rail to deform both the rail and the pickets. Also, optionally, a series or cluster of tools can be pressed against the rail to deform both the rail and a plurality of pickets all at the same time. Alternatively, the recesses and the protuberance may be formed independently. The recesses may also be formed in the pickets and the protruberabances may be formed in the rail simultaneously by first positioning a rail over the pickets and then pressing a gang of tools against the rail to deform both the rail and the plurality of pickets all at the same time. 
         [0008]    One specific manufacturing method for a fencing assembly includes the steps of providing a series of pickets in a spaced-apart relationship, providing a generally U-shaped rail with picket recesses formed an upper portion thereof, the rail including a profile for receiving and retaining a sliding cover; slipping the U-shaped rail over the pickets, with a portion of the pickets extending through the picket recesses formed in the rail, forcing a tool against the rail to deform both the rail and the pickets to create a fastener-less connection between the pickets and the rail, providing a sliding cover; and sliding the sliding cover into engagement with the rail to conceal the fastener-less connection between the pickets and the rail. The step of forcing a tool against the rail is effective to form recesses in the pickets and form protuberance in the rail. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a front elevation view of a metal fence assembly according to preferred form of the present invention. 
           [0010]      FIG. 2  is a detailed, sectional view of a portion of the metal fence assembly of  FIG. 1 . 
           [0011]      FIG. 3  is a detailed, sectional view of a portion of the metal fence assembly of  FIG. 1 . 
           [0012]      FIG. 4  is a detailed, sectional view of a portion of the metal fence assembly of  FIG. 1  depicting a manufacturing operation thereof. 
           [0013]      FIG. 5  is a detailed, sectional view of a portion of the metal fence assembly of  FIG. 1  in an alternate form and depicting a manufacturing operation thereof. 
           [0014]      FIG. 6  is a detailed, sectional view of a portion of the metal fence assembly of  FIG. 1  depicting a manufacturing operation thereof in an alternate form. 
           [0015]      FIG. 7  is a detailed, sectional view of a portion of a metal fence assembly in an alternate form of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The fence assembly  10  according specific embodiments of this invention a fencing assembly that can reduce both manufacturing and installation costs be reducing the need for fasteners. More specifically, the fence assembly  10  provides a system of pickets  20  and support rails  30  (collectively) that can be held in place by appropriately positioned dimples  40 . 
         [0017]    Referring now to  FIG. 1 , the fencing assembly  10 , when mounted, can be used to enclose yard spaces, decks, porches and the like. The fence assembly  10  includes a plurality of horizontally spaced pickets  20  and at least one support rail  30 . In the exemplary embodiments, the railing assembly  10  comprises three individual support rails  30   a ,  30   b ,  30   c  (as seen in  FIG. 1 ) to space, align, and secure the pickets  20  and to provide for structural rigidity. Each picket  20  can also include an endcap coupled to the top of the same (or formed in the top portion itself) to close off the top of the picket and/or to provide a decorative element to the railing assembly  10 . In exemplary embodiments, the pickets  20  and rails  30  can be formed from extruded metal. In exemplary embodiments, the pickets  20  are square aluminum extrusions and the rails  30  are roughly rectangular aluminum extrusions (but U-shaped). While specific shapes of fence components such as the rails and pickets are shown in the figures, it is contemplated that the style and particular applications for picket and rail fences can shape the size and design of fence assembly. 
         [0018]    As shown in  FIGS. 2 and 3 , the rails  30  can have a substantially “U” shaped cross-section and generally in use, are oriented open-side-down such that the “bottom” of the “U” forms the top of the rail  30 . In alternative embodiments, the rails  30  can have a substantially “J” shaped cross-section or rectangular shaped cross-section. In still other embodiments, the rails  30  can include other cross-sections as desired. 
         [0019]    As shown in  FIGS. 3 and 4 , the rails  30  include a pair of L-shaped guides  32 ,  33  for guiding, securing and supporting a cover strip  34  (or alternatively referred to as a concealment strip) thereon. Once in place, the cover strip  34  may be securely held there by the guides  32 ,  33 . The cover strip  34  includes a pair of feet or nubs  36 ,  37  for being slidably captured by the guides  32 ,  33  of the cover strip  34 . In exemplary embodiments, the cover strip  34  is captured by the rail body and is permitted to slide horizontally along the rail  30  (at least until the fencing assembly is assembled). 
         [0020]    In one embodiment, each of the rails  30  may include a plurality of dimples  40  for receiving a picket at a bulge  42 . The dimple  40  can be shaped to accept at least a portion of the bulge  42 , so to help secure the picket within the rail  30 . As shown, the cross-sectional shape dimple  40  providing some clearance between the extension and the side surfaces of the pickets. In one example, the clearance front-to-back is smaller than the clearance side-to-side. Providing greater clearance side-to-side allows for greater range of “racking”—a greater range of angles between the pickets and the rails to better follow rising or falling terrain. However, it is contemplated that greater clearance may require a deeper protuberance. 
         [0021]    As shown in  FIGS. 4 ,  5  and  6 , the fence assembly can be manufactured using a manufacturing operation incorporating one or more pressing tools T. For example,  FIG. 4  shows that the dimples can be formed independently using a single pressing tool T by selecting the appropriate position of the dimple along the appropriate face of the rail  30  and pressing the pressing tool T therein. Alternatively,  FIG. 5  shows that multiple dimples may be simultaneous formed using a series or cluster of tools T by pressing the series of tools T into the appropriate places along the rail  30 . One ordinary skill in the art may create the dimples  40  in the rail  30  using methods known in the art. 
         [0022]    As shown in  FIG. 7 , a sectional view of a portion of a metal fence assembly in an alternate form of the invention. In this embodiment, the faces of rails are squared off so to avoid the need for the cover strips  34  shown in  FIG. 1 . As shown, the dimples can be placed in the back face of the rail  30 , so that the dimples are not seen from the front of the fence, which improves the overall appearance of the fencing assembly. 
         [0023]    In exemplary embodiments, the protuberance is shown as a bulge  40  on the exterior surface of the rail. It is contemplated, that in alternative example embodiments other exterior shapes, can be utilized as desired. For example, a star shape or diamond type of shape may be pressed into the rail  30 . One of ordinary skill in the art may select an appropriate shape without undue experimentation. 
         [0024]    In use and application, fence assembly  10  can be used to prepare a fence between along using a series of pickets  20  and rails  30 . More particularly, a method for preparing such a fence can have the steps of: 
         [0025]    (a) providing a series of pickets in a spaced-apart relationship; 
         [0026]    (b) providing a generally U-shaped rail with picket recesses formed an upper portion thereof, the rail including a profile for receiving and retaining a sliding cover; 
         [0027]    (c) slipping the U-shaped rail over the pickets, with a portion of the pickets extending through the picket recesses formed in the rail; 
         [0028]    (d) forcing a tool against the rail to deform both the rail and the pickets to create a fastener-less connection between the pickets and the rail; 
         [0029]    (e) providing a sliding cover; and 
         [0030]    (f) sliding the sliding cover into engagement with the rail to conceal the connection between the pickets and the rail. 
         [0031]    While the fence assembly  10  is disclosed as manufactured of aluminum, the picket and rail assembly can be easily and readily manufactured other materials. For example, the pickets and rails can be formed from other materials such metals and/or metal alloys, wood, rubber, plastic, and/or other materials available in the art. 
         [0032]    While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.