Abstract:
A gate bracket is formed of a planar web in which two rectangular portions along two edges of the web are bent to define a first pair of perpendicular flanges, and two other rectangular portions are bent from an inner portion of the web to form a second pair of perpendicular flanges. The flanges of the first pair are spaced from the flanges of the second pair by a distance corresponding to the dimensions of the structural members used to construct the gate. The invention provides a rigid bracket of simpler and lighter construction than prior art brackets.

Description:
FIELD OF THE INVENTION 
     This invention relates to a set of brackets for constructing a wooden gate. 
     BACKGROUND OF THE INVENTION 
     Corner gate brackets can be used to frame right angle joints between structural members of a gate at each of four corners. Such gate brackets are meant to provide a reliable guide for the positioning of the structural members to assist the do-it-yourself handy man. In addition, corner gate brackets are meant to minimize or eliminate the distortion of the gate structure over time. 
     Gate brackets are typically made of metal so as to resist bending and to ensure a rigid structure. Typically, a gate bracket comprises elongate flat metal members arranged in perpendicular relationship so as to guide the formation of a right angle between the pieces of structural lumber which are made to abut the elongate members. An example of such a system is disclosed in Boroviak, U.S. Pat. No. 6,896,244. 
     Parallel elongate flat metal members may be provided in a spaced relationship for bracketing structural lumber on two opposed sides and to provide a perpendicular arrangement of such elongate members. Such a system is disclosed in Cosgrove, U.S. Design Pat. No. D410,835. In Cosgrove, each pair of parallel elongate flat metal members form a U-shape and the two U-shaped pairs are welded together to form the overall bracket. 
     To provide structural rigidity for gate brackets, typically either a brace member is provided, as in Boroviak, or relatively thick metal members are provided, as in Cosgrove. In Boroviak, the diagonal brace member is welded to each of the perpendicular elongate metal members, which are in turn welded together at the intersection. 
     It is an object of the present invention to provide a structural gate bracket that serves to effectively frame a right angle between structural pieces, such as 2×4 pieces of lumber, while maintaining the structural relationship of the joint, over time, and at the same time not providing undue weight to the gate bracket, avoiding overly thick metal elements or excessive welding. 
     This and other objects of the invention will be better understood with reference to the detailed description of the invention which follows. 
     SUMMARY OF THE INVENTION 
     According to the invention, there is provided a web extending in a plane. A first pair of perpendicular elongate portions are provided normal to the plane of the web, preferably along two edges of the web. A second pair of perpendicular elongate portions are provided normal to the plane of the web in spaced parallel relationship to the first pair. 
     In another aspect of the invention, each pair of elongate portions comprises flanges of said web. 
     In a further aspect, an opening is provided in said web member between the first and second pairs of elongate portions. 
     In a further aspect, the opening extends between a first pair of parallel first and second members and between a second pair of parallel first and second members thereby defining a substantially L-shaped opening. 
     In another aspect, the invention comprises a web extending in perpendicular directions in a plane, said web including a first flange extending normal to said plane parallel to a first one of said directions, a second flange extending normal to said plane parallel to a second one of said directions in an end-to-end perpendicular, abutting relationship to said first flange. The web has an outer perimeter, an opening extending in generally perpendicular directions within said perimeter, a third flange normal to said plane along an edge of said opening and in spaced relationship to said first flange and a fourth flange normal to said plane along an edge of said opening and in spaced relationship to said second flange. 
     In another aspect, the invention comprises a method of forming a gate bracket comprising:
         providing a web extending generally in perpendicular directions within a plane and having an opening within the perimeter thereof, said opening extending generally in said perpendicular directions;   bending one edge of said web to provide a first flange normal to said plane;   bending a second edge of said web to provide a second flange normal to said plane and abutting said first flange in a perpendicular relationship;   bending a portion of said web that is adjacent to an edge of said opening to form a third flange normal to said plane;   bending a portion of said web that is adjacent to an edge of said opening to provide a fourth flange normal to said plane and in perpendicular abutting relationship to said third flange.       

     The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the invention and to the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be described by reference to the detailed description of the invention and to the drawings thereof in which: 
         FIG. 1  is a front perspective view of a first embodiment of the invention; 
         FIG. 2  is a rear perspective view of the first embodiment of the invention; 
         FIG. 3  is a plan view of the first embodiment; 
         FIG. 4  is a plan view of a web member, prior to bending, according to the method of the first embodiment; 
         FIG. 5  is a front perspective view of a web member of  FIG. 4  after the bending of the first and second flanges according to the method of the first embodiment; 
         FIG. 6  is a rear perspective view of a second embodiment of the invention; and 
         FIG. 7  is a front perspective view of a third embodiment of the invention; 
         FIG. 8  is a front perspective view of a fourth embodiment of the invention; and 
         FIG. 9  is a plan view of the fourth embodiment of the invention, prior to bending. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Throughout the following description specific details are set out to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the present invention. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense. 
     Referring to  FIGS. 1 ,  2  and  3  the gate bracket of the first embodiment  10  includes a web  12  extending within a plane generally along two perpendicular directions  14  and  16  in a generally L-shaped configuration. 
     Web  12  has a generally L-shaped opening  18  that extends in perpendicular directions parallel to directions  14  and  16 . Opening  18  is spaced inwardly from the perimeter  20  of the web  12 . 
     A first flange  22  extends normal to the plane of the web  12  along a perimetral edge  24  of web  12 , parallel to direction  14 . A second flange  26  extends normal to the plane of the web  12  along a perimetral edge  28  of web  12 , parallel to direction  16 . First  22  and second  26  flanges are in abutting perpendicular relationship to one another. 
     A third flange  30  extends normal to the plane of the web  12  along an edge  32  of opening  18 . Third flange  30  extends parallel to first flange  22  and in spaced relationship therewith. 
     A fourth flange  34  extends normal to the plane of the web  12  along an edge  36  of opening  18 . Third  30  and fourth  34  flanges are in abutting perpendicular relationship to one another. 
     The spacing between first  22  and third  30  flanges is selected so as to correspond to the dimensions of structural pieces (such as lumber, plastic or metal), to be used in the gate system, as is the spacing between second  26  and fourth  34  flanges. 
     One end of each of the third and fourth flanges may optionally be further bent away from opening  18  as at  38 ,  40  in order to provide additional structure rigidity to the flanges. 
     A hinge  42  may be provided on selected brackets according to whether the bracket will be used on the hinge side of the gate to be constructed. 
     One advantage of the first embodiment of the invention is that the entire structure, save for the attachment of a hinge, may be formed from a single flat sheet of materials, as will be described by reference to  FIGS. 4 and 5 . 
     There is first provided a web  12  as shown in  FIG. 4  that extends generally in two perpendicular directions  14  and  16 . Web  12  is cut at  17 ,  19 ,  21  and  23 , with cut  19  being parallel to direction  14  and cut  21  being parallel to direction  16 . Each cut  17 ,  19 ,  21 ,  23  is spaced inwardly from the edges of web  12 . A gap  15  is provided at the juncture cut lines  19  and  21 . 
     An elongated rectangular portion  30  is bent from the plane of the web so as to be normal to it and an elongated rectangular portion  34  is bent from the plane of the web so as to be normal to it to form flanges  30  and  34 . 
     Short end portions  29 ,  31  of flanges  30 ,  34  may then be bent along lines  33 ,  35  so as to be normal to flanges  30 ,  34  to provide structural rigidity to flanges  30 ,  34 . 
     An elongated rectangular portion  22  along edge  25  of web  12  is bent so as to form a flange  22  that is normal to the plane of the web  12 . An elongated rectangular portion  26  along edge  27  of web  12  is bent so as to form a flange  26  that is normal to the plane of the web  12 . Once bent, flanges  22  and  26  are in abutting perpendicular relationship and flanges  30 ,  34  are in abutting perpendicular relationship, as seen in  FIGS. 1 and 2 . 
     As shown in a second embodiment  60  illustrated in  FIG. 6 , the shape of the web  12  may be altered in area  68 , for example to increase rigidity, and the hinge  42  may not be provided on selected brackets. 
     As shown in the third embodiment  70  shown in  FIG. 7 , alternate embodiments of the invention do not require web  12  to extend into area  68  beyond flanges  30  and  40 . Optional piece  76  could be welded between flanges  30  and  40  to assist with the structural integrity of the bracket. 
     A fourth embodiment  80  is shown in  FIG. 8  in which a straight edge  86  can brace the portion between perpendicular structural members on a corner. Flanges  82  and  84  can be attached to the outside edges of structural members while flanges  88  and  90  can be attached to the inside edges. Flange  82  together with flange  88  and flange  84  together with flange  90  can firmly hold the structural members (such as 2×4 lumber pieces) of the corner of a gate in place. When folded in position, flanges  88  and  90  leave openings  92  and  94  in embodiment  80 . The edge along  86  can be reinforced by folding the edge over itself, as shown in  FIGS. 8 and 9 . Further, a hole  96  may be provided, for example to reduce the overall material used and the weight of the embodiment. For versions of embodiment  80  used on the side of the gate to which a hinge should be attached, a hinge may be attached to one of flanges  82  and  84 , and preferably to flange  84 . As shown in  FIG. 9  with reference to planar layout  98 , embodiment  80  can be made from a flat piece of unitary material, such as sheet metal. 
     In a method of assembly of a gate or door, four brackets as described above, may be used in the construction of a gate. Two brackets placed on adjacent corners may have hinges, whereas the two other brackets may not have hinges. Structural pieces, such as lumber, plastic or metal members may be used in the assembly of the gate. Typically four structural pieces of lumber (or equivalent) will be used to create a gate frame in a square or rectangular formation. Gate face structural members, such as 2×4 pieces of lumber, can then be secured to the gate frame to complete the gate. As understood in the art, the face structural members could be attached to one side of the gate frame, on both sides, or having face structural members in an alternating pattern with structural members secured to opposing sides of the gate frame. 
     Many other variations or additional features can be practiced in accordance with this invention. For example, a structural brace  66  could be added between flanges  30  and  34 . The structural brace would help maintain the structural integrity of the corner of the gate. The structural brace could be placed at any suitable angle, such as  45  degrees from each of flanges  30  and  34 . 
     Portions  64  of web  12  could be punched out, cut out, or otherwise removed from the structure without departing from the scope of the invention. Cutting out portions  64  of web  12  could be of any desired shape and location and would reduce the amount of material, such as metal, and reduce the weight of the gate bracket. 
     In certain embodiments, reinforcing lines  62  could be used to add structural integrity to the metal. Reinforcing lines  62  could be depressions formed on one side of the metal, with a corresponding protrusion on the opposite side of the metal. To maximize effectiveness of the reinforcing lines  62 , the lines may be linear. Reinforcing lines  62  could be added to web  12  or flanges  30  and  31 . 
     It will be appreciated by those skilled in the art that the first and second embodiments have been described above in some detail but that certain modifications may be practiced without departing from the principles of the invention.