Abstract:
A bracket system for forming gate assemblies comprising at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system.

Description:
RELATED APPLICATIONS 
       [0001]    This application (Attorney&#39;s Ref. No. P216405kru) is a continuation of U.S. patent application Ser. No. 12/268,987 filed Nov. 11, 2008. 
         [0002]    U.S. patent application Ser. No. 12/268,987 is a continuation of U.S. patent application Ser. No. 11/888,553 filed Jul. 31, 2007, now U.S. Pat. No. 7,448,599 which issued on Nov. 11, 2008. 
         [0003]    U.S. patent application Ser. No. 11/888,553 is a continuation of U.S. patent application Ser. No. 11/410,736 filed Apr. 25, 2006, now U.S. Pat. No. 7,249,755 which issued on Jul. 31, 2007. 
         [0004]    U.S. patent application Ser. No. 11/410,736 is a continuation of U.S. patent application Ser. No. 11/087,483 filed Mar. 22, 2005, now U.S. Pat. No. 7,032,892, which issued on Apr. 25, 2006. 
         [0005]    U.S. patent application Ser. No. 11/087,483 is a continuation of U.S. patent application Ser. No. 10/456,247 filed Jun. 5, 2003, now U.S. Pat. No. 6,896,244, which issued on May 24, 2005. 
         [0006]    U.S. patent application Ser. No. 10/456,247 is a continuation of U.S. patent application Ser. No. 09/976,380 filed on Oct. 11, 2001, now abandoned. 
         [0007]    U.S. patent application Ser. No. 09/976,380 is a continuation-in-part of U.S. Design patent application Ser. No. 29/067,042 filed on Feb. 27, 1997, now U.S. Pat. No. D520,349, which issued on May 9, 2006. 
         [0008]    U.S. Design patent application Ser. No. 29/067,042 claims priority of Canadian Industrial Design Application No. 1996-2618 filed on Nov. 26, 1996, now Canadian Industrial Design Registration No. 83049, which registered on Feb. 6, 1998. 
         [0009]    The subject matter of the foregoing related applications are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0010]    The present invention relates to hardware for use in the construction of gates and, more specifically, to gate hardware adapted to brace the vertical and horizontal support members of a wooden gate and rotatably connect these members to a fixed structural member. 
       BACKGROUND OF THE INVENTION 
       [0011]    Gates are often used to allow selective access through a wall or fence. Conventionally, gates are constructed as follows. Two vertical support members and two horizontal support members are fastened together in a rectangular shape to form what will be referred to herein as a gate box. Fence boards or the like are fastened to the support members, and one of the vertical support members is rotatably attached by two or more hinge assemblies to a structural member such as a wall or post. 
         [0012]    Using conventional gate building techniques, fasteners such as nails or screws are driven through one support member into another support member to form the corners of the gate box. Over time, the force of gravity and wood shrinkage will cause these fasteners to loosen, allowing the gate box to sag out of its desired rectangular shape. 
         [0013]    Accordingly, metal L-brackets, wooden brace members, triangular pieces of plywood, and the like are often fastened to the adjacent ends of the support members to strengthen the inside corners of the gate box. In other situations, a wire is placed in tension between the upper proximal and lower distal corners of the gate box to support the lower distal corner of the gate box and thereby reduce sagging of the gate. Such bracing techniques are somewhat effective but also commonly employ fasteners that are susceptible to failure and can be relatively time consuming to implement. 
         [0014]    Another problem with conventional gate building techniques is that fasteners such as nails or screws are similarly used to attach the hinge assemblies to the vertical support member adjacent to the structural member. The loads are transferred to the gate through the screws placed in tension. As the wood shrinks and the gate is opened and closed, the fasteners under tension tend to loosen and may eventually fail. 
         [0015]    As the hinge fasteners loosen, the entire gate assembly may sag relative to the hinge assemblies and thus the structural member, even if the gate box maintains its rectangular shape. The use of braces at the corners of the gate box will worsen sagging at the hinges because the materials and hardware used for bracing increase the weight of the gate; this increased weight increases the forces of gravity on the fasteners used to attach the hinge assemblies to the proximal vertical support member. 
         [0016]    The Applicant is aware of a product sold in Canada as early as approximately 1993 under the tradename “Artistic Steel Gate Frames”. The Artistic Steel Gate Frame product comprises distal and proximal brace members, with hinges being attached to the proximal brace member. A gate assembly constructed using the Artistic product would use upper and lower horizontal wooden support members, but would not use vertical support members. Instead, the distal and proximal brace members would form the structure of the vertical sides of the gate. Accordingly, the brace members of the Artistic product were sold in a plurality of sizes, with each size corresponding to a given distance between the upper and lower horizontal support members. 
         [0017]    One problem with the Artistic product is that this system requires the manufacturer to produce and keep in inventory, and the retailer to stock, multiple sizes of brace members. 
         [0018]    In addition, the end user is limited to one of these multiple sizes of brace members; one could not create a gate assembly having a custom distance between the upper and lower horizontal support members. 
         [0019]    From the foregoing, it should be clear that one object of the present invention is to create bracket systems and methods that are strong, that are easy and inexpensive to use, and which allow significant flexibility in the final design of the gate assembly. 
       SUMMARY OF THE INVENTION 
       [0020]    The present invention is a bracket system or method for forming gate assemblies. The bracket system comprises at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system of the present invention 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a perspective view of a gate frame system of the present invention comprising distal brace members and proximal brace assemblies; 
           [0022]      FIG. 2  is an exploded, front elevation view of a gate assembly incorporating the gate frame system of  FIG. 1 ; 
           [0023]      FIG. 3  is a partial cut-away, front elevation view of the gate assembly of  FIG. 2  attached to a fence post; 
           [0024]      FIG. 4  is a front elevation view of the distal brace member depicted in  FIG. 1 ; 
           [0025]      FIG. 5  is a side elevation view of the distal brace member depicted in  FIG. 1 ; 
           [0026]      FIG. 6  is a bottom plan view of the distal brace member depicted in  FIG. 1 ; 
           [0027]      FIG. 7  is a top plan view of the distal brace member depicted in  FIG. 1 ; 
           [0028]      FIG. 8  is a front elevation view of the proximal brace member depicted in  FIG. 1 ; 
           [0029]      FIG. 9  is a side elevation view of the proximal brace member depicted in  FIG. 1 ; 
           [0030]      FIG. 10  is a bottom plan view of the proximal brace member depicted in  FIG. 1 ; and 
           [0031]      FIG. 11  is a top plan view of the proximal brace member depicted in  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    Referring initially to  FIG. 1 , depicted therein is a gate bracket system  20  constructed in accordance with, and embodying, the principles of the present invention. Referring for a moment to  FIGS. 2 and 3 , the gate bracket system  20  is adapted to form a gate box  22  to be used as part of a gate assembly  24 ; the gate assembly  24  is in turn to be connected to a structural member such as a fence post  26  ( FIG. 3 ) of a larger structure such as a fence  28 . 
         [0033]    The exemplary gate assembly  24  comprises in addition to the bracket system  20  distal and proximal vertical support members  30  and  32 , upper and lower horizontal support members  34  and  36 , and a plurality of fence members  40 . The exemplary support members  30 - 36  are conventional wooden two-by-fours, but other materials and sizes may be used as the support members  30 - 36 . The exemplary fence members  40  are also conventionally made out of wood, but other materials and various sizes of any type of material may be used to form the fence members  40 . 
         [0034]    The support members  30 - 36  and fence members  40  do not form a part of the present invention. A description of the construction and operation of these members  30 - 40  is not necessary to describe how to make and use the present invention and is included herein simply to illustrate the environment in which the present invention operates. 
         [0035]    The fence post  26  is conventionally a wooden four-by-four, but other materials and sizes may be used to form the structural member to which the gate assembly  24  is rotatably attached. For example, rather than a fence post  26 , the structural member may be a wall of a structure. The fence post  26  and fence  28  also are or may be conventional and are not part of the present invention. As with the support and fence members  30 - 40  introduced above, a description of the construction and operation of the post  26  and fence  28  is not necessary to describe how to make and use the present invention. The fence post  26  and fence  28  are described herein simply to illustrate the environment in which the present invention operates. 
         [0036]    The gate bracket system  20  of the present invention comprises first and second distal brace members  50  and  52  and first and second brace assemblies  54  and  56 . The first brace assembly  54  in turn comprises a first proximal brace member  60  and a first hinge assembly  62 , while the second brace assembly comprises a second proximal brace member  64  and a second hinge assembly  66 . 
         [0037]    The exemplary brace members  50 ,  52 ,  60 , and  64  each comprise a horizontal portion  70 , a vertical portion  72 , and a brace portion  74 . An outer end  72   a  of the vertical portions  72  is rigidly connected to an attachment region  70   a  of the horizontal portions  70 . The exemplary brace portion  74  is preferably rigidly connected at an angle between bracing regions  70   b  and  72   b  of the horizontal and vertical portions  70  and  72 , respectively. 
         [0038]    The choice of materials and shapes of the materials are not essential to any particular implementation of the present invention. The primary requirements of the brace members  50 ,  52 ,  60 , and  64  are that these members each define a horizontal support surface  80  and a vertical support surface  82  such that these surfaces rigidly extend from each other at a right angle. In the exemplary system  20 , the horizontal support surfaces  80  are formed on the horizontal portions  70  and the vertical support surfaces  82  are formed on the vertical portions  72 . 
         [0039]    A plurality of fastener holes  90  are formed in the brace members  50 ,  52 ,  60 , and  64 ; the fastener holes  90  are adapted to allow fasteners  92  to attach, in a conventional manner, the brace members  50 ,  52 ,  60 , and  64  to the support members  30 - 36 . The fasteners  92  are preferably self-tapping screws but can be nails, bolts, or the like. The fasteners  92  are not part of the gate bracket system  20  of the present invention per se but, as will be described in further detail below, are used to combine the bracket system  20  with the support members  30 - 36  to form the gate assembly  24 . 
         [0040]    The exact number and location of the fastener holes  90  is not critical to any given implementation of the present invention. In a broadest form of the bracket system  20 , the fastener holes  90  can be formed anywhere along the horizontal portions  70  and vertical portions  72 . The only requirement for the number and spacing of these holes is that the fasteners  92  extend through these holes  90  and into the support members to rigidly secure the brace members to the support members. 
         [0041]    Given the foregoing general understanding of the present invention, the distal bracket members  50  and  52  and the proximal bracket assemblies  54  and  56  of the present invention will now be described in further detail with reference to  FIGS. 4-11 . 
         [0042]    The attachment and bracing regions  70   a  and  70   b  of the horizontal portions  70  of the exemplary bracket members  50 ,  52 ,  60 , and  64  are formed located generally as follows. 
         [0043]    The horizontal portions  70  have an outer end  70   c  and an inner end  70   d . The exemplary attachment regions  70   a  are located between approximately 15-30%, and preferably approximately 20%, of the distance between the horizontal portion ends  70   c  and  70   d  as measured from the outer ends  70   c . The bracing regions  70   b  are located between approximately 80-95%, and preferably approximately 88%, of the distance between the horizontal portion ends  70   c  and  70   d  as measured from the outer ends  70   c.    
         [0044]    The horizontal portions  70  further define spacing regions  70   e  (between the attachment regions  70   a  and the outer ends  70   c ), inner regions  70   f  (between the bracing regions  70   b  and the inner ends  70   d ), and intermediate regions  70   g  (between the attachment regions  70   a  and the bracing regions  70   b ). 
         [0045]    The length of the spacing regions  70   e  is determined such that the vertical support members  34  and  36  fit snugly between the vertical portions  72  and the outer ends  70   c . In the case of the proximal bracket assemblies  54  and  56 , the length of the spacing regions  70   e  allows the vertical support members  34  and  36  to fit snugly between the vertical portions  72  of the third and fourth bracket members  60  and  64  and the first and second hinge assemblies  62  and  66 , respectively. When, as is typical, two-by-four dimensional lumber is used to form the vertical support members, the length of the spacing regions  70   e  will be approximately 3½″, or slightly greater to allow for variations in the true dimensions of the lumber. 
         [0046]    The vertical portions  72  each comprise the outer ends  72   a  discussed above and an inner end  72   c . The bracing regions  72   b  are located approximately 85% of the distance between the horizontal portion ends  72   a  and  72   c  as measured from the outer ends  72   a . The vertical portions  72  thus each define a main region  72   d  between the outer end  72   a  and the bracing region  72   b  and an inner end region  72   e  between the bracing region  72   b  and the inner end  72   c.    
         [0047]    In the horizontal portions  70  of the exemplary brace members  50 ,  52 ,  60 , and  64 , first, second, and third fastener holes  90   a ,  90   b , and  90   c  are formed in the spacing regions  70   e , inner regions  70   f , and intermediate regions  70   g , respectively. The first, second, and third fastener holes are spaced approximately 15%, 46%, and 96%, respectively, of the distance between the horizontal portion ends  70   c  and  70   d  as measured from the outer ends  70   c.    
         [0048]    In the vertical portions  72  of the exemplary brace members  50 ,  52 ,  60 , and  64 , fourth and fifth fastener holes  90   d  and  90   e  are formed in the main region  72   d  and a sixth fastener hole  90   f  is formed in the inner end region  72   e . The fourth, fifth, and sixth fastener holes  90   d ,  90   e , and  90   f  are spaced approximately 15%, 46%, and 96% of the distance between the horizontal portion ends  72   a  and  72   c  as measured from the outer ends  72   a.    
         [0049]    The fastener holes  90  of the exemplary brace members  50 ,  52 ,  60 , and  64  are formed along a horizontal center line A of the horizontal portion  70  and a vertical center line B of the vertical portion  72 . 
         [0050]    The exemplary horizontal and vertical portions  70  and  72  are made of flat pieces of rigid metal, but other relatively rigid materials and shapes that function in a similar manner may be used. For ease of manufacturing, the exemplary horizontal and vertical portions  70  and  72  are identical in length, and the fastener holes  90  are formed at identical locations therein; only one part thus needs to be fabricated and stocked to form the exemplary brace members  50 ,  52 ,  60 , and  64 . 
         [0051]    The brace portion  74  is typically round or flat metal stock, but other shapes and materials may be used. For example, the brace portion  74  may be a triangular web of flat material that extends between the horizontal and vertical portions  70  and  72 . In this case, the entire brace member may be cast of metal or injection molded from plastic. If a triangular web or similar brace portion is used, it may be necessary to form the fastener holes  90  such that they are offset from the horizontal and vertical centerlines A and B. 
         [0052]    From the foregoing, it should be clear that the exemplary brace members  50 ,  52 ,  60 , and  64  are identical, which is preferred for manufacturing purposes. However, these brace members  50 ,  52 ,  60 , and  64  need not be identical to practice the present invention in its broadest form. 
         [0053]    The first and second hinge assemblies  54  and  56  are or may be conventional and will be described herein only to the extent necessary for a complete understanding of the present invention. 
         [0054]    As is conventional, the hinge assemblies  54  and  56  each comprise a gate plate  120  and a post plate  122 . These plates define hinge projections  124  that receive a hinge pin (not shown). The hinge pin allows the gate and post plates  120  and  122  to rotate relative to each other about a hinge axes C and D defined by the hinge assemblies  54  and  56 . 
         [0055]    The outer ends  70   c  of the horizontal portions  70  of the first and second brace members  60  and  64  are rigidly connected to the gate plates  120 . In particular, the horizontal center lines A of the horizontal portions  70  of these brace members  60  and  64  are tangential to circles centered about the hinge axes C and D, respectively. The vertical center lines B of the vertical portions of the brace members  60  and  64  are parallel to the hinge axes C and D, respectively. 
         [0056]    An array of fastener holes  90  is formed in the post plate  122  to allow this plate to be rigidly attached to the fence post  26 . Preferably four fastener holes  90  are formed in the post plate  122 . The drawing depicts fastener holes  90  in the gate plate  120 ; these holes  90  in the plate  120  need not be used, but will be present if off-the-shelf hinge assemblies  62  and  66  are used. 
         [0057]    The process of combining the bracket system  20  with the support members  30 - 36  to form the gate box  22  will now be described with reference to  FIG. 2 . 
         [0058]    Initially, as is conventional, the support members  30 - 36  are cut to the desired lengths. The length vertical support members  30  and  32  generally correspond to the height of the gate assembly  24 , while the length of the horizontal support members  34  and  36  closely correspond to the width of the gate assembly  24 . The minimum lengths of the support members  30 - 36  are determined by the horizontal portions  70  and vertical portions  72  of the brace members  50 ,  52 ,  60 , and  64 ; in particular, the support members  30 - 36  must be at least twice as long as the lengths of the horizontal and vertical portions  70  and  72  to prevent overlapping of the horizontal portions  70  or vertical portions  72  of adjacent brace members. 
         [0059]    The first and second distal brace members  50  and  52  and first and second brace assemblies  54  and  56  are arranged such that: (a) horizontal and vertical support surfaces  80   a  and  82   a  of the first distal brace member  50  define first and second support surfaces of the bracket system  20 ; (b) horizontal and vertical support surfaces  80   b  and  82   b  of the second distal brace member  50  define third and fourth support surfaces of the bracket system  20 ; (c) horizontal and vertical support surfaces  80   c  and  82   c  of the first proximal brace member  60  define third and fourth support surfaces of the bracket system  20 ; and (d) horizontal and vertical support surfaces  80   d  and  82   d  of the second proximal brace member  54  define third and fourth support surfaces of the bracket system  20 . 
         [0060]    The fasteners  92  are then inserted through the fastener holes  90  of the brace members  50 ,  52 ,  60 , and  64  and into the support members  30 - 36  to form the gate box  22 . In particular, fasteners  92  are driven through the holes  90  and into the support members  30 - 36  such that: (a) the upper horizontal support member  30  is drawn tight against the first and fifth support surfaces defined by the first distal brace member  50  and second proximal brace member  60 ; (b) the lower horizontal support member  32  is drawn tight against the second and sixth support surfaces defined by the second distal brace member  52  and fourth proximal brace member  64 ; (c) the distal vertical support member  34  is drawn tight against the third and fourth support surfaces defined by the first and second distal brace members  50  and  52 ; and (d) the proximal vertical support member  36  is drawn tight against the seventh and eight support surfaces defined by the first and second proximal brace members  60  and  64 . 
         [0061]    The exact order of the attachments described in the preceding paragraph is not critical to the present invention in its broadest form. However, with the brace members  50 ,  52 ,  60 , and  64  described herein, fasteners  92  are preferably driven through at least the first fastener holes  90   a  formed in the spacing regions  70   e  of the horizontal portions  70  before fasteners  92  are driven through the fastener fourth, fifth, or sixth fastener holes  90   d - e  of the vertical portions  72 . Otherwise, the vertical support members  34  and  36  may block access to the first fastener holes  90   a . Preferably, fasteners  92  are driven through the first through third fastener holes  90   a - c  before fasteners are driven through the fifth through sixth fastener holes  90   d - e.    
         [0062]    With the gate box  22  formed as described above, the hinge axes C and D will be substantially aligned. The gate box  22  so formed may thus then be attached to the fence post  26  by fasteners  92  extending through the fastener holes  90  in the post plate  122  and into the post  26 . When the post plates  122  are rigidly connected to the post  26 , the gate box  22  pivots relative to the fence post  26  about the hinge axes C and D. 
         [0063]    The gate assembly  24  may be formed before or after the gate box  22  is attached to the fence post  26  by attaching the fence members  40  to at least one, and preferably at least two, of the support members  30 - 36  of the gate box  22 . 
         [0064]    Given the foregoing, it should be clear that the present invention may be embodied in forms other than those depicted and described herein. The scope of the present invention should thus be determined by the claims appended hereto and not the preceding detailed description of the preferred embodiment.