Abstract:
A fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and one or more pivoting, sliding connectors for connecting a picket to a rail, with the sliding, pivotal connection concealed by the rail. The connector is slidably mounted to the rail and is pivotally connected to the picket. In one embodiment, an elongated connector strip is concealed by the rail and spans multiple pickets. In another embodiment, the assembly includes a plurality of shorter connectors, one for each picket/rail connection.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 12/702,887, filed Feb. 9, 2010, which claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/151,122, filed Feb. 9, 2009, the entire scope and content of which are hereby incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention in general relates to fencing and railing systems, and in particular relates to connectors for fencing and railing systems. 
       SUMMARY 
       [0003]    Briefly described, in a first example embodiment the present invention relates to a fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and a connection between the pickets and the rails. The picket/rail connection is slidably mounted to the rail and pivotally connected to the picket to permit a sliding, pivotal motion. The sliding, pivotal connection allows the pickets to be oriented at greater angles relative to the rails (i.e., it allows the assembly to rack to a greater degree, thereby allowing the fencing/raining to follow more steeply changing terrain or contours). 
         [0004]    In one preferred form, the fencing/railing assembly includes one or more elongated connector strips that are each concealed by the rail and that each span a corresponding set of multiple adjacent pickets. In another preferred form, the fencing/railing assembly includes a plurality of shorter connectors, one for each picket/rail connection. 
         [0005]    The connectors, be they shorter individual-picket connectors or longer multi-picket connector strips, can include small projections (e.g., bosses) that extend from one surface thereof and engage holes (e.g., recesses) formed in the pickets. Advantageously, this provides a fastener-less but still pivotal connection. Preferably, the rails each have an inner profile that is sized and shaped to slidably retain or capture the connector between the rail and the picket, while permitting the connector strip to slide relative to the rail and be concealed by the rail during normal use. For example, the rail can have an inwardly extending shelf or ledge that slidingly supports the connector strip so that the connector strip slides atop the shelf. 
         [0006]    The fencing/railing assembly, including the pickets, the rails, and the concealed connectors, can be made of extruded aluminum, plastic, or other materials. Also, the rails can be generally U-shaped and have picket openings formed in one portion thereof for receiving the pickets therethrough. Optionally, a leading, inner edge of the railing may be beveled or eased to facilitate slipping the rail over the connector during assembly. 
         [0007]    In another aspect, the present invention relates to a pre-assembled fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes the same components as those described above. But these components are pre-assembled at a factory or other assembling facility. And the assembly is shipped in this pre-assembled state, ready for installation, so this part of the assembly process is not done on-site in the field. 
         [0008]    In yet another aspect, the present invention relates to a method of manufacturing a fencing/railing assembly to be positioned between a pair of posts and mounted thereto. One such example method includes the steps of: (a) providing a series of pickets each with one or more connector holes formed therein; (b) providing a connector strip with a series of connector bosses formed on at least one side thereof; (c) attaching the connector strip to the series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets; (d) providing an at least three-sided rail (e.g., a generally U-shaped rail) with picket openings formed in an upper portion thereof; and (e) slipping the rail over the pickets and over the connector strip to secure the connector strip in place and conceal the connector strip. 
         [0009]    These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a front elevation view of a fencing/railing assembly according to a first example embodiment of the present invention. 
           [0011]      FIG. 2  is a side view of the fencing/railing assembly of  FIG. 1 . 
           [0012]      FIG. 3  is a side sectional view of a portion of the fencing/railing assembly taken at line  3 - 3  of  FIG. 1 . 
           [0013]      FIG. 4  shows the left portion of the fencing/railing assembly of  FIG. 3 , with hidden features shown in phantom lines. 
           [0014]      FIG. 5  is a perspective, exploded view of the fencing/railing assembly of  FIG. 1 , depicting the fencing/railing assembly being assembled. 
           [0015]      FIGS. 6A-6E  are front, top, back, side, and perspective views of a connector strip of the fencing/railing assembly of  FIG. 1 . 
           [0016]      FIGS. 7A-7B  are schematic illustrations depicting the range of movement of a prior art picket-and-rail arrangement. 
           [0017]      FIGS. 7C-7D  are schematic illustrations depicting the range of movement of a picket-and-rail arrangement of the fencing/railing assembly of  FIG. 1 . 
           [0018]      FIG. 8  is a perspective view of a connector of a fencing/railing assembly according to a second example embodiment of the invention. 
           [0019]      FIGS. 9-12  are plan, side, bottom, and perspective views of a connector boss strip of a fencing/railing assembly according to a third example embodiment of the invention. 
           [0020]      FIG. 13  is a side view of a boss of the connector boss strip of  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The present invention may be understood more readily by reference to the following detailed description taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein. 
         [0022]    Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. 
         [0023]    Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views,  FIGS. 1-6E  and  7 C- 7 D show a fencing and/or railing assembly  10  according to a first example embodiment of the present invention. The railing assembly  10  is typically used to enclose yard spaces, decks, porches and the like. 
         [0024]    Generally, the railing assembly  10  comprises a plurality of horizontally spaced pickets  20  and at least one support rail  30 . The pickets  20  are typically arranged generally vertically with the rail  30  transverse to them. In the depicted embodiment, the railing assembly comprises three 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  40  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 example embodiments, the pickets  20  and railing  30  are formed from extruded aluminum, however, in alternative embodiments, the pickets and railing can be formed from solid aluminum, other metals and/or metal alloys, wood, rubber, plastic, and/or other materials known in the art. In example embodiments, the pickets  20  are hollow, square aluminum extrusions and the railings  30  roughly rectangular (but U-shaped) aluminum extrusions; however, in alternative embodiments, the pickets and railing can be formed in different shapes. 
         [0025]    As seen in  FIGS. 3 and 4 , the rails  30  can have a substantially “U” shaped cross-section and, in use, are generally 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-section shapes as desired. The top wall of the rail  30  includes a series of horizontally spaced picket openings  39  through which the pickets extend. In depicted example embodiments the rail  30  is shown having a decorative bulge  38  on the exterior surface of the rail, however, in alternative example embodiments other exterior shapes can be utilized as desired. 
         [0026]    As shown in  FIGS. 3 and 4 , the rails  30  include at least one concealed ledge or shelf  32  for supporting a connector or boss strip  34  (or alternatively referred to as a dimpled strip) thereon. The shelf or shelves  32  extend inwardly from the inner surface of one or both sidewalls of the rail  30 . Optionally, the lower leading edges of the shelf  32  (or another portion of the rail  30 ) can be chamfered, ramped, or beveled to facilitate a slight outward deflection and smooth movement over the boss strip  34  during assembly. Once in place, the boss strip  34  is securely held there by the shelf  32  with the boss strip supported by the shelf and secured in place between the shelf and the top wall of the rail  30 . The boss strip  34  is captured between the corresponding sidewall of the rail  30  and the picket  20  but permitted to slide horizontally between the two and along the rail atop the shelf  32 . Additionally, the connector strip  34  can be made of a metal, plastic, or any other suitable material. 
         [0027]    In addition, the boss strip  34  includes at least one inwardly extending boss (e.g., a nub, pin, or other protruding structure)  36  that is received in a pivot or connector hole  22  (e.g., a recess or through-hole) in one of the pickets  20  for rotatably coupling the boss strip to that picket (as will be described in greater detail below with reference to  FIGS. 7C-7D ). In an alternative embodiment, the boss/nub extends outward from the picket and the pivot hole is formed in the connector strip (this is an “opposite” or “vice versa” arrangement of that described above). In another alternative embodiment, aligning pivot holes are formed in the connector strip and the picket, a pivot pin is provided, and the two ends of the pivot pin are inserted into the two pivot holes. In yet another alternative embodiment, the pivot hole is horizontally slotted to provide for additional sliding motion. 
         [0028]    And in still another alternative embodiment, the connector/boss strip is eliminated, the pickets each include at least one horizontally slotted connector hole, and the rails each include at least one inwardly extending boss that is received into the slotted connector hole. In this embodiment, the pickets pivot about the boss and the boss slides along the slotted connector hole such that the rail/boss and picket slide too. The opposite or vice versa arrangement can alternatively be provided, with the boss on the pickets and the slots in the pickets. As no connector strips are provided, and the strips in the above-described embodiments provide structural support for the overall fence/railing assembly, the rails and/or pickets of this embodiment are designed with relatively greater strength (e.g., a stronger material and/or thicker walls). 
         [0029]    Thus, the railings  30  each have an inner profile that is sized and shaped to retain the connector or boss strip  34  between the rail and the picket while permitting it to slide and pivot relative to the pickets. With this construction, a sliding, pivoting connection is obtained and also concealed. The connection is also achieved without the use of any threaded fasteners. 
         [0030]    In use, the railing assembly  10  can be assembled as partially demonstrated in  FIG. 5 . For example, the plurality of pickets  20  are first inserted into and extended through the picket openings  39  of the rails  30 . Next, the connector or boss strips  34  (better seen and understood by viewing  FIGS. 6A-6E ) are coupled to pickets  20  by inserting the bosses/nubs  36  into the corresponding holes  22  formed in the pickets. Finally, the rails  30  are lowered (from the depicted positions of  FIG. 5 ) vertically along the pickets  20  and over the boss strips  34 , where they are snapped into place by forcing each rail ledge or shelf  32  over the boss strip, for example, by the beveled or ramped leading edge riding over the strip and deflecting slightly thereby. 
         [0031]    As shown in  FIG. 5 , multiple connector boss strips  34  can be used with each rail in the railing assembly  10 , with each boss strip being long enough that it is coupled to a set of multiple of the pickets  20 . The set of pickets can include all of the pickets  20  in a fence/rail section (between posts) or only some of them. In the typical commercial embodiment depicted, each boss strip is long enough that it is coupled to approximately five pickets  20 , and thus it has five bosses/nubs  36 . This coordinates together the pivoting of all of the pickets  20  engaged by a connector strip  34  (those in the picket set) relative to the rail  30  and that connector strip  34 . For example, if a connector strip  34  were to be in engagement with five pickets  20 , movement of a single picket amongst the five pickets would result in the other four pickets moving in synchronization with the single picket that is originally moved. In addition, by spanning multiple pickets  20 , the connector strips  34  provide structural support for the overall fence/rail assembly  10 , so the pickets and/or rails  30  can be designed to provide less overall structural strength (e.g., with thinner walls and/or less-strong materials). 
         [0032]    In alternative embodiments, longer or shorter boss strips  34  can be utilized as desired, such that each boss strip can accommodate less than five pickets or more than five pickets. In still other alternative embodiments, a relatively short, single boss strip or connector is used for each picket/rail connection. As seen in  FIG. 8 , for example, a short boss or connector strip  134  according to a second example embodiment is so short that it doesn&#39;t span from one picket to another and it only includes a single boss/nub  136 . 
         [0033]    In manufacturing the product, a simplified technique or method is accomplished. In an example method, a pre-assembled section of fencing/railing assembly is constructed and shipped for sale. This allows the sections to be assembled under factory conditions, rather than under field conditions, for maximum efficiency and quality control. The pre-assembled fencing/railing assembly includes a length of fencing/railing ready to be installed between a pair of posts or uprights. Thus, the user would install the pre-assembled section of fencing/railing between the posts in the field. 
         [0034]    The manufacturing method for constructing the pre-assembled section can include the steps of: 
         [0035]    (a) providing a series of pickets with connector holes formed therein; 
         [0036]    (b) providing at least one connector strip with one or a series of connector bosses formed on at least one side thereof; 
         [0037]    (c) attaching the connector strip to the one or series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets; 
         [0038]    (d) providing a rail with picket openings formed in an upper portion thereof and with at least one shelf formed on an inner surface thereof; and 
         [0039]    (e) slipping the rail over the pickets (with the pickets extending through the picket openings) and over the connector strip to secure the connector strip in place on the shelf and conceal the connector strip. 
         [0000]    This manufacturing method allows for easy and economical manufacture, as well as providing a consistently good manufacturing quality. Also, when the pre-assembled section of fencing/railing is assembled, the connector strip is not readily visible (it is concealed by the rail). 
         [0040]    In addition to concealing the connection and being readily pre-assembled in a factory for later field-installation by a user, a fencing/railing assembly according to the present invention also adjusts to follow rising or falling terrain better than known fencing/railing. As demonstrated by comparing a known prior art railing assembly ( FIGS. 7A-7B ) to the present invention ( FIGS. 7C-7D ), it can be seen that the present invention is better able to pivot the pickets relative to the rails in comparison to known railing assemblies. For instance, known railing assemblies incorporate screws S and/or bolts to rotatably couple pickets P to rails R, as shown in  FIGS. 7A-7B . Such couplings are time consuming to install and only allow for a limited range of rotation and little if any horizontal movement. In fact, the known railing assembly of  FIGS. 7A-7B  only allows the pickets to rotate about 15 degrees in either direction before being obstructed by the edge of the picket opening. 
         [0041]    In stark contrast, the present invention utilizes a sliding pivotal connection between the pickets  20  and the rails  30  that is very easy and fast to install and allows for limited horizontal movement of the pickets  20  along the rails  30 . In particular, the connector boss strip  34  slides within the rail  30  in the transverse directions denoted by the arrows X when the pickets  20  are pivoted in the angular directions denoted by the arrows Y, thereby allowing the pivot point between the connector hole  22  of the picket and the rail to slide one way or the other, as shown in  FIGS. 7C-7D . Because of this, the picket  20  is afforded a higher degree of rotation within the picket openings  39  of the rail, while the pickets and picket openings are the same size as in prior art systems. In typical commercial embodiments, utilizing the present invention permits the pickets  20  to rotate about the boss  36  at least 36 degrees (as compared to the known railing assembly&#39;s typical rotational limit of about 15 degrees), using a similar opening gap between the picket and the edge of the picket opening in the railing—the additional freedom of motion is not due to simply making the opening larger. The amount of rotation depicted in  FIGS. 7C-7D  is meant to be exemplary of the capabilities of the present invention and is in no way meant to limit the scope of the present invention. 
         [0042]    The above-described embodiments can be provided pre-assembled, with the cost of the materials and assembly being about the same as the prior art systems unassembled. Alternatively, the above-described embodiments can be provided unassembled and assembled on-site in the field during installation. 
         [0043]      FIGS. 9-13  show a connector or boss strip  234  of a fence/rail assembly according to a third example embodiment of the invention. The connector boss strip  234  can be used in fence/rail assemblies that are pre-assembled or field-assembled. In this embodiment, the connector boss strip  234  includes bosses  236  with ribs  250  that better secure the bosses into the connector holes of the pickets. This is particularly beneficial when used in fence/rail assemblies that are field-assembled. In addition, the connector boss strip  234  includes internal openings  252  that reduce the amount of material used without reducing the structural integrity of the connector strips. It will be understood that the dimensions shows in  FIGS. 9-13  are representative of typical commercial embodiments and are not limiting of the invention; the connector boss strip  234  can be provided with other dimension ins larger or smaller sizes. 
         [0044]    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.