FENCE GATE ASSEMBLY, FENCE GATE KIT, SYSTEM AND METHODS OF MANUFACTURING THEREOF

BACKGROUND

Fences and fence gates typically are installed in outdoor areas, such as lawns, yards, gardens, outdoor decks, and so forth. A fence or a fence gate includes one or more posts fixed to the ground, an upright coupled to each post, and rails coupled to the upright.

Conventionally, the rails are coupled to the upright by external coupling mechanisms, for example, external fasteners or brackets. However, external coupling mechanisms are visible after assembly of the fence gate or fence, and therefore may be aesthetically unappealing.

Further, manufacturers typically provide fence gate kits that include various components that have to be assembled on-site by a customer. Assembling individual components with each other, including coupling the uprights with the rails, may be a time consuming and complex task, especially for an unskilled customer. For example, the customer may have to install multiple fasteners, brackets, and so forth, in order to couple the uprights with the rails. The assembly process also may require usage of various tools that may be unavailable to the customer or difficult to operate. Customers inexperienced with installing fences, misuse of tools, intentional unauthorized shortcuts, and other human errors when installing fences may leave persons susceptible to accidents.

Thus, there is a need for a fence gate system and method of assembly that minimizes use of tools, enhances safety, and does not require specialized skills. Such a system and method may facilitate efficient on-site assembly of fence gates or fences. There is also a need for a fence gate system that is aesthetically pleasing by reducing a use of visible external coupling mechanisms.

SUMMARY

Embodiments of the invention generally are directed to a fence gate assembly and methods of assembling the fence gate assembly. More particularly, embodiments of the invention are directed to a fence gate kit, an insert of the fence gate kit, a fence gate system, methods of assembling the fence gate kit, and methods of manufacturing the fence gate kit.

Embodiments disclosed herein relate to an insert for coupling an upright with a rail of a gate, a fence, and the like. More specifically, the embodiments disclosed herein relate to an insert coupled within the upright and which couples the upright with the rail of a fence gate. The insert is pre-installed within the upright so that an on-site assembly process of the fence gate may be simplified and be safer. Moreover, since the insert is installed within the upright, the fence gate, in an assembled state, may be more aesthetically pleasing.

Embodiments in accordance with the present invention are directed to a fence gate assembly. The assembly may include an upright including a first wall, a second wall opposite to the first wall, a third wall extending between the first and the second wall, and a fourth wall spaced from the third wall and extending between the first wall and the second wall, wherein the first wall, the second wall, the third wall, and the fourth wall create a longitudinal opening. The assembly also may include an insert received within the longitudinal opening of the upright and coupled to the upright via an adhesive. Further, the insert may include a rear wall abutting the second wall of the upright in the coupled state of the insert and a pair of side walls extending from the rear wall, wherein the rear wall and the pair of side walls at least partly form a cavity. The insert may further include a support portion extending from the rear wall and disposed between the pair of side walls. The assembly also may include a rail coupled to the insert and extending at least partially within the cavity of the insert.

Embodiments in accordance with the present invention further provide a method of manufacturing a fence gate kit that may be assembled into a fence gate. The method may include providing an upright including a first wall, a second wall opposite to the first wall to form a lateral opening, a third wall extending between the first and second wall, and a fourth wall spaced from the third wall and extending between the first wall and the second wall, wherein the first wall, the second wall, the third wall, and the fourth wall form a longitudinal opening. The method also may include sliding an insert within the longitudinal opening of the upright, the insert including a rear wall, a pair of side walls extending from the rear wall, and a support portion extending from the rear wall and disposed between the pair of side walls, wherein the rear wall and the side walls at least partly form a cavity. The method may further include coupling the insert to the upright via an adhesive and inserting a rail through the lateral opening and at least partly received within the cavity of the insert, the rail comprising a channel slideably received on the support portion of the insert.

Embodiments in accordance with the present invention further provide a fence gate system. The system may include a post extending from a ground surface; a hinge coupled to the post; and an upright coupled to the hinge, wherein the upright includes a first wall having a lateral opening, a second wall opposite to the first wall, a third wall extending between the first and second wall, and a fourth wall spaced from the third wall and extending between the first wall and the second wall, wherein the first wall, the second wall, the third wall, and the fourth wall form a longitudinal opening. The system also may include an insert received within the longitudinal opening of the upright and coupled to the upright via an adhesive, the insert including a rear wall abutting the second wall of the upright in the coupled state of the insert; a pair of side walls extending from the rear wall, wherein the pair of side walls and the rear wall at least partly form a cavity; and a support portion extending from the rear wall and disposed between the pair of side walls. The system also may include a rail inserted through the lateral opening and at least partially received within the cavity of the insert, the rail further comprising a channel to receive at least partially the support portion therein, wherein the rail is coupled to the insert. The system may further include multiple balusters slideably received with the channel of the rail and a cap configured to close the longitudinal opening of the upright.

Embodiments of the present invention may provide a fence gate assembly and system, a fence gate kit, a method of manufacturing the fence gate kit, and methods for assembling the fence gate that simplify an on-site assembly of the fence gate, enhance safety during assembly, and improve aesthetic appeal of the fence gate in the assembled state.

Embodiments of the present invention may provide a racked fence gate assembly and system and a racked fence gate kit that provides for simplified on-site assembly of a racked fence gate, enhances safety during assembly, and improves aesthetic appeal of the racked fence gate in the assembled state.

These and other advantages will be apparent from the present application of the embodiments described herein.

The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the embodiments disclosed herein are best understood from the following detailed description when read in connection with the accompanying drawings. For the purpose of illustrating the embodiments disclosed herein, there are shown in the drawings embodiments that presently are preferred, it being understood, however, that the embodiments disclosed herein are not limited to the specific instrumentalities disclosed. Included in the drawings are the following figures:

FIG. 1 is a side view of a fence gate system, according to embodiments disclosed herein;

FIG. 2A is a sectional view of a portion of the fence gate system taken at line A-A′ of FIG. 1 with a cap removed;

FIG. 2B is a detailed sectional view of the portion of the fence gate system of FIG. 2A;

FIG. 3 is a top view of an upright of the fence gate system of FIG. 1 with the cap removed, according to embodiments disclosed herein;

FIG. 4 is a detailed sectional view of a portion of the fence gate system of FIG. 1;

FIG. 5A illustrates a top view of an upright of the fence gate system, according to embodiments disclosed herein;

FIG. 5B illustrates a front view of the upright of FIG. 5A;

FIG. 6A is a front view of a rail member of the fence gate system, according to embodiments disclosed herein;

FIG. 6B is a side view of the rail member depicted in FIG. 6A;

FIGS. 7A to 7C illustrate various views of an insert of the fence gate system, according to embodiments disclosed herein;

FIGS. 8A to 8C illustrate various views of an insert of the fence gate system, according to embodiments disclosed herein;

FIGS. 9A to 9C illustrate various views of an insert of the fence gate system, according to embodiments disclosed herein;

FIGS. 10A to 10C illustrate various views of an insert of the fence gate system, according to embodiments disclosed herein;

FIG. 11 illustrates a method of manufacturing a fence gate kit, according to embodiments disclosed herein;

FIG. 12A shows a fence installed on sloping ground with a non-racked fence gate;

FIG. 12B shows a fence installed on sloping ground with a racked fence gate;

FIG. 12C shows a fence installed on sloping ground with a partially racked fence gate;

FIG. 13 is a side view of a racked fence gate system, according to embodiments disclosed herein;

FIG. 14A shows sectional views of the proximal and distal ends of a rail as inserted into proximal and distal uprights of the racked fence gate system of FIG. 13;

FIGS. 14B and 14C are respective enlarged detailed sectional views of the proximal and distal ends of the top rail as inserted into proximal and distal uprights of the racked fence gate system of FIG. 13;

FIG. 15A shows trimmable areas of the proximal and distal ends of a rail prior to trimming and assembly to the respective proximal and distal uprights of the racked fence gate system of FIG. 13;

FIGS. 15B and 15C are respective enlarged detailed views of the proximal and distal ends of a rail after trimming and prior to assembly to the respective proximal and distal uprights of the racked fence gate system of FIG. 13;

FIGS. 16A and 16B show respective templates that may be utilized to assist trimming of the proximal and distal ends of a rail prior to assembly to the respective proximal and distal uprights of the racked fence gate system of FIG. 13; and

FIG. 17 illustrates a method of manufacturing a racked fence gate kit, according to embodiments disclosed herein.

While embodiments of the present invention are described herein by way of example using several illustrative drawings, embodiments of the invention are not limited to the embodiments or drawings described. The drawings and the detailed description thereto are not intended to limit the present invention to the particular form disclosed, but also encompass all modifications, equivalents, and alternatives falling within the spirit and scope of embodiments of the present invention as recited by the claims.

The headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C”; “at least one of A, B, or C”; “one or more of A, B, and C”; “one or more of A, B, or C”; and “A, B, and/or C” means A alone; B alone; C alone; A and B together; A and C together; B and C together; or A, B, and C together.

The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, and “having” also may be used interchangeably.

FIG. 1 illustrates a side view of a fence gate system 100, according to an embodiment of the present disclosure. Fence gate system 100 may be installed in any outdoor region, including, but not limited to, yards, lawns, gardens, outdoor decks, porches, and the like.

Fence gate system 100 includes a post 102, a pair of hinges 104, a pair of uprights 106, a pair of rails 108, a pair of caps 110, and a plurality of balusters 112. As illustrated in FIG. 1, post 102 extends from a ground surface ‘S’. Post 102 may be embedded partially within the ground such that post 102 is substantially stationary with respect to ground surface ‘S’. Post 102 may be a hollow or solid elongated structure having any suitable cross-section, for example, but not limited to, rectangular, square, polygonal, oval, circular, elliptical, and so forth. Post 102 also may have ribs (not shown) to impart rigidity to the hollow elongated structure.

The pair of hinges 104 pivotally connect post 102 to adjacent upright 106. One hinge of the pair of hinges 104 is positioned proximate to a top end of post 102, while the other hinge 104 is positioned distal to the top end of post 102. A first part 104a of each of hinges 104 is connected to post 102, while a second part 104b of each of hinges 104 is connected to upright 106. Further, first part 104a and second part 104b are connected pivotally to each other. Therefore, hinges 104 may allow pivotal movement of upright 106 with respect to post 102. Hinges 104 may be connected to post 102 and upright 106 via various methods, such as mechanical fasteners, adhesives, or a combination thereof.

Each of uprights 106 may have a hollow elongated structure having a longitudinal axis ‘L’. Further, each of uprights 106 has a top end 114 and a bottom end 116. A top longitudinal opening (not shown in FIG. 1) of each of uprights 106 is closed by cap 110. Further, the pair of rails 108 is disposed between the pair of uprights 106. Rails 108 extend along a transverse axis ‘T’, which is substantially perpendicular to longitudinal axis ‘L’. One rail of the pair of rails 108 is located proximate to top end 114 of each of uprights 106, while the other rail 108 is located proximate to bottom end 116 of each of uprights 106. Rails 108 may be coupled to uprights 106 via inserts (not shown in FIG. 1).

Balusters 112 are connected to and disposed between rails 108. In various embodiments, one or more U-channels (not shown) also may be located adjacent to uprights 106 in order to retain balusters 112 between uprights 106. Although columnar balusters are illustrated, a variety of shapes are usable for balusters 112. Each of balusters 112 may have substantially flat hollow structures. Balusters 112 may abut each other, or a clearance may exist between them.

Hinges 104, uprights 106, rails 108, caps 110, and balusters 112 may form a fence gate assembly 118 that is pivotally coupled to post 102. The components of fence gate assembly 118 may be part of a fence gate kit that is assembled on-site and coupled to post 102. Alternatively, post 102 may also be part of the fence gate kit.

Fence gate system 100 and fence gate assembly 118, as described above, are purely exemplary in nature, and various alternatives may be envisioned within the scope of the disclosure. For example, fence gate system 100 may have three rails 108, three hinges 104, and a plurality of balusters 112.

FIG. 2A is a sectional view of upright 106 of fence gate system 100 with cap 110 (shown in FIG. 1) removed. Upright 106 of FIG. 2A is located adjacent to post 102 (shown in FIG. 1). However, various internal components, as shown in FIG. 2A, may be common to both uprights 106. As illustrated in FIG. 2A, two inserts 202 are coupled to upright 106 in order to secure corresponding rails 108 to upright 106. One of inserts 202 is located proximate to top end 114 of upright 106, while the other insert 202 is located proximate to bottom end 116 of upright 106. In an exemplary embodiment, fence gate assembly 118 may be provided with two inserts 202 positioned at top end 114 and bottom end 116 of upright 106. However, a number and positions of inserts 202 may vary as required by the size of the installed fencing.

FIG. 2B is a detailed view of a region ‘C’ of FIG. 2A. FIG. 3 is a top view of upright 106 with cap 110 removed. FIG. 4 is a detailed sectional view of fence gate system 100. FIGS. 5A and 5B are top and front views, respectively, of upright 106. Referring to FIGS. 2B, 3, 4, 5A, and 5B, upright 106 includes a first wall 204, a second wall 206 opposite to first wall 204, a third wall 207 extending between first wall 204 and second wall 206, and a fourth wall 208 spaced from third wall 207 and extending between first wall 204 and second wall 206. In the illustrated embodiment, third and fourth walls 207 and 208 are substantially parallel to each other. First second, third, and fourth walls 204, 206, 207, and 208 may have substantially any shape to provide a suitable cross-section to upright 106. For example, first, second, third, and fourth walls 204, 206, 207, and 208 may be curvilinear, rectangular, and so forth. Upright 106 also may have any cross-section, for example, but not limited to, rectangular, square, polygonal, oval, circular, elliptical, and so forth. In the illustrated embodiment, upright 106 has a width ‘Wu’ and a length ‘Lu’. Further, upright 106 may have stiffening ribs (not shown) that impart structural strength.

First wall 204 may include a groove 209 that receives one of the U-channels or a portion of balusters 112 in order to form a mechanical joint. First wall 204 further includes a pair of lateral openings 210. One of lateral openings 210 is proximate to top end 114 of upright 106 and receives one of rails 108, while the other lateral opening 210 is proximate to bottom end 116 of upright 106 and receives the other rail 108.

In an embodiment, lateral openings 210 may be substantially parallel to transverse axis ‘T’. Each of lateral openings 210 may be rectangular, oval, elliptical, circular, and so forth. Further, lateral openings 210 may have chamfered or filleted edges. In the illustrated embodiment, each of lateral openings 210 are substantially rectangular with a width ‘Wo’ and a length ‘Lo’.

The first, second, third, and fourth walls 204, 206, 207, and 208 include a longitudinal opening 211 at each of top and bottom ends 114 and 116 of the upright. In an embodiment, longitudinal openings 211 may extend along longitudinal axis ‘L’. Further, longitudinal opening 211 may extend from top end 114 to bottom end 116 of upright 106. Each of longitudinal openings 211 receives insert 202. Further, first wall 204, second wall 206, third wall 207, and fourth wall 208 may include an end surface 213 at each of top end 114 and bottom end 116 of upright 106.

Insert 202 includes a rear wall 212, a pair of side walls 214 extending from rear wall 212, a top wall 216 extending from rear wall 212 and a bottom wall 218 opposite to top wall 216. Therefore, a front end of insert 202 is open to enable insertion of rail 108. Rear wall 212, side walls 214, top wall 216, and bottom wall 218 together form a cavity 220 (shown in FIG. 7C) to at least partly receive corresponding rail 108 therein. Each of top wall 216 and bottom wall 218 may include a groove 221 similar in shape to groove 209 of upright 106. Further, top and bottom walls 216 and 218 may have a width ‘Wi’ and a length ‘Li’ such that insert 202, in the coupled state, may be located entirely within upright 106. Bottom wall 218 also may support rail 108 thereon. Therefore, width ‘Wi’ and length ‘Li’ may be lesser than or equal to width ‘Wu’ and length ‘Lu’, respectively, of upright 106. Further, such dimensions of insert 202 also enable insertion of insert 202 through longitudinal opening 211 of upright 106.

Side walls 214 of insert 202 include multiple internal protrusions 222 that are regularly spaced and engage with rail 108 to secure rail 108 to insert 202. Though internal protrusions 222 illustrated in FIG. 2B have a rectangular shape, internal protrusions 222 may have any other alternative shape, such as polygonal, oval, and the like. An adhesive may be applied, resulting in an adhesive joint between insert 202 and upright 106.

Insert 202 further includes a support portion 224 extending from rear wall 212. Support portion 224 may have a hollow elongated structure having a suitable cross-section that may be received within a channel 226 of rail 108. Channel 226 may extend along a length of rail 108 (i.e., along the transverse axis ‘T’) and slideably receive balusters 112 therein. Support portion 224 may guide rail 108 during insertion into insert 202, and at least reduce any lateral movement of rail 108.

In some other embodiments, mechanical fasteners 228 couple insert 202 to rail 108. Mechanical fasteners 228 may be screws, bolts, and the like. Mechanical fasteners 228 may extend from top wall 216 of insert 202, through rail 108 and into support portion 224. In another embodiment, mechanical fasteners 228 also may extend through bottom wall 218 of insert 202. In the illustrated embodiment, mechanical fasteners 228 extend substantially parallel to longitudinal axis ‘L’. Mechanical fasteners 228 may be installed after insertion of rail 108 into insert 202. Though two such mechanical fasteners 228 are illustrated in FIGS. 3 and 4, any number of mechanical fasteners 228 may be used.

As illustrated in FIG. 4, rear wall 212 of insert 202 may abut second wall 206 of upright 106 in the coupled state. In an embodiment, insert 202 may be fixedly coupled to upright 106 via an adhesive. Rear wall 212 may include recesses (not shown) that may facilitate application of adhesive and subsequent bonding with second wall 206 of upright 106. The adhesive may be, but is not restricted to, PVC glue or PVC cement. The adhesive may be applied on second wall 206, third wall 207, and/or fourth wall 208 (shown in FIG. 5A) of upright 106. The adhesive also may be additionally applied on rear wall 212 and/or side walls 214 of insert 202 (shown in FIG. 3). Moreover, upright 106 may include one or more support walls (not shown) to support insert 202 within a space 230 formed between first and second walls 204 and 206. For example, one of the support walls may support bottom wall 218 of upright 106 in the coupled state. Further, the support walls also may help in positioning insert 202 within upright 106 such that cavity 220 of insert 202 (shown in FIG. 7C) is aligned with lateral opening 210 (shown in FIG. 5B) of upright 106. This may facilitate insertion of rail 108 through lateral opening 210 into cavity 220. The adhesive may be applied further on the support walls. In an embodiment, mechanical fasteners 228 may extend further through the support walls to secure insert 202, upright 106, and rail 108 with each other.

In various embodiments, insert 202 may be coupled to rail 108 and/or upright 106 by adhesives, mechanical fasteners 228, friction fit, or any combination thereof. In other embodiments, insert 202 may be coupled to rail 108 and/or upright 106 by other attachment methods, for example, a tongue and groove joint, a snap-fit connection, welding, brazing, and so on.

As illustrated in FIG. 4, cap 110 covers longitudinal opening 211 of upright 102. Cap 110 may be secured to upright 106 without any additional fasteners that may be visible from outside. Cap 110 also may prevent insert 202 and mechanical fasteners 228 from being visible from outside, thereby improving an aesthetic appearance of fence gate system 100. Cap 110 may be secured to upright 106 by various methods, such as, but not limited to, a tongue and groove joint, a snap-fit connection, a screwed joint, welding, adhesives, brazing, and so forth. Cap 110 also may be detachably coupled to upright 106 to enable any maintenance and/or repair activities.

FIGS. 6A and 6B illustrate front and side views, respectively, of rail 108. Rail 108 has a substantially hollow elongated structure including a top section 302, a pair of side sections 304 extending from top section 302, a bottom section 305 extending between the pair of side sections 304, and two legs 306 extending from bottom section 305. Mechanical fasteners 228 (shown in FIG. 4) may extend through top section 302 and bottom section 305 in order to couple rail 108 to insert 202. Further, upon insertion within cavity 220 (shown in FIG. 7C), bottom wall 218 (shown in FIG. 4) may support legs 306 of rail 108 thereon. Rail 108 further includes a first horizontal member 308 and a second horizontal member 310 extending between the pair of side sections 304. Rail 108 also includes pair of vertical members 312 extending between top section 302 and second horizontal member 310. First and second horizontal members 308 and 310 and vertical members 312 may act as stiffeners and impart structural strength to rail 108.

As illustrated in FIG. 6A, bottom section 305 and legs 306 form channel 226 to receive one or more balusters 112 (shown in FIG. 2B) and support portion 224 of insert 202 therein. Therefore, channel 226 slides on support portion 224 upon insertion of rail 108 within cavity 220 (shown in FIG. 7C) of insert 202. Each of legs 306 includes multiple projections 314 that extend into channel 226 and also extend laterally along the length of channel 226. Projections 314 may be flexible ridges that guide support portion 224 and secure rail 108 to insert 202. Projections 314 also may engage with balusters 112 and retain them within channel 226. Projections 314 may be integrally formed with corresponding legs 306. Alternatively, projections 314 may be separately manufactured and attached to corresponding legs 306 via various methods, such as, adhesives, mechanical fastening, welding, brazing, dovetailing, etc.

As illustrated in FIG. 6A, rail 108 may have a width ‘Wr’ and a length ‘Lr’. Referring to FIGS. 5B and 6A, width ‘Wr’ and length ‘Lr’ may be less than or equal to width ‘Wo’ and length ‘Lo’, respectively, of lateral opening 210 in order to facilitate insertion of rail 108 through lateral opening 210 into upright 106.

FIGS. 7A, 7B, and 7C illustrate a top view, a front view, and a perspective view, respectively, of insert 202. Insert 202 includes rear wall 212, pair of side walls 214 extending from rear wall 212, top wall 216 extending from rear wall 212 and disposed between side walls 214, and bottom wall 218 opposite to top wall 216. Rear wall 212, top wall 216, pair of side walls 214 and bottom wall 218 together at least partially enclose cavity 220 to at least partly receive therein rail 108 (shown in FIGS. 6A and 6B). Top wall 216 and bottom wall 218 include groove 221 that is similar in shape to groove 209 (shown in FIG. 5A) in order to facilitate insertion of insert 202 through longitudinal openings 211 of upright 106. Top wall 216 and bottom wall 218 also may include a pair of cut outs 238 between groove 221 and side walls 214. The cut outs 238 may flex during insertion of rail 108 into insert 202 and help in accommodating rail 108 at least partly within cavity 220. Further, an upper part of each of side walls 214 may diverge and provide a width greater than a width formed between a lower part of each of side walls 214.

As illustrated in FIG. 7B, each of side walls 214, top wall 216 and bottom wall 218 include multiple internal protrusions 222 to engage with rail 108 to secure rail 108 to insert 202. Internal protrusions 222 extend from each of side walls 214 into cavity 220 of insert 202. Internal protrusions 222 also extend from top wall 216 and bottom wall 218 into cavity 220. The internal protrusions 222 extending from side walls 214 may have a variable length in order to maintain a uniform internal width ‘Wi’ between internal protrusions 222. Specifically, internal protrusions 222 extending from the lower part of each of side walls 214 may have a length that is lesser than a length of internal protrusions 222 extending from the upper part of each of side walls 214. Moreover, internal protrusions 222 extending from top and bottom walls 216 and 218 also may provide an internal length ‘Li’ there between. In an embodiment, internal width ‘Wi’ and internal length ‘Li’ may be lesser than or equal to width ‘Wr’ and length ‘Lr’, respectively, of rail 108 in order to enable a friction fit between insert 202 and rail 108. In a further embodiment, internal protrusions 222 may deform during insertion of rail 108 into cavity 220 and grip rail 108 in order to retain more effectively rail 108 within cavity 220. Though internal protrusions 222, as illustrated in FIG. 7B, have a substantially rectangular shape, internal protrusions 222 may have any other alternative shape, such as polygonal, oval, and the like.

In an embodiment, internal protrusions 222 may only extend partially along a length of insert 202. For example, internal protrusions 222 may be located adjacent to rear wall 212. Further, internal protrusions 222 also may be connected to rear wall 212. However, in alternative embodiments, internal protrusions 222 may extend along the length of insert 202.

In an embodiment, internal protrusions 222 may be integral with the corresponding walls of insert 202. An adhesive may be applied, resulting in an adhesive joint between insert 202 and rail 108.

As illustrated in FIGS. 7B and 7C, each of side walls 214 include a plurality of external protrusions 234 configured to engage with upright 106 (shown in FIG. 5A) to secure insert 202 to upright 106 (not shown). Specifically, external protrusions 234 may engage with third and fourth walls 207 and 208 of upright 106. In an embodiment, external protrusions 234 also may deform during insertion of insert 202 to retain insert 202 within upright 106.

In the illustrated embodiment, external protrusions 234 extend along the length of insert 202. However, in an alternative embodiment, external protrusions 234 may extend only partly along the length of insert 202. Further, external protrusions 234 are present only on the lower parts of side walls 214 and absent on the upper parts. This may enable width ‘Wi’ of insert 202 to be uniform. Further, in an embodiment, width ‘Wi’ of insert 202 may be greater than or equal to width ‘Wu’ of upright 106 in order to enable a friction fit between insert 202 and upright 106 (shown in FIG. 3). External protrusions 234 also may facilitate application of an adhesive on side walls 214 to form an adhesive joint between insert 202 and upright 106. External protrusions 234 may further impart structural strength to insert 202.

Though external protrusions 234 illustrated in FIG. 7B have a rectangular shape, external protrusions 234 may have any other alternative shape, such as polygonal, oval, and the like. Further, external protrusions 234 may be deformable to enable insert 202 to be inserted within longitudinal opening 211 of upright 106. In an embodiment, external protrusions 234 may be integral with side walls 214 and have a coating to increase friction between insert 202 and upright 106. In an alternative embodiment, external protrusions 234 may be made of a material different from a material of side walls 214, and may be attached to side walls 214 by various methods, such as adhesives, welding, brazing, and the like.

Referring to FIGS. 7B and 7C, top wall 216 includes a pair of extensions 236 that are flush with end surface 213 (shown in FIG. 5B) of upright 106 in the coupled state of insert 202. Extensions 236 may act as an indicator of a proper placement of insert 202 within longitudinal opening 211 of upright 106. Specifically, when extensions 236 are flush with end surface 213, insert 202 is longitudinally aligned with lateral opening 210. In the illustrated embodiment, extensions 236 extend from two ends of top wall 216 and are substantially perpendicular to top wall 216. However, extensions 236 may be disposed at any intermediate location on top wall 216. Further, extensions 236 also may be oriented at any suitable angle with respect to top wall 216. Though extensions 236 are illustrated as being substantially rectangular, extensions 236 may have substantially any suitable alternative shape, such as polygonal, oval, etc.

Insert 202 further includes support portion 224 extending from rear wall 212. Support portion 224 includes a first section 224a and a second section 224b. A width of first section 224a may be greater than a width of second section 224b. First section 224a may receive legs 306 (shown in FIG. 6A) and bottom section 305 of rail 108 thereon during insertion of rail 108 into cavity 220. Second section 224b, having the lesser width, may enable insertion of projections 314 of legs 306. Projections 314 may engage with second section 224b to guide and to retain rail 108 within cavity 220. Therefore, a shape and dimensions of support portion 224 may be based on a shape and dimensions of channel 226 of rail 108.

FIGS. 8A, 8B, and 8C illustrate a top view, a front view, and a perspective view, respectively, of an insert 402, according to an embodiment of the present disclosure. Side walls 414 of insert 402 provide a uniform width between them. Accordingly, internal protrusions 422 extending from side walls 414 have similar lengths. Moreover, external protrusions 434 are located throughout a length of each of side walls 414. Extensions 436 also protrude beyond a length of top wall 418 to maintain a uniform external width. Other features of insert 402 may be substantially identical or equivalent to insert 202.

FIGS. 9A, 9B, and 9C illustrate a top view, a front view, and a perspective view, respectively, of an insert 502, according to an embodiment of the present disclosure. Side walls 514 of insert 502 provide a uniform width between them. Accordingly, internal protrusions 522 extending from side walls 514 have similar lengths. Moreover, external protrusions 534 are located throughout a length of each of side walls 514. Extensions 536 also protrude beyond a length of top wall 518 to maintain a uniform external width. Insert 502 further includes an auxiliary support portion 540 extending from a rear wall 512. Auxiliary support portion 540 may support first horizontal member 308 (shown in FIG. 6A) of rail 108. Further, auxiliary support portion 540 is substantially rectangular with chamfered edges. However, auxiliary support portion 540 may have any alternative shape, such as elliptical, polygonal, circular, and so forth. Other features of insert 502 may be substantially identical or equivalent to insert 202.

FIGS. 10A, 10B, and 10C illustrate a top view, a front view, and a perspective view, respectively, of an insert 602, according to an embodiment of the present disclosure. Side walls 614 of insert 602 provide a uniform width between them. Accordingly, internal protrusions 622 extending from side walls 614 have similar lengths. Moreover, external protrusions 634 are located throughout a length of each of side walls 614. Extensions 636 also protrude beyond a length of top wall 618 to maintain a uniform external width. Insert 602 further includes an auxiliary support portion 640 extending from a rear wall 612. Auxiliary support portion 640 may support first horizontal member 308 (shown in FIG. 6A) of rail 108. Further, auxiliary support portion 640 is substantially U-shaped. Other features of insert 602 may be substantially identical or equivalent to insert 202.

Each of inserts 202, 402, 502, and 602 may correspond to a particular rail configuration and/or upright configuration. Further, each of inserts 202, 402, 502, and 602 may have one or more markings to match the corresponding insert with the corresponding rail and/or upright. The markings may include letters, numbers, alphanumeric codes, symbols, and so forth.

An exemplary assembling operation of fence gate assembly 118 will be explained hereinafter with reference to FIGS. 1 to 7C. Different components of fence gate assembly 118 may be available as a fence gate kit that may include uprights 106 with corresponding inserts 202 pre-installed therein, rails 108, balusters 112, mechanical fasteners 228, cap 110, and hinges 104. The fence gate kit may additionally include an adhesive dispenser, multiple U-channels, and post 102. However, post 102 may be pre-installed in ground surface ‘S’ and may not be part of the fence gate kit.

Balusters 112 and the U-channels may be laid on a suitable surface with balusters 112 arranged next to each other and between the U-channels. Balusters 112 at each end may be coupled to the corresponding U-channels. Balusters 112 and the U-channels may be then slid into channels 226 of each of rails 108. Rails 108 may be then coupled to inserts 202 that are pre-installed within uprights 106 at both ends. The U-channels also may be slid within grooves 209 formed by first walls 204 of corresponding uprights 106. In an embodiment, the adhesive dispenser may be used to apply an adhesive on internal surfaces of inserts 202 and/or external surfaces of rails 108. Rails 108 may be then slid through corresponding lateral openings 210 into cavities 220 of corresponding inserts 202. Rails 108 may be slid along transverse axis ‘T’ for coupling with corresponding inserts 202. Mechanical fasteners 228 may be then installed through longitudinal openings 211 of corresponding uprights 106 in order to secure rails 108 to inserts 202. Specifically, mechanical fasteners 228 may be struck with a tool (for example, a hammer) to drive mechanical fasteners 228 through top wall 216 of corresponding inserts 202 into corresponding rails 108. Caps 110 may be then used to close longitudinal openings 211 from top ends 114 of corresponding uprights 106. Optionally, caps 110 also may be provided at bottom ends 116 of corresponding uprights 106. Rails 108, balusters 112, the U-channels, uprights 106, and caps 110 may thus form fence gate assembly 118.

The first parts 104a of hinges 104 may be coupled to post 102. Fence gate assembly 118 may be placed at a suitable height and distance with respect to post 102, and second parts 104b of hinges 104 are coupled to upright 106 adjacent to post 102. Thus, fence gate system 100 is formed.

The above assembly operation is purely exemplary in nature, and fence gate assembly 118 and fence gate system 100 may be assembled in any alternative manner as per the convenience of an end user.

Inserts 202 are pre-installed within uprights 106 in order to enable the end user to directly insert rail 108 into cavity 220 formed by insert 202. In particular, the end user mainly may slide the elements without use of specialized skill or tools. Thus, a time and complexity associated with assembling fence gate system 100 may be reduced.

Apart from the installation of mechanical fasteners 228, the end user may not have to handle any tools or perform any striking/drilling operations. This may enhance the safety of the assembling operation. In an embodiment, rail 108 may be retained within insert 202 by friction fit and/or adhesives and may not require additional fasteners. Therefore, the fence gate kit may be assembled without any tools or fasteners that may be dangerous to the end user.

Further, inserts 202 are enclosed completely within uprights 106, and caps 110 close longitudinal openings 211. Therefore, fence gate assembly 118 does not have any external brackets or fasteners, thereby improving an aesthetic appeal of fence gate assembly 118. Lack of external brackets, fasteners, or protruding structures may enable the end user to easily paint various components of fence gate assembly 118, if required.

Caps 110 also may prevent entry of moisture or particulate matter within longitudinal openings 211. This may prevent damage and corrosion to the internal components, and thus increase a life of fence gate assembly 118.

Different inserts may be provided within uprights 106 in order to allow end users to install a rail and picket assembly of their choice.

FIG. 11 is a flowchart of an exemplary method 700 of manufacturing the fence gate kit in accordance with an embodiment of the disclosed subject matter. The flowchart is provided merely for exemplary purposes, and embodiments are intended to include or otherwise cover any methods or procedures for manufacturing the fence gate kit.

At step 702, method 700 includes providing upright 106 including first wall 204 having two lateral openings 210, second wall 206 opposite to first wall 204, a third wall 207 extending from between first and second walls 204 and 206, and fourth wall 208 spaced from third wall 207 and extending between first and second walls 204 and 206. The first, second, third, and fourth walls 204, 206, 207, and 208 form a longitudinal opening 211. Upright 106 may be formed by various manufacturing methods, such as molding, casting, machining, or a combination thereof. The walls of upright 106 may be formed integrally (e.g., extruded) or may be manufactured separately and then assembled together. In the illustrated embodiment, two uprights 106 may be provided.

Method 700 may further include providing balusters 112, caps 110, hinges 104, and mechanical fasteners 228. Balusters 112 are received slideably in channel 226 of rail 108. Cap 110 closes longitudinal opening 211 of corresponding upright 106.

At step 704, method 700 includes sliding insert 202 within longitudinal opening 211 of upright 106. Insert 202 may be inserted into upright 106 along longitudinal axis ‘L’. Insert 202 includes rear wall 212, side walls 214, and support portion 224 extending from rear wall 212. Further, rear wall 212 and side walls 214 at least partly enclose cavity 220.

Insert 202 may be formed by various manufacturing methods, such as molding, casting, machining, or a combination thereof. The walls and support portion 224 of insert 202 may be integrally formed or may be manufactured separately and then assembled together.

In the illustrated embodiment, two inserts 202 may be inserted within each of uprights 106, one from top end 114 and another from bottom end 116. Prior to insertion of insert 202, an adhesive, such as PVC cement, may be applied on external surfaces of rear wall 212 and side walls 214. Additionally, the adhesive may be applied on interior surfaces of uprights 106.

At step 706, method 700 includes coupling insert 202 to upright 106 via the adhesive. An additional curing process may be required to form the adhesive joint between insert 202 and upright 106. Insert 202 may be additionally or optionally coupled to the upright via fasteners, mechanical joints, friction fit, or a combination thereof.

At step 708, method 700 includes providing rails 108 inserted through lateral opening 210 and at least partly received within cavity 220 of insert 202. Rail 108 further includes channel 226 slideably received on support portion 224 of insert 202. Mechanical fasteners 228 may be installed to couple rail 108 to insert 202 after sliding rail 108 within cavity 220.

Rail 108 may be formed by various manufacturing methods, such as molding, casting, machining, or a combination thereof. Various sections of rail 108 may be integrally formed or may be manufactured separately and then assembled together.

The present invention may be utilized in a variety of different usage environments, both indoors and outdoors, in which the environments may include sloped ground, terrain, floor, or other surfaces having a sloping grade or elevation in continuous or terraced (i.e., stepped) arrangements.

FIGS. 12A, 12B, and 12C show various illustrative arrangements of a fence 1200 that is installed over sloping ground 1205. As shown in the illustrative arrangements, the sloping ground is somewhat irregular (i.e., non-uniform), but in other arrangements (not shown), the slope may be more uniform. In typical implementations, the top and/or bottom edges of the fence are substantially parallel to the sloping ground. Thus, for example, if the grade of the sloped ground is 8 degrees, then fence may be installed so that the top and/or bottom edges have a similar angle. However, variations in slope angle between the fence and ground can occur, and the present invention may be adapted to accommodate such variations.

In FIG. 12A, the fence 1200 uses a gate 1210 that is non-racked. A non-racked gate has vertical and horizontal edges that are substantially orthogonal so that the gate has a rectangular shape and the top and bottom edges are level with a horizontal plane. Thus, the top and bottom edges of the non-racked gate are not parallel with the top and bottom edges of the fence panels (representatively indicated by reference numeral 1215).

In FIG. 12B, the fence 1200 uses a racked gate 1220 in which the vertical and horizontal edges are non-orthogonal and thereby form an oblique angle. The gate has a shape of a parallelogram in which the top and bottom edges are substantially parallel and the left and right edges are substantially parallel. In some installations, the racking angle (i.e., the angular variation from level or horizontal) can be substantially similar to the slope of the ground 1205 and/or the fence 1200, but variations in angles between the fence, racked gate, and ground may occur according to a variety of factors including functional and aesthetic factors. In alternative embodiments (not shown in FIG. 12B), the racking angle utilized for the top and bottom gate edges may be different such that the edges are non-parallel.

In FIG. 12C, the fence 1200 uses a partially racked gate 1225 in which the vertical edges of the gate are parallel, but the top and bottom gate edges are non-parallel. As shown, the top edge of the gate is level, while the bottom edge is racked so that it slopes downwards from left to right to match the slope of the ground 1205 and that of the fence panel 1215). Such partially racked gate may be utilized, for example, to minimize a gap 1230 between the gate and the ground, as shown in FIG. 12A, while keeping the top gate edge level for aesthetic reasons. In alternative embodiments (not shown in FIG. 12C), the top edge of the gate may be angled, while the bottom edge is level.

FIG. 13 is a side view of a racked fence gate system 1300, according to embodiments disclosed herein, that includes the racked fence gate 1220. The racked fence gate system further includes a post 102, a pair of hinges 104, a pair of uprights 106, inserts 202 (FIG. 2), a pair of rails 1308, a pair of caps 110, and a plurality of balusters 1312, as those elements were previously described above in the text accompanying FIG. 1. In the description that follows, the upright 106 that is closest to the hinges is termed the “proximal” upright and the other upright that is furthest from the hinges is termed the “distal” upright. The same terminology convention is utilized to disambiguate between the ends of the rails.

Rails 1308 extend laterally and downward, from the proximal upright to the distal upright, along a racking angle (indicated by reference numeral 1305) which is oblique (i.e., non-orthogonal) to the longitudinal axis ‘L’ of the uprights 106. The rails 1308 may be similarly arranged as rails 108 shown in FIG. 1 and described in the accompanying text, other than, for example, the trimming that is performed prior to assembly into the uprights, as discussed below.

In an illustrative example which is not to be construed as a limitation on the scope of the present invention, the racking angle may be about 8 degrees downwards from horizontal (or negative 8 degrees when using the right-hand rule convention). An 8-degree racking angle provides for a drop in elevation of about 3½ inches over a span of 4 feet. Other racking angles may be utilized as may be needed for a given implementation or installation of a racked fence gate system.

Balusters 1312 are connected to and disposed between the rails. The balusters may be similar to the balusters 112 shown in FIG. 1 and described in the accompanying text, other than, for example, the trimming that is performed prior to assembly into the rails, as discussed below. The balusters are typically disposed in the gate in such a way that their longitudinal edges are parallel to the longitudinal axis ‘L’ of the uprights. However, other baluster orientations with respect to the uprights may be utilized to meet the needs of a particular implementation or installation of the present invention.

Prior to gate assembly, the tops and bottoms of the balusters are trimmed to remove material along the racking angle 1305 such that they thereby fit into the U-channels (not shown) of the rails 1308 in a substantially close-fitting manner (i.e., without showing the gaps that would otherwise occur between the balusters and the rails). The trimming can be performed in advance of gate assembly, for example, in a factory environment or in the field by a fence installation technician using hand and/or power tools and other equipment. Such tools can include a marking tool (e.g., marker), an angle finding device (e.g., protractor), linear measuring device (e.g., ruler), cutting devices (e.g., saw and/or knife), and associated personal protection and safety equipment for the technician. Such tools and equipment may be included in a larger racked fence gate system kit that may also include fasteners (e.g., nails, self-tapping screws, etc.) and adhesives (e.g., PVC glue or cement) and associated tools (e.g., screwdrivers) that the technician may utilize when installing the system in the field with other fence components.

So that the rails 1308 can be captured securely in the uprights 106 along the racking angle 1305, portions of the rails are trimmed to thereby enable engagement within the inserts 202 (FIG. 2) such that the racking angle 1305 can be maintained. FIG. 14A shows respective sectional views of the proximal and distal ends of a rail 1308 as respectively inserted into the inserts 202 provided in the proximal and distal uprights 106 of the racked fence gate system 1300 (FIG. 13). FIGS. 14B and 14C are respective enlarged detailed sectional views B and C of the proximal and distal ends of the top rail as inserted into inserts in the uprights. The assembled rails may be affixed to the inserts in the uprights to provide a completed racked fence gate using mechanical fasteners in a similar manner as with a non-racked fence gate as shown in FIG. 4 and described in the accompanying text.

As shown in FIG. 15A, the proximal end of rail 1308 includes a trimmable portion 1505 and the distal end includes a trimmable portion 1510 (the trimmable portions are highlighted in the drawing using cross-hatching). As with the balusters, the trimmable portions of the rail may be pre-trimmed in advance of gate assembly, for example, in a factory environment or by a technician, using hand and/or power tools and other equipment, contemporaneously with fence installation in a field environment.

As stated in the note A in the drawing, a portion of the bottom section 1305 of the rail is removed during the trimming of the distal trimmable portion 1510. Bottom section 1305 may be configured in a similar manner as bottom section 305 in rail 108 as shown in FIG. 6A and described in the accompanying text. FIGS. 15B and 15C are respective enlarged detailed views B and C of the proximal and distal ends of rail 1308 after the removal of the trimmable portions (including a portion of the bottom section 1305 that is not shown).

FIGS. 16A and 16B show templates 1605 and 1610 that may be respectively utilized to assist trimming of the proximal and distal ends of rail 1308 prior to assembly to the respective proximal and distal uprights 106 of the racked fence gate system of FIG. 13 with an 8-degree maximum racking angle. It is emphasized that the dimensions shown are intended to be non-limiting and are illustratively provided for applications in which an 8-degree racking angle is appropriately utilized. Other racking angles may be implemented using different suitable dimensions for the templates, as will be readily appreciated by a person of skill in the fence gate arts.

The templates 1605 and 1610 may be provided as part of a field installation kit that can accompany components of the present racked fence gate system. The templates can be formed from any suitable material to enable the trimmable portions of the rail 1308 to be identified. For example, the templates can include thin materials such as cardstock, paper, plastic film or sheets, and the like, which may be overlaid on the rail so that the trimmable portions may be marked using a marker, scribe, or other suitable tool. The technician can then use a tool such as a saw to trim material from the rail by following the markings from the templates. In alternative embodiments, the dimensions shown on the templates can be provided to the technician using other forms of communications such as a chart, manual, software application, telephone hotline, and the like. The technician can then mark the trimmable portions using the provided dimensions using suitable measuring tools such as a protractor and tape measure.

FIG. 17 illustrates a method of manufacturing a racked fence gate kit, according to embodiments disclosed herein. In step 1705, an upright is provided having a longitudinal axis and comprising a first wall, a second wall opposite to the first wall forming a lateral opening, a third wall extending between the first and second wall, and a fourth wall spaced from the third wall and extending between the first wall and the second wall, wherein the first wall, the second wall, the third wall, and the fourth wall form a longitudinal opening.

In step 1710, an insert is slideably positioned within the longitudinal opening of the upright, the insert comprising a rear wall, a pair of side walls extending from the rear wall, and a support portion extending from the rear wall and disposed between the pair of side walls, wherein the rear wall and the pair of side walls at least partly enclose a cavity.

In step 1715, the insert is coupled to the upright using, for example, an adhesive and/or mechanical fasteners. In step 1720, a portion of a proximal end of a rail having a longitudinal axis is trimmed.

In step 1725, the trimmed proximal end of the rail is slideably positioned through the lateral opening and at least partially into the insert such that the longitudinal axis of the upright and the longitudinal axis of the rail are obliquely oriented at the racking angle, in which the rail comprises a channel slideably received on the support portion of the insert.

Though the above embodiments are described with reference to a fence gate system and assembly, embodiments of the present disclosure are intended to cover any fence assembly having one or more uprights with inserts pre-installed within the uprights. The pre-installed inserts may be easily coupled with corresponding rails, thereby enabling quick and simple assembly of the fence.

Although the invention has been described with reference to exemplary embodiments, it is not limited thereto. Changes and modifications may be made to the preferred embodiments of the invention and such changes and modifications may be made without departing from the spirit of the invention. The claims are intended to cover all such equivalent variations as fall within the spirit and scope of the invention.

To avoid unnecessarily obscuring the present invention, the preceding description omits well known structures and devices. This omission is not to be construed as a limitation of the scope of the present invention. Specific details are set forth by use of the embodiments to provide an understanding of the present invention. However, the present invention may be practiced in a variety of ways beyond the specific embodiments set forth herein.

A number of embodiments of the present invention may be practiced. It is possible to provide some features of the present invention without providing others.

The present invention, in various embodiments, configurations, and aspects, includes components, methods, processes, systems, and/or apparatus substantially as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, configurations, and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, for example, for improving performance, achieving ease, and/or reducing cost of implementation.

The foregoing discussion of the present invention has been presented for purposes of illustration and description. It is not intended to limit the present invention to the form or forms disclosed herein. In the foregoing detailed description, for example, various features of the present invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the present invention requires more features than are recited expressly in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this detailed description, with each claim standing on its own as a separate embodiment of the present invention.

Moreover, though the description of the present invention has included descriptions of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present invention for example, as may be within the skill and knowledge of those in the art, after understanding the present disclosure, without intending to publicly dedicate any patentable subject matter.

	Number	Date	Country
Parent	16840866	Apr 2020	US
Child	17583293		US
Parent	15263799	Sep 2016	US
Child	16574253		US

	Number	Date	Country
Parent	16574253	Sep 2019	US
Child	16840866		US

FENCE GATE ASSEMBLY, FENCE GATE KIT, SYSTEM AND METHODS OF MANUFACTURING THEREOF

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CROSS-REFERENCE TO RELATED APPLICATION

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