Patent Application
20100096608
The Applicant's teaching disclosed herein relates to fence systems, for example privacy fences and picket fences, and to one or more methods and apparatuses associated with elements of fence systems and the connection structure and assembly thereof.
The following paragraphs are not an admission that anything discussed therein is citable as prior art or part of the general knowledge of people skilled in the art.
U.S. Pat. No. 5,702,090 (Edgman) discloses a plastic fence assembly, particularly adapted for use as residential privacy fencing and the like, comprising plural post members which are formed of hollow extruded plastic and have opposed side walls and end walls intersected by one or more elongated channels. Elongated spacer elements may be inserted in the channels and retained therein by interlocking projections on the spacer elements and recesses formed in the sidewalls of the post channels. The spacer elements support side edges of vertically extending picket members, brackets for horizontally extending center rail members and to position at least one or both of elongated top and bottom rail members of the fence assembly. The top and bottom rail members have elongated slots formed therein for receiving opposite ends of generally planar boardlike picket members. The top and bottom rail members and the spacer members may be cut to length as may the post and picket members to provide fencing of a desirable height and distance between posts.
U.S. Pat. No. 5,988,599 (Forbis) discloses a modular fence system. The system includes fence planks designed for insertion into open channels of upper and lower fence rails. The fence rails are supported in a horizontal orientation between intermittent fence posts, with the fence planks extending vertically between the rails. The planks include resilient protrusions at their upper ends. The protrusions of the planks are designed to fit into internal passages formed in the open channels of the upper fence rail, into engagement with ledges defining the passages, to inhibit inadvertent removal of the planks from the upper rail.
U.S. Pat. No. 6,478,287 (DeSouza) discloses a fence panel constructed from extruded hollow polyvinyl plastic boards. The boards are arranged with vertical end boards and filler boards between the end boards. Three horizontal rails each have a board on each side of the vertical boards with a horizontal filler board between the top rail boards to seal off the upper ends of the vertical boards. All of the boards are secured together with a plastic adhesive without the use of any mechanical fasteners.
U.S. patent application publication 2008/0217598 (Dombroski) discloses a fence assembly that is made up of a plurality of fence sections. Each section is made up of panels with top, bottom and side edges and front and rear surfaces. Slots are spaced from and milled into the panels along one of the sets of edges. A pair of trim extends over and covers the set edges and each trim has projections that snap or slide into the front and rear slots. Alternatively the edges of the panel may be beaded and slid over the slotted side of the trim. The fence sections are coupled pivotably to fence posts such that the panels may pivot, under force of wind, about either their top or bottom end. The panels are restored to generally vertical position by the force of gravity. A counterweight within the fence post linked to the panels can be used to restore panels to their vertical position. In an alternate embodiment, the brackets coupling the panels to the fence posts may slide along the fence posts and the panels bow in response to high winds. The fence panels may include resilient strips along their vertical edges.
U.S. patent application 2008/0023684 (Diamond et al.) discloses a non-metallic fence system that has a singular snap lock mechanism for permitting the easy construction of the fence. It also includes a securing device for fixing a fabric to a fence having a rigid body including at least two prongs therefrom and an open face strut profile capable of receiving the prong therein, wherein the prongs are locked within the open face and the fixture can be removed by twisting 90 degrees.
The following summary is intended to introduce the reader to the disclosure provided herein but not to define any invention. In general, this disclosure describes one or more methods or apparatuses related to injection drive units in injection molding machines.
According to one aspect, a fence system includes a first extruded lineal extending lengthwise along a first longitudinal axis. The first lineal has a sidewall with at least a first slot in the sidewall and the first slot extends generally perpendicular to the longitudinal axis. The fence system also includes a second extruded lineal extending lengthwise along a second longitudinal axis. The second extruded lineal includes at least a corresponding first attachment leg extending outward from the second extruded lineal and parallel to the second longitudinal axis. The first attachment leg is integrally extruded with the second extruded lineal and is received in the first slot to secure together the first and second extruded lineals.
According to some aspects, a fence section comprises: a) a generally horizontal first rail having an upper face with a first panel recess extending lengthwise along the first rail and extending laterally between opposed first recess sidewalls, the first rail including a first tongue extending laterally from one towards the other of the first recess sidewalls and lengthwise along the first rail; b) a generally horizontal second rail spaced vertically above the first rail and having a lower face with a second panel recess extending lengthwise along the second rail and extending laterally between opposed second slot sidewalls, the second rail including a second tongue extending laterally from one towards the other of the second recess sidewalls and lengthwise along the second rail; and c) a plurality of vertical members extending generally vertically between the first rail and the second rail, each vertical member having a panel height extending between upper and lower ends of the panel and a panel thickness extending laterally between opposed front and back panel faces, the lower end of each vertical member being received in the first panel recess and the upper end of each vertical member being received in the second panel recess. Each vertical member has a constant cross-sectional panel profile along the panel height, and each vertical member includes a lower slot and an upper slot extending horizontally across a width of the vertical member and lengthwise of the rail, the lower slot receiving the first tongue therein and the upper slot receiving the second tongue therein.
In some examples, the vertical members can be in the form of fence panels, pickets, boards, or slats. The vertical members and/or the rails can, in some examples, be formed of plastic and can be injection molded.
In some examples, each vertical member comprises an extruded lineal, made of, for example, but not limited to, a plastic material. The upper and lower slots can comprise cuts (for example, saw cuts) or a similar material-removal feature in the lineals. The slots can be parallel to, and spaced equally apart from, the upper and lower edges of panels.
In some examples, the rails can comprise extruded lineals. The rails can have a constant cross-sectional profile along their length. The rails can be made of a plastic material. Each of the rails, including, for example, the first and second rails and an optional third rail can have a common rail profile. In other words, a length of extruded lineal having the common rail profile can be used as any one of the first, second, or third rails.
According to some aspects, a fence section, comprises: a) a generally horizontal lower rail having an upper face with a lower panel recess extending lengthwise along the first rail and extending laterally between opposed first and second lower recess sidewalls, the lower rail including a lower rail first tongue extending laterally from the first lower recess sidewall towards the second lower recess sidewall and lengthwise along the lower rail, and a lower rail second tongue extending laterally from the second lower recess sidewall towards the first lower recess sidewall and lengthwise along the lower rail; b) a generally horizontal upper rail spaced vertically above the lower rail and having a lower face with an upper panel recess extending lengthwise along the upper rail and extending laterally between opposed first and second upper recess sidewalls, the upper rail including an upper rail first tongue extending laterally from the first upper recess sidewall towards the second upper recess sidewall and lengthwise along the upper rail, and a upper rail second tongue extending laterally from the second upper slot sidewall towards the first upper slot sidewall and lengthwise along the upper rail; and c) a plurality of fence panels extending generally vertically between the lower rail and the upper rail, each fence panel having a panel height extending between upper and lower ends of the panel and a panel thickness extending laterally between opposed front and back panel faces, the lower end of each fence panel being received in the lower panel recess and the upper end of each fence panel being received in the upper panel recess. Each fence panel has a constant cross-sectional panel profile along the panel height, and each fence panel includes a first and a second lower groove and a first and a second upper groove extending horizontally across a width of the fence panel and lengthwise of the rail, the first lower groove receiving the lower rail first tongue therein, the second lower groove receiving the lower rail second tongue therein, the first upper groove receiving the upper rail first tongue therein, the second upper groove receiving the upper rail second tongue therein.
In some examples, the front and/or back faces of fence panel can comprise one or more vertical channels extending along the height of the panel. The channel(s) can give the illusion that each panel comprises a plurality of slats. Each channel can comprise a channel face, and opposed lateral faces. The channel can have the same depth as each of the grooves, and each tongue can abut the channel face(s).
In some examples, each fence panel is provided with cooperating male and female engagement elements, such that each fence panel may be connected to one or more other fence panels. The male and female engagement elements can be configured such that when a male engagement element is inserted into a female engagement element, the joint provides the appearance of a channel. For example, each female engagement element can comprise opposed walls, between which the male engagement element is inserted. The opposed walls can be provided at a distance from the front and back faces of the panel, respectively, that is equal to the depth of the channel(s), and the width of each opposed walls can be equal to the width of the channel face.
In some examples, the first and second lower tongues and the first and second upper tongues are joined to the first and second upper and lower slot sidewalls, respectively, at a vertical position generally at the outer ends of the first and second upper and lower sidewalls. In other examples, the first and second lower tongues and the first and second upper tongues are joined to the first and second upper and lower slot sidewalls, respectively, at a vertical position spaced from the outer ends of the first and second upper and lower sidewalls.
According to some aspects, a connection structure for a fence comprises a first extruded lineal extending lengthwise along a first longitudinal axis and having a sidewall with at least a first slot in the sidewall. The first slot extends generally perpendicular to the longitudinal axis. The connection structure also comprises a second extruded lineal extending lengthwise along a second longitudinal axis, the second extruded lineal including at least a corresponding first attachment leg extending outward from the second extruded lineal and parallel to the second longitudinal axis. The first attachment leg can be integrally extruded with the second extruded lineal and is received in the first slot to secure together the first and second extruded lineals.
In some examples, the first extruded lineal comprises a second slot parallel to, and spaced apart from, the first slot, and the second extruded lineal comprises a corresponding second attachment leg parallel to the first attachment leg and received in the second slot.
In some examples, each slot comprises an opening through one sidewall. Each opening may have opposed slot edge faces and opposed slot end faces. Each slot edge face and each slot end face may extend laterally from an outer surface of the sidewall to an inner surface of the sidewall.
In some examples, the slot edge faces are parallel to each other.
In some examples, the slot edge faces are oblique relative to the first longitudinal axis.
In some examples, each attachment leg comprises a distal portion spaced apart from the second extruded lineal and a barb extending from the distal portion. Each barb may comprise an abutment surface that bears against the inner surface of the sidewall adjacent the respective slot into which the attachment leg is received for retaining the attachment leg within the slot when the attachment leg is fully inserted into the respective slot.
In some examples, the second extruded lineal comprises a base surface. Each attachment leg may extend from the base surface. The base surface may oppose the abutment service and be spaced apart from the abutment surface by a distance greater than a thickness of the first extruded lineal sidewall.
In some examples, the slot end faces are spaced apart by a first width and the attachment leg received within each slot has a second width. The second width may be generally equal to the first width so that translation of the first extruded lineal relative to the second extruded lineal along the second longitudinal axis is inhibited when the attachment leg is received within the slot.
In some examples, each barb comprises at least one resilient retaining member. The at least one resilient member may be moveable between insertion and retention positions. When the at least one resilient retaining member is in the insertion position the barb can pass between the slot edge faces, and when the at least one resilient retaining member is in the retention position the barb is inhibited from passing between the slot edge faces.
In some examples, the at least one resilient retaining member comprises the abutment face.
According to some aspects, a fence section comprises an upper horizontal rail and a lower horizontal rail extending along respective upper and lower rail axes. The lower rail is spaced vertically below the upper horizontal rail. Each of the rails can comprise a respective extruded lineal including integrally formed attachment legs. The fence section can further comprise a plurality of vertical members each extending between the upper and lower horizontal rails. Each of the vertical members comprises at least one upper slot and at least one lower slot. At least portions of the attachment legs of the upper and lower rails are received within respective ones of the slots to secure each vertical member to the upper and lower horizontal rails.
In some examples, each of the vertical members extends along a respective vertical axis. The upper and lower slots may be generally elongated in a lateral direction generally perpendicular to the vertical axis, and the slots may be generally narrow in the vertical direction. The upper and lower slots can each have a slot length extending generally perpendicular to the vertical axis, and a slot thickness extending in the vertical direction. The slot thickness can be less than the slot length. In some examples, the slot thickness can be only a fraction of the slot length, for example only about one-fifth, or about one-tenth, or about one-fifteenth, or less than about one-twentieth of the slot length.
In some examples, the upper and lower slots can form an opening through a sidewall of each vertical member. Each opening may comprise opposed slot edge faces and opposed slot end faces. Each slot edge face and each slot end face may extend laterally from an outer surface of the sidewall to an inner surface of the sidewall.
In some examples, the slot edge faces are parallel to each other.
In some examples, the slot edge faces are oblique relative to the outer surface of the sidewall.
In some examples, the slot end faces are parallel to each other and are spaced apart by a slot length and the slot edge faces are spaced apart by a slot height.
In some examples, each attachment leg comprises opposing attachment leg end faces spaced apart by an attachment leg length. The attachment leg length may be less than the slot length of the corresponding slot.
In some examples, each attachment leg includes a barb. Each barb may comprise an abutment surface that bears against the inner surface of the sidewall adjacent the respective corresponding slot, into which the attachment leg is received when the attachment leg is fully inserted into its slot.
In some examples, the upper and lower rails each comprise a base surface. Each attachment leg may extend from one base surface. Each base surface may oppose the abutment surfaces of the attachment legs extending therefrom, and may be spaced apart from the abutment surfaces by a distance greater than a thickness of the sidewall.
In some examples, each barb has a generally wedge-shaped cross-section comprising a leading edge spaced apart from its abutment surface so that the each barb facilitates insertion of the attachment leg into its slot and resists removal of the attachment leg from its slot.
In some examples, each attachment leg is resiliently moveable between a first position for inserting the attachment leg and barb through the respective slot and a second position for retaining the attachment leg within the respective slot. In the second position the abutment surface may engage the inner surface of the sidewall, and the attachment leg may be biased toward the second position.
In some examples, each barb comprises at least one resilient retaining member. The at least one resilient member may be moveable between insertion and retention positions. When the at least one resilient retaining member is in the insertion position, the barb has a barb height that is less than the slot height. When the at least one resilient retaining member is in the retention position, the barb has a barb height that is greater than the slot height.
In some examples, each resilient retaining member is biased toward the retention position.
In some examples, the resilient retaining member comprises the abutment surface. When the attachment leg is fully inserted in its slot and the resilient retaining member is in the retention position, the abutment surface may engage the inner surface of the sidewall.
In some examples, each attachment leg further comprises a protrusion. The protrusion may extend away from the attachment leg and may be intermediate the resilient retaining member and the base surface.
In some examples, each the protrusion has a protrusion height that can be less than the slot height.
In some examples, each protrusion is registered with one slot edge face when the attachment leg is fully received in its slot to inhibit vertical displacement between the vertical members and upper and lower rails.
In some examples, both horizontal rails have a common extruded profile comprising a downward opening, generally C-shaped channel. The channel may have a horizontal upper wall and first and second vertical, laterally spaced apart, integrally formed rail sidewalls. The profile may define an internal cavity between the rail sidewalls and adjacent the upper wall.
In some examples, the upper wall of each horizontal rail comprises a plurality of apertures spaced apart along the length of the rail. The apertures in the upper horizontal rail may be aligned with corresponding apertures in the lower horizontal rail and each vertical member may pass through respective aligned ones of the apertures in the upper and lower horizontal rails.
In some examples, each vertical member extends beyond the upper wall of the upper horizontal rail and extends beyond a bottom edge of the sidewalls of the lower horizontal rail.
In some examples, the attachment legs include laterally opposed first and second attachment legs extending inwardly towards each other from the first and second sidewalls respectively.
In some examples, each vertical member comprises a set of opposing upper slots and a set of opposing lower slots formed in opposing sidewalls of the vertical member for receiving the first and second opposed attachment legs of the upper and lower rails respectively.
In some examples, both horizontal rails have a common extruded profile comprising spaced apart top and bottom walls connected by integrally formed first and second rail sidewalls forming a generally rectangular channel.
In some examples, the attachment legs extend from an outer surface of the first rail sidewall of both horizontal rails.
In some examples the fence section comprises attachment legs extending from an outer surface of the second rail sidewall of both horizontal rails.
In some examples, the plurality of vertical members comprises first and second sets of vertical members. The attachment legs may extend from the first rail sidewall of the upper and lower horizontal rail and may be received within the corresponding upper and lower slots of the vertical members in the first set of vertical members, thereby securing each vertical member in the first set of vertical members adjacent the first sidewall of both horizontal side rails.
In some examples, the attachment legs extend from the second sidewall of the upper and lower horizontal rails and are received within the corresponding upper and lower slots of the vertical members in the second set of vertical members, thereby securing each vertical member in the second set of vertical members adjacent the second sidewall of both horizontal side rails.
In some examples, vertical members from the first and second sets are arranged in an alternating sequence along the length of the upper and lower horizontal side rails.
In some examples, the attachment leg length is generally equal to the slot length so that translation of each vertical member relative to the upper and lower horizontal rails along the upper and lower rail axes is inhibited when the attachment leg is received its slot.
In some examples, the attachment of the vertical members to the upper and lower horizontal rails comprises only the connection between the attachment legs and slots and is free from other fastening means.
In some examples, the connection between the attachment legs and slots comprises a snap-fit connection.
According to some aspects, a method of assembling a fence section comprises the steps of: a) providing a first horizontal rail having at least one integrally formed attachment leg extending therefrom, b) providing a second horizontal rail, the second horizontal rail being spaced apart from the first horizontal rail and having at least one integrally formed attachment leg extending therefrom, c) providing a plurality of vertical members, each vertical member having at least one upper slot formed in a sidewall for receiving one attachment leg from the first horizontal rail and at least one lower slot formed in the sidewall for receiving one attachment leg from the second horizontal rail, and d) connecting each vertical member to the first and second horizontal rails by inserting one attachment leg on the first horizontal rail into the at least one upper slot on each vertical member and inserting one attachment leg on the second horizontal rail into the at least one lower slot on each vertical member.
According to some aspects, a method of making a fence system includes extruding a vertical member profile along an extrusion axis, and cutting the profile to length along a cutting axis generally perpendicular to the extrusion axis to form vertical members for a fence. During or after the profile is cut to length, at least one upper and at least one lower attachment slot can be cut into the vertical member, parallel to the cutting axis and adjacent upper and lower ends of each vertical member. The method can include extruding upper and lower rail profiles, each including an attachment leg extending laterally outwardly of the rail profiles for engagement with the slots of the vertical members.
The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.
Referring to
Referring to
In the example illustrated, the rail profile 116 includes a distal lattice recess 134 associated with the distal face 122. The distal lattice recess 134 includes opposed distal lattice recess sidewalls 136a, 136b each having an outer end 138a, 138b at the distal face 122, and an inner end 140a, 140b disposed vertically intermediate the distal face 122 and the panel recess base 132. A distal lattice recess base 142 extends generally laterally between the inner ends 140a, 140b of the distal lattice recess sidewalls 136a, 136b.
A frangible cover strip 143 can be provided for releasably covering the distal lattice recess 134. The frangible cover strip 143 can extend laterally between the outer ends 140a, 140b of the distal lattice recess sidewalls 136a, 136b. In the example illustrated, the distal face 122 is generally planar, and the frangible cover strip 143 is coplanar with the distal face 122.
In the example illustrated, the connection between opposed lateral edges of the cover strip 143 and the adjacent outer ends 138a, 138b of the distal lattice sidewalls 136a, 136b comprises a thinned section of extruded material (e.g. having opposed v-grooves), facilitating tearing away the cover strip 143 to provide access to the recess 134 for use.
The rail profile 116 can additionally or alternatively be provided with a proximal lattice recess 144 associated with the proximal face 120. The proximal lattice recess 144 has laterally spaced apart proximal lattice recess sidewalls 146a, 146b each having an outer end 148a, 148b at the panel recess base 132, and an inner end 150a, 150b vertically intermediate the panel recess base 132 and the distal lattice recess base 142. A proximal lattice recess base 152 extends laterally between the inner ends 150a, 150b of the proximal lattice recess sidewalls 146a, 146b.
The rail profile 116 further includes at least one tongue 158 extending from one panel recess sidewall inwardly of the recess 124, towards the opposing panel recess sidewall. In the example illustrated, the tongue 158 extends from the panel recess sidewall 126a laterally (generally horizontally) towards the other panel recess sidewall 126b. The tongue 158 is joined to the panel recess sidewall 126a at a vertical position generally intermediate the inner and outer ends 128a, 130a thereof.
Referring to
Referring to
As seen in
A third rail 172 can be mounted atop the lattice panel 170. In the example, illustrated, the third rail 172 has the same common rail profile 116 as the first and second rails 112, 114. An upper marginal portion of the lattice panel 170 is received in the proximal lattice recess 144 (see also
In an alternate example shown in
In
Referring to
The profile 216 can also include pressure tabs 227 extending generally from the panel recess base towards the proximal face of the profile 216. The pressure tabs 227 are configured to bear against the end face of the panel 215. This can facilitate secure mounting of the panels 215 in the panel recesses 224.
In
Referring to
The front and back faces 417a, 417b can be provided with one or more recessed channels 486 extending along the height 460 of the panel. Each channel 486 comprises opposed channel side faces 490a, 490b, extending generally orthogonally from the respective panel face 417a, 417b and towards the panel interior (i.e. towards the opposing panel face), and a channel base 492 extending between the lateral faces. The channel base 492 is, in the example illustrated, generally planar and parallel to the faces 417a, 417b. The orthogonal (or lateral) extent of the channel side faces 490a, 490b generally defines a channel depth D1. The spacing between the channel side faces 490a, 490b (measured parallel to the rails) generally defines a channel width W1. The channels 486 provide the panels 415 with raised panel portions 425 on either side of the recessed channels 486. The raised panel portions 425 can create the appearance of a plurality of side-by-side slats each extending longitudinally along the height 460 of the panel 415.
In the example shown, each panel 415 comprises one channel 486 spaced approximately mid-way between the vertically extending ends 423a, 423b. However, in other examples, more than one channel 486 may be provided on each face.
Referring to
Further, the width W2 (extending parallel to the rails 412, 414) of each wall 494a, 494b is generally equal to the width W1 of the channel face 492. Accordingly, referring to
Referring to
Referring to
To provide the grooves 466a, 466b, 468a, 468b, a saw cut can be made across the entire width 421 of the panel 415. The depth of cut can be set to generally equal the channel depth D1, so that the thickness of the extruded wall forming the raised panels 425 is cut through, but the wall forming the base 492 is below the depth of cut and so remains uncut.
Upon installation, when the tongues 458a, 458b are received in the slots 466 and 468, the innermost edges of the tongues 458a, 458b generally abut the channel bases 492. This can help to close off what would otherwise be an opening between the outer edges 428a, 428b of the panel slot sidewalls 426a, 426b and the base panel 492 of the channels 486. If left uncovered, such openings could admit snow, dirt, water or other matter to invade the rails. Further, as grooves 466, 468 are not provided in channels 486 (i.e. grooves 466, 468 are not cut into the channel bases 492), the channel bases 492 may provide additional strength to the panels 415.
Another example of a fence section 1100 is shown in
Referring still to
Each of the vertical members 1150 defines and extends along a respective vertical axis, for example vertical axis 1156. The vertical members 1150 are, in the example illustrated, extruded lineals that each have the same extruded cross section. In some examples each vertical member 1150 may be extruded as a separate member, or may be an injection molded member, or the vertical members 1150 may each be cut to length from a single, longer extruded member. The vertical axis of each vertical member generally coincides with the extrusion direction of the vertical members. The upper 1152 and lower slots of the vertical members 1150 extend generally perpendicular to its vertical axis. The upper 1152 and lower slots may be formed in the vertical members 1150 using a secondary manufacturing process after the vertical members 1150 have been extruded, for example by cutting, routing, machining and milling. In the example illustrated the upper 1152 and lower slots are formed by plunge cutting with a saw blade having a thickness generally equal to the thickness of the slot. The saw blade can have a depth a cut that provides a slot all the way through the sidewall, and having notches in each edge wall orthogonal to the sidewall.
In some examples the upper 1152 and lower slots are cut into the sidewall 1160 so that the slot faces 1162, 1164 are generally orthogonal to the outer surface 1166 of the sidewall 1160. Such slots may be created by cutting the vertical members 1150 using a saw blade that is generally orthogonal to the sidewalls 1160. In other examples, the slots are cut into the sidewall 1160 so that the slot edge faces 1162 are at an oblique angle 1163 relative to outer surface 1166. This type of angle slot may be formed by cutting the vertical members 1150 with an angled saw blade. Angled slot edge faces 1162 may provide clearance for the attachment legs 1130 to flex and bend as they are snapped or snap-fit into the slots while maintaining the vertical connection to and support of the rail members 1110, 1112 once the attachment legs 1130 have been fully inserted into their respective slots. The slot end faces 1164 are parallel to each other and are spaced apart by a slot length 1159b and the slot edge faces 1162 are spaced apart by a slot height 1159a.
In the example illustrated, each attachment leg 1130 comprises opposing attachment leg end faces 1132 spaced apart by an attachment leg length. The attachment leg length is generally equal to, but slightly less than the slot length 1159b of the corresponding slot so that the attachment leg end faces 1132 can closely fit between the slot end faces 1164 without interfering with the slot end faces 1164 so that the attachment leg 1130 can be inserted into its slot.
Referring to
Referring still to
Referring still to
In the example illustrated in
Referring to
When the rails 1110, 1112 have a generally C-shaped profile, as illustrated in
Complementing the arrangement of opposing attachment legs 1130 each vertical member 1150 includes a set of complimentary opposing upper slots 1152 and a set of opposing lower slots 1154 formed in opposing sidewalls 1160 of the vertical member 1150 for receiving the opposing pairs of attachment legs 1130 on the upper and lower rails 1110, 1112 respectively.
In this example, the rail sidewalls 1120, 1122 may also be at least partially resilient to enable them to flex outwardly when the vertical members 1150 are inserted through the internal cavity 1124 when the attachment legs 1130 are not aligned with the slots 1152, 1154, and then to return to their original configuration after the attachment legs 1130 are inserted through the slots 1152, 1154.
The apertures 1126 in the upper walls 1118 of the rails 1110, 1112 are illustrated as being generally rectangular, with rounded corners that are shaped to snugly receive the vertical members 1150. In other examples, both the apertures 1126 and the vertical members 1150 maybe of a different configuration. While the vertical members 1150 are shown as being generally rectangular, it is understood that the cross-sectional shape (and its dimensions and proportions) of the vertical members 1150 may be any suitable shape, including square, rectangular, triangular, circular and polygonal. Similarly, the apertures 1126 may be of any desired size and shape that can receive a corresponding vertical member. The apertures may have the same general shape and size as the vertical members so that the vertical members closely fit within the apertures with little visible gap between the surfaces of the vertical member and the receiving aperture. Alternatively, the apertures may be of a different size and/or shape than the vertical members so that the vertical members are loosely received within the apertures. For example, a round vertical member could be loosely received within a larger, square aperture.
In an alternate example shown in
Referring now to
Fence section 1200 also includes a plurality of vertical members 1250 extending between the upper and lower horizontal rails 1210, 1212. Referring to
Referring to
With reference to
In some examples the slots 1252, 1254 can be cut into the sidewall 1260 so that the slot faces 1262, 1264 are generally orthogonal to the outer surface 1266 of the sidewall 1260. Such slots 1252, 1254 may be created by plunge cutting the vertical members 1250 using a saw blade that is generally orthogonal to the sidewalls 1260. In other examples, the slots 1252, 1254 are cut into the sidewall 1260 so that the slot edge faces 1262 are at an oblique angle relative to the outer surface 1266. The slot end faces 1264 are parallel to each other and are spaced apart by a slot length 1259b and the slot edge faces 1262 are spaced apart by a slot height 1259a.
Referring to
Referring to
Referring to
Each attachment leg 1230 may also be resilient, or include some resilient portions, so that it is moveable between a first position for inserting the attachment leg 1230 and barb 1234 through its slot 1252, 1254 and a second position for retaining (or securing or locking) the attachment leg 1230 within its slot 1252, 1254. When the attachment leg 1230 is in its first or insertion position the barb 1234 can be passed through the slot 1252, 1254 from outside the vertical member 1250 to inside the hollow interior of the vertical member 1250. To facilitate insertion of the attachment leg 1230 and barb 1234, an angled portion of the barb 1234 (extending from the leading edge 1240 to the abutment surface 1236 in the example shown) may engage a slot edge face 1262 and act as a cam surface to guide the barb 1234 as it is inserted, as described in detail above with respect to fence section 1100. When the attachment leg 1230 is in the second position the abutment surface 1236 engages the inner surface 1268 of the sidewall 1260. The resilient nature of the attachment leg 1230 biases the attachment leg 1230 is second position.
In the example of the fence section 1200 illustrated in
In one example, as illustrated in
In another example, as illustrated in
In this configuration, the attachment legs 1230 extending from the first rail sidewall 1220 of the upper and lower horizontal rails 1210, 1212 are received within and connected to the corresponding upper and lower slots 1252, 1254 of the vertical members 1250 in the first set of vertical members 1250a thereby securing each vertical member in the first set of vertical members 1250a adjacent the first sidewall of both horizontal side rails. Similarly, the attachment legs 1230 extending from the second sidewall 1222 of the upper and lower horizontal rails 1210, 1212 are received within and connected to the corresponding upper and lower slots 1252, 1254 of the vertical members 1250 in the second set of vertical members 1250b, thereby securing each vertical member 1250 in the second set of vertical members 1250b on the opposite side of the rails 1210, 1212 from the first set of vertical members 1250a, adjacent the second sidewall 1222 of both horizontal side rails 1210, 1212. When assembled in this configuration, the fence section 1200 can be described as a double-sided fence.
In the double-sided configuration, the first and second sets of vertical members 1250a, 1250b can be arranged to directly oppose each other, or, as illustrated in
In either the single-sided or double-sided configurations the attachment legs 1230 have an attachment leg length 1231 (the distance between opposing attachment leg end faces 1232, shown in
In each of the examples of fence sections described above, the attachment of the vertical members 1250 to the upper and lower horizontal rails 1210, 1212 includes only the connection between the attachment legs 1230 and the slots 1252, 1254 and is free from other fastening means. The connection between the attachment legs 1230 and the slots 1252, 1254 is a press-fit or snap-fit connection wherein an attachment leg 1230 is aligned with a corresponding slot 1252, 1254 and an insertion force is applied (by a user or during the manufacturing process) to push the attachment leg 1230 (including barb 1234) completely into its slot 1252, 1254. During insertion process the attachment leg 1230 (or a portion thereof) may deflect or bend as it passes through its slot 1252, 1254 and then “snap back” or return to its original position to positively engage a portion of the vertical member 1230 and retain the attachment leg 1230 within its slot 1252, 1254 once fully inserted. Fully inserted is understood to mean inserted to the extent necessary for the attachment leg 1130, 1230 to operatively or positively engage its slot 1252, 1254 so as to be retained therein to functionally secure the vertical members 1150, 1250 to the rails 1110, 1112, 1210, 1212. In the examples described, the attachment legs 1130, 1230 may be considered fully inserted when the they have been inserted to the point where abutment surface 1136, 1236 of the barb 1134, 1234 engages the inner surface 1168, 1268 of the vertical member sidewall 1160, 1260. When a functional or operational engagement between the vertical members and the rails is achieved an attachment leg 1130, 1230 may be considered fully inserted, even if a portion of the attachment leg 1130, 1230 extends beyond the outer sidewall surface 1168, 1268 such that a portion of the attachment leg is visible to the user after the fence sections have been assembled and the vertical members are slightly spaced from the rails.
Generally, a method for assembling a fence section using the snap-fit connectors described above includes providing a first and second horizontal rails that are parallel to, and spaced apart from each other. Both the first and second rails include at least one integrally formed attachment leg extending therefrom. In addition to the first and second rails the assembly method includes providing a plurality of vertical members. The size and shape of the vertical members may be dictated by user preferences or by the style of fence section being created (for example fence sections 1100, 1200). Each vertical member provided includes at least one upper slot formed in a sidewall for receiving one attachment leg from the first horizontal rail and at least one lower slot formed in the sidewall for receiving one attachment leg from the second horizontal rail. Depending on the fence style selected the upper and lower slots may be formed on the same sidewall or on opposing sidewalls. The fence panel is then assembled by connecting each vertical member to the first and second horizontal rails by inserting each attachment leg on the first horizontal rail into a corresponding upper slot on each of the vertical members and inserting each attachment leg on the second horizontal rail into the corresponding lower slot on each on each vertical member.
Referring to
Referring to
When the resilient retaining member 1335 is in the insertion position (as best shown in
The resilient retaining member 1335 of each barb 1334 forms the abutment surface 1336 and when the attachment leg 1330 is fully inserted in its slot (as defined above) the resilient retaining member 1335 moves to the retention position so that the abutment surface 1336 engages the inner surface 1368 of the vertical member sidewall 1360. In the examples illustrated, when the retaining member 1335 is inserted and moved to the retention position the base surface 1338 of the rail 1310 contacts the outer surface 1366 of the vertical member sidewall 1360.
In some examples, the contact between the retaining member 1335 and the base surface 1338 and the inner and outer surfaces 1366, 1368 of the vertical member sidewall 1360 creates a satisfactory connection between the rails and the vertical members. In other examples, as shown in
Each protrusion 1339 has a protrusion height 1339a (shown in
Referring now to
Similarly to the example of
Referring now to
The second extruded lineal 1410 extends lengthwise along a second longitudinal axis 1414 and includes an attachment leg 1430 (also referred to as a first attachment leg) corresponding to the slot 1452. The attachment leg 1430 extends outward from the second extruded lineal 1410 and is generally parallel to the second longitudinal axis 1414. The first attachment leg 1452 is integrally formed with the second extruded lineal 1410 and is inserted into or received within in the first slot 1452 to secure the first extruded lineal 1450 to the second extruded lineal 1410.
Optionally, as shown in
In the single-slot and double-slot examples, each slot 1452, 1453 forms an opening that extends through the sidewall 1460. Each opening or slot 1452, 1453 has opposed slot edge faces 1462 and opposing slot end faces 1464. The slot edge faces 1462 and slot end faces 1464 extending through the sidewall 1460 from the outer surface 1466 of the sidewall 1460 to the inner surface 1468 of the sidewall 1460.
In the example illustrated, the slot edge faces 1462 are parallel to each other and perpendicular to the outer surface 1466 of the sidewall 1460 and the first longitudinal axis 1456. In another example, the slot edge faces 1462 are at an oblique angle relative to the first longitudinal axis 1456 (for example the slot edge faces 1162 and 1262 described above).
Each attachment leg 1430, 1431 has a distal portion spaced apart from the second extruded lineal 1410 and a barb 1434 that extends from the distal portion. Each barb 1434 includes an abutment surface 1436 that engages and bears against a portion of the inner surface 1468 of the sidewall 1460 that is adjacent the slot 1452, 1453 into which the attachment leg 1430, 1431 is received. This engagement between the abutment surface 1436 and the inner sidewall surface 1468 may help to retain the attachment leg 1430, 1431 within its slot 1452, 1453 when the attachment leg 1430, 1431 is fully inserted into its slot 1452, 1453.
The second extruded lineal 1410 also includes a base surface 1438 that cooperates with the abutment surface 1436 to secure the second extruded lineal 1410 to the first extruded lineal 1450. Each attachment leg 1430, 1431 extends from the base surface 1438 and the base surface 1438 generally opposes the abutment service 1436 (either physically—i.e. the surfaces are facing each other, or operationally/functionally—i.e. the abutment surface and the base surface exert generally opposing forces on the first extruded lineal) and is spaced apart from the abutment surface 1436 by a distance 1472 that is greater than the thickness T of the first extruded lineal sidewall 1460.
The slot end faces 1464 are spaced apart by a first width 1474 (also referred to as a slot width) and the attachment legs 1430, 1431 received within each slot 1452, 1453 second width 1476. The second width 1476 is generally equal to, but at least slightly shorter than, the first width 1474 so the attachment legs 1430, 1431 can fit within the slots 1452, 1453 but translation or sliding of the first extruded lineal 1450 relative to the second extruded lineal 1410 along the second longitudinal axis 1414 is inhibited when the attachment legs 1430, 1431 are received in their slots 1452, 1453.
While the above description provides examples of one or more processes or apparatuses in accordance with the applicant's contribution to the state of the art as disclosed herein, it will be appreciated that other processes or apparatuses may be within the scope of such contribution, and any exclusive right that may be granted to the applicants in respect of such contribution is not necessarily limited to the aforementioned examples as specifically described herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2669440 | Jun 2009 | CA | national |
This application claims priority from U.S. Provisional Patent Appn. Ser. No. 61/106,665, filed on Oct. 20, 2008; and U.S. Provisional Patent Appn. Ser. No. 61/109,764, filed on Oct. 30, 2008; and Canadian Pat. Appn. Ser. No. 2,669,440, filed on Jun. 18, 2009, each of which is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61106665 | Oct 2008 | US | |
| 61109764 | Oct 2008 | US |
