Patent Application
20250116131
The invention relates to improving methods and apparatus for making brackets for fences, and more particularly, the invention relates to improving methods and apparatus for making brackets for louvered panels. fences.
Louvered panels, also known simply together as a louver, are parallel horizontal panels or slats that are usually arranged in even spacing and unform angle. In the past, louvered panels have been utilized mainly with windows because they allow for ventilation and penetration of natural light while keeping out rain, snow, and heat.
The present invention is a louvered fence bracket for retaining multiple louver boards, also called louvers, louver panels, or slats, in a desired angle and a desired spacing for a fence or a similar structure, such as a pergola. The louvered fence bracket comprises at least two bracket portions and at least one parallelogrammatic support body portion. Each bracket portion is comprised of a rectangular bracket body, a first sliding prevention portion, and at least one second sliding prevention portion. The first sliding prevention portion is attached perpendicularly to a width of the rectangular bracket body to form an end bracket for receiving and retaining a louver board. The at least one second sliding prevention portion is attached perpendicularly to a length of the rectangular bracket body to form at least one side bracket for receiving and retaining the louver board. The at least one parallelogrammatic support body portion is comprised of a first short side, a second short side, and at least one fastener receiver. The at least one parallelogrammatic support body portion attaches to a second length of the rectangular bracket body of one of the at least two bracket portions by the first short side and the length of the rectangular bracket body of another of the at least two bracket portions by the second short side to align the at least two bracket portions at the desired angle and the desired spacing. The at least one fastener receiver attaches the louvered fence bracket to a fencing post using a fastener.
In an embodiment, the at least two bracket portion is at least three bracket portions and the at least one parallelogrammatic support body portion is at least two parallelogrammatic support body portions. In such embodiment, a first bracket portion is connected to a second bracket portion with a first parallelogrammatic support body portion and the second bracket portion is connected to a third bracket potion with a second parallelogrammatic support body portion. In an embodiment, the first bracket portion is welded to the second bracket portion with the first parallelogrammatic support body portion and the second bracket portion is welded to a third bracket potion with a second parallelogrammatic support body portion to form the louvered fence bracket. In an embodiment, the at least one second sliding prevention portion of each of the at least three bracket portions may be at least two second sliding prevention portions to form at least two side brackets. The at least one fastener receiver of each of the at least two parallelogrammatic support body portions may be at least one hole for attaching the louvered fence bracket to the fencing post using at least one screw. The material for the louvered fence bracket may be comprised of one or more of sheet metal, plastic, or resin. In an embodiment, the louvered fence bracket may further comprise at least one louver support for preventing twisting and warping of at least one louver board. In an embodiment, the louvered fence bracket may further comprise at least one cap board for securing at least one louver board in place in the louvered fence bracket.
Another embodiment of the present invention is a louvered fence bracket system for retaining multiple louver boards in a desired angle and a desired spacing for a fence or a similar structure, the louvered fence bracket system. The louvered fence bracket system is comprised of at least one louvered fence bracket, a side support board, and a fascia mount. Each louvered fence bracket is comprised of a vertical bracket body, a sliding prevention portion, a top connection portion at the top end of the vertical bracket body, and a bottom connection portion at the bottom end of the vertical bracket body. The vertical bracket body has a height, a top end with an alignment receiver and a notch forming portion, and a bottom end with a notch forming portion. The sliding prevention portion attaches at the desired angle to a first side of the vertical bracket body for receiving and retaining a louver board. Multiple louvered fence brackets can be connected together by connecting the top end of one of the at least one louvered fence bracket to the bottom end of another one of the at least one louvered fence bracket. A notch forms from the notch forming portion of the top end of the one of the at least one louvered fence bracket and the notch forming portion of the bottom end of the another one of the at least one louvered fence bracket when connected. The side support board attaches to each of the vertical bracket body of the at least one louvered fence bracket using the alignment receiver of the top end and retaining ends of the louver boards in place. The fascia mount attaches perpendicularly to the side support board and is for aligning a second side of vertical bracket body of each of the at least one louvered fence bracket and is adapted for attaching the louvered fence bracket system to the fence post.
In an embodiment, the sliding prevention portion further comprises a bend adapted for receiving and retaining an edge of the louver board. In an embodiment, the fascia mount may further be adapted for overlaying the fence post. In an embodiment as shown in
In an embodiment, the multiple louvered fence brackets may be connected by welding together the top end of the vertical bracket body of one of the at least one louvered fence bracket and the bottom end of the vertical bracket body of another one of the at least one louvered fence bracket, thereby forming one continuous louvered fence bracket body. In such embodiment, the louvered fence bracket system may further comprise at least one cap board for securing at least one louver board in place in the louvered fence bracket system. The at least one cap board may have a zigzag shape to cover multiple louvered fence brackets and multiple louver boards. The zigzag shape of each of the at least one cap board may be comprised of at least one short portion and at least one long portion. Each of the short portion may be shaped to cover a top of one of the sliding prevention portion of the at least one louvered fence bracket and a top of one of the multiple louver boards held by the respective louvered fence bracket.
Methods of making the louvered fence bracket and the louvered fence bracket system are also described herein.
Louver boards are aesthetically pleasing and enhance privacy as it is harder to peek through them due to their design. Because of their advantages, louvered boards have been further utilized in many applications including fencing, roofs, wind breaks, shower areas, enclosed areas under decks, and interior room dividers. Modern louver boards are often constructed with aluminum, metal, wood, or glass. Louvered fences, or louver fencings, have become a popular choice for those who want enhanced privacy and seclusion of their property while allowing for increased airflow than traditional wooden fences can provide. Louvered fences are therefore used in many commercial and residential purposes.
The standard method of producing louvered fencing includes numerous repetitive measurements to establish each louver board's required spacing and angle for each individual louver board. Extensive measurements are necessary for the desired appearance of each louver board's spacing, centering, angle, and leveling. Repeating these actions for each louver board requires the constructor's investment of substantial time and materials. After completing measurements, the louver boards must also be affixed to the post through methods including but not limited to 1) cutting slots into the post using a guide or a jig, 2) affixing the louver board to the post with nails making cuts into the post, and 3) using highly skilled techniques of nailing louver boards in place. Methods used depend on the skill of the constructor and the cost and availability of materials. The stability of each louver support requires several screws for attachment, which must accurately align to provide the desired parallel finished appearance. Repeating these actions on each supporting post of the fence also requires investment of substantial time and materials. Materials commonly used to support the louver boards, including wood and plastic, have a limited useful life and are susceptible to environmental damage and decay. Therefore, skilled carpentry is required on every step to achieve the desired level of consistency and quality, leading to high labor costs. If not done correctly and accurately, a quality product may not be achieved, resulting in disappointment and frustration among the persons involved, and lead to setbacks in construction time and cost through redoing work or repurchasing materials that were made unusable.
The louvered fences that are currently available are cumbersome to put together, mainly when assembled by unskilled labor. Therefore, a means to construct louvered fence accurately in spacing and angle in less time while reducing the skill, materials, and fasteners required to build a louvered fence is needed. Consequently, a novel bracket designed to simplify and expedite the construction of louvered fences while maintaining quality is provided.
With a general reference to
The louvered fence bracket 100, or the substantially similar louvered fence bracket 210 of the louvered fence bracket system 200, can be made from any material that can be formed into a correct shape for the louvered fence bracket 100 or the louvered fence bracket 210 of the louvered fence bracket system 200 and withstand the weight and stresses typical for fence brackets. Materials used should be resistant to corrosion in outdoor environments. The material for the louvered fence bracket can be, but are not limited to, sheet metal, plastic, and resin. For example, sheet metals such as aluminum, carbon steel, stainless-steel, galvanized steel, powder-coated steel, Corten steel (also known as weathering steel) with thicknesses of 0.5 mm to 3 mm can be used. Plastics such as polycarbonate, thermoplastic polyolefin (TPO), acrylic, acrylonitrile butadiene styrene (ABS) can be used. Various types of resin and composites can be also used.
The louvered fence bracket 100 or the louvered fence bracket 210 of the louvered fence bracket system 200 may attach to fence posts, such as wood, using standard, readily available fasteners, such as nails, bolts, and screws. Other means known in the art for attaching a fence bracket to a fence post may be used. For a more permanent fence, a number of recycled materials can be used as fence posts as well.
The louvered fence brackets 100 or the louvered fence brackets 210 of the louvered fence bracket system 200 may have bracket bodies (e.g., rectangular bracket body 111 and vertical bracket body 211, respectively), which can be considered to be “shelves,” spaced and angled to support each louver board 500 (see
The dimensions of the louvered fence bracket 100 components or the louvered fence bracket system 200 components can vary as desired and needed to accommodate different lumber types and sizes of the louver board 500. Typical use cases may include louver boards 500 with thickness of 5/4″ and width of 6″, thickness of 1″ and width of 6″, thickness of 5/4″ and width of 6″, thickness of ⅝″ and width of 6″, thickness of 1″ and width of 4″, and thickness of ⅝″ and width of 4″.
With reference to
In an embodiment shown in
Further, in the embodiment shown in
Still further, in the embodiment shown in
As shown in the embodiment in
In
In an embodiment, the louvered fence bracket 100 may further comprise at least one louver support for preventing twisting and warping of at least one louver board 500. The louvered fence bracket 100 also may further comprise at least one cap board for securing at least one louver board 500 in place in the louvered fence bracket 100.
With reference to
According to an embodiment as shown in
For the louvered fence bracket system 200 as shown in
For the louvered fence bracket system 200 as shown in
Referring to
In an embodiment, the at least one L-bracket can easily be added to the inside of the louvered fence bracket 210 of the louvered fence bracket system 200 so a 2″×4″ cap board can be installed across the top or bottom of the louvered area. This may finish the louvered fence area so it can be easily mown or trimmed along the bottom, for example, without damaging the louver boards 500, and can be replaced when needed, increasing the ease of maintenance. Further, in an embodiment, louver boards 500 can be easily secured from the back side because the louver boards 500 are held in place in the front by fascia mount 240. Additional securing of each louver board 500 is also possible from the back of the louvered fence bracket 210 of the louvered fence bracket system 200.
In an embodiment, the louver boards 500 may be mounted vertically to a structure (other than vertical fence posts) rather than horizontally using the louvered fence bracket 100 or the louvered fence bracket system 200. In an embodiment, the louvered fence bracket 100 or the louvered fence bracket system 200 can be used in a pergola where the surfaces they are attached to are not fence posts and are not parallel to one another.
In an embodiment, the louvered fence bracket 100 or the louvered fence bracket system 200 can be further comprised of a support (louver support) that work in conjunction with the louvered fence bracket 100 or the louvered fence bracket system 200, to prevent twisting and warping, especially of long louver boards 500.
A method of building a fence using the louvered fence bracket 100 comprises the steps of: 1) securing at least two fence posts 603 such that a surface of each of the fence posts 603 face one another; 2) aligning the at least one parallelogrammatic support body portion 120 of the bracket portion 110 of one louvered fence bracket 100 with the front edge of one of the at least two fence posts 603 (a first fence post); 3) attaching the louvered fence bracket 100 to the first fence post 603 using a fastener that is appropriate for the fence post material, such as wood screws or lag screws for wood posts and self-tapping metal screws for metal posts; 4) aligning the at least one parallelogrammatic support body portion 120 of the bracket portion 110 of another louvered fence bracket 100 with the front edge of another of the at least two fence posts 603 (a second fence post), and leveling the another louvered fence bracket 100 with the louvered fence bracket 100 attached to the first fence post 603; 5) sliding louver boards 500 into position between the two louvered fence brackets 100; and 6) using the appropriate fastener to attach each louver board 500 to the two louvered fence brackets 100.
There are several methods for making the louvered fence bracket 100 and the at least one louvered fence bracket 210 of the louvered fence bracket system 200. Generally, as shown in the flowchart in
One method of making the louvered fence bracket 100 and the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is to laser cut and bend 223 with a brake press. Such method of manufacturing the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is comprised of following steps: 1) cutting a material to make at least one flat louvered fence bracket having a bracket body and at least one sliding prevention portion; and 2) using a brake press machine to form a bend in the at least one sliding prevention portion of the at least one louvered fence bracket. Lasers, waterjet, or other cutting tool known in the art may be used to cut the material.
Another method is to laser cut, then bend with a metal stamping tool and press. Such method of manufacturing the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is comprised of following steps: 1) obtaining a custom stamping or die tool; 2) cutting a material to make at least one flat louvered fence bracket having a bracket body and at least one sliding prevention portion; 3) mounting the stamping or die tool onto a stamping press; and 4) using the stamping press on the at least one sliding prevention portion of the at least one louvered fence bracket at least one flat to form a bend in the at least one sliding prevention portion of the at least one louvered fence bracket. The custom-built stamping die/tool allows one tool to be used over and over. Lasers, waterjet, or other cutting tool known in the art may be used to cut the material.
Another method is to cut and bend with a metal stamping tool and press. Such method of manufacturing the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is comprised of following steps: 1) obtaining a custom stamping or die tool; 2) mounting a stamping or die tool onto a stamping press; 3) feeding bracket material into the stamping press; and 4) using the stamping press on the bracket material to form at least one flat louvered fence bracket having a bracket body and at least one sliding prevention portion and form a bend in the at least one sliding prevention portion of the at least one louvered fence bracket. The custom-built stamping die/tool allows one tool to be used over and over.
Another method is to use a mold. Such method of manufacturing the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is comprised of following steps: 1) obtaining a custom mold; and 2) injecting a bracket material into the mold to form at least one flat louvered fence bracket having a bracket body and at least one sliding prevention portion with a bend. The custom mold allows one tool to be used over and over, and the custom mold should be one that is appropriate for the material used for the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200.
Another method is to use a 3D printer. Such method of manufacturing the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is comprised of following step: using a 3D printer to print at least one flat louvered fence bracket having a bracket body and at least one sliding prevention portion with a bend.
The methods of making the louvered fence bracket 100 or the at least one louvered fence bracket 210 of the louvered fence bracket system 200 is not limited to the methods mentioned above. Any other method that is appropriate for the material used and known or will be known in the art may be used.
The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”
In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.
Embodiments of the present disclosure have been described with reference to the embodiments illustrated in the attached drawing figures. However, equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. Therefore, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the claimed subject matter in its broader aspects. The appended claims are intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.
This is a U.S. non-provisional patent application claiming the benefits and priorities of co-pending U.S. provisional Patent Application Ser. No. 63/588, 751, filed on Oct. 8, 2023, and co-pending U.S. provisional Patent Application Ser. No. 63/624,821, filed on Jan. 25, 2024, both of which are incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63588751 | Oct 2023 | US | |
| 63624821 | Jan 2024 | US |
