Ornamental fencing system and method for assembling the same

Abstract: A fence has at least one fence section which extends between a pair of posts. Each of the fence section has an upper and lower horizontal rail extending between the posts. A plurality of channels extends transversally through the rails. Pickets are vertically inserted through the channels of the upper and lower rails, each picket having its top extremity projecting upwardly of the upper rail. Picket caps are each associated with a corresponding one of the pickets. Each picket cap has a body portion rigidly affixed to the top extremity of its corresponding picket, the picket also having a first arm and a second arm projecting on opposite sides of the body portion and extending along the upper rail of the fence section. The first arm of each picket cap is attached to the second arm of the picket cap affixed to an adjacent picket with attaching means. (end of abstract)

Ornamental fencing system and method for assembling the same description/claims

Brief Patent Description

Full Patent Description

Patent Application Claims

PRIORITY

This application claims priority from U.S. Provisional Patent Application No. 60/996,752 filed Dec. 4, 2007, the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to fences, and more particularly relates to ornamental fences.

BACKGROUND OF THE INVENTION

Ornamental fences are often used as protective enclosures around swimming pools and gardens or for delimiting backyards and entryways. They are generally made of galvanized steel and include vertical posts, horizontal rails, pickets and decorative parts.

A problem with existing ornamental fences is that they are made of welded pre-assembled sections which are difficult to transport and store due to their size, typically 5 feet×8 feet. In addition, shipping fees for sending pre-assembled sections are also prohibitive due to their size, limiting the market of ornamental fences to areas close to where the sections are manufactured. Moreover, the assembly process of ornamental fences requires welding skills and specialized tools, making it difficult for regular home-owners to install the fences by themselves. Ornamental fence buyers must typically rely on skilled fence installers for assembling the fences, contributing to the high cost of existing fencing systems.

In order to overcome some of the above mentioned problems, non-welded fencing systems have been designed. However, such prior art fencing systems require many small parts to be assembled and screwed. Another disadvantage of proposed fencing systems that do not require pickets to be welded to horizontal rails is that their assembly parts cannot be used with existing pickets devised for welded fencing systems. Manufacturers must then design, manufacture and hold in stock different types of pickets for different types of fences, rather than using type of pickets.

The prior art in the field includes are U.S. Pat. No. 7,025,335 (ZHU); U.S. Pat. No. 6,431,764 (CONNER); U.S. Pat. No. 4,991,823 (STANISH); U.S. Pat. No. 6,752,386 (BUNDY); U.S. Pat. No. 6,804,921 (NEYLON); U.S. 2005/0045863 (MACKAY); U.S. 2005/0285091 (KO); U.S. 2006/0001015 (FORBIS et al.); U.S. 2007/0080332 (ALLEN); U.S. 2008/0179581 (MULGREW) and U.S. 2008/0250749 (WELDON et al.).

U.S. Pat. No. 7,025,355 (ZHU) discloses a modular picket fence. In the first embodiment described, the pickets are provided with locking slotted apertures and locking clips inserted in said apertures, the clips engaging against a surface of the rails of the fence, hence retaining the pickets in the rails. In the other embodiment described, a spring clip is inserted in a transverse aperture of the picket, the spring clip retaining the picket in the rails of the fence. While this fence system offers a modular solution, several parts need to be assembled, and the overall assembly process requires a lot of steps. Pickets traditionally used in welded fence system can not be used without or with few modifications since apertures must be made in the pickets. The pickets are also affixed to both rails of the fence, for ensuring proper rigidity and stability to the fence.

U.S. 2005/0045863 (MACKEY) discloses a modular metal fence panel assembly wherein the pickets are affixed to inverted U-shape rails with elongated-locking bars inserted in the rails. The locking bars are provided with regularly spaced tabs which engage in recesses made in the pickets. Collars are inserted on the top ends of the pickets for positioning the picket recesses in register with the locking bar tabs. While this invention involves fewer parts than ZHU, pickets traditionally used in welded metal fence cannot be used without modifications.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a fence having at least one fence section which extends between a pair of posts. Each of the fence section includes an upper horizontal rail and a lower horizontal rail extending between the posts and connected to them. A plurality of channels extends transversally through the rails. A plurality of pickets are vertically inserted through the channels of the upper and lower rails, each picket having its top extremity projecting upwardly of the upper rail. A plurality of picket caps are each associated with a corresponding one of the pickets. Each picket cap has a body portion rigidly affixed to the top extremity of its corresponding picket, the picket also having a first arm and a second arm projecting on opposite sides of the body portion and extending along the upper rail of the fence section. The first arm of each picket cap is attached to the second arm of the picket cap affixed to an adjacent picket with attaching means.

In accordance with another aspect of the present invention, there is provided a kit for use in a fence as described above, the kit including a plurality of picket caps and attaching means. Each picket cap has a body portion rigidly affixable to a top extremity of a corresponding picket, a first arm and a second arm projecting on opposite sides of the body portion. The attaching means are for attaching together the respective first arm and second arm of pairs of picket caps when affixed to adjacent pickets.

In accordance with a further aspect of the present invention, there is also provided a method for building a fence section. The method includes the steps of:

- a) erecting and fixing a pair of posts to a rigid surface;
- b) connecting ends of an upper horizontal rail and a lower horizontal rail to each one of the pair of posts, the rails extending substantially orthogonally to the posts and such that the channels of the upper rail are aligned with the channels of the lower rail;
- c) affixing each of a plurality of picket caps to a top end of a corresponding one of a plurality of pickets. Each picket cap has a body portion rigidly affixable to the top extremity of the corresponding picket, each picket cap further having a first arm and a second arm projecting on opposite sides of the body portion;