TITLE Fencing System and Method of Fencing Installation

FIELD OF THE INVENTION The invention relates to fences and barriers. In particular, although not exclusively, the invention relates to an improved metal picket fencing system comprising interchangeable components.

BACKGROUND TO THE INVENTION Picket fences have been popular for hundreds of years. Such popularity is due to picket fencing's durability and attractive appearance, and its ease of assembly. Modern materials and manufacturing methods have created numerous alternative design options for picket fences. The termite resistance and low cost of many metals provide a common alternative to traditional wood fences. Further, various new shapes, sizes and attachment mechanisms are available for assembling the posts, cross members and pickets of a fence. Several prior art picket fence patents are described below.

US Patent No. 5,372,354 describes a picket fence permitting adjacent sections to be oriented angularly. Upper rails are mounted removably to posts and lower rails are mounted removably and rotatably to the posts. Relatively complex and rigid attachment means are used to connect palings between the upper and lower rails.

US Patent No. 5,531 ,427 describes a metallic fence system that includes a conventional look of a wooden fence. Adjustable pickets can be varied in width to suit particular applications.

US Patent No. 5,581 ,868 describes a method and apparatus for constructing a metal picket fence. Pickets are pressed into holes to form fence panels that are fastened to posts. An angled, self-locking pin system is provided to lock picket ends in the frame tube holes to prevent removal of the pickets.

US Patent No. 6,631 ,887 describes a vertical fencing system having vertical tubes and a horizontal rail. The rails include inturned parts to permit rotation and locking of the vertical tubes during assembly.

US Patent No. 6,824,123 describes a picket fence and rail mounting system that is transformable by a consumer into various styles. The system includes upper and lower elongate metal rails having hollow interiors. A plurality of pickets are transversely slidable through openings in the rails. The pickets each have notches to assist in securing the pickets to the rails. Finials and decorative inserts may be secured to the fence to provide various styles. Prior art metal picket fences, including features of the above described fences, often remain difficult to assemble, are not easily adapted to various landscapes, and include visually unappealing fasteners and locking mechanisms, which protrude from pickets, rails and posts.

There is therefore a need for an improved fence system and method of fencing installation that overcomes many of the above described disadvantages of the prior art.

OBJECTS OF THE INVENTION

Therefore an object of the present invention is to overcome or at least alleviate one or more of the above limitations including providing an improved fencing system and a method of fencing installation.

SUMMARY OF THE INVENTION

Accordingly, in one form, the present invention is a fencing system comprising: at least two posts; at least two perforated rail sections connected to the posts; a plurality of palings extending between the at least two perforated rail sections; and covering rail sections assembled adjacent the perforated rail sections.

Optionally, the at least two perforated rail sections are identical components which are inverted to create upper and lower rail sections.

Optionally, the covering rail sections are snap fit together with the perforated rail sections and cover fasteners connecting the perforated rail sections to the posts.

Optionally, the perforated and covering rail sections are L-shaped and form a rectangular channel when assembled together.

Optionally, the covering rail sections include clamping tabs to secure the ends of the palings.

In another form, the present invention is a method of installing a fence system comprising the steps of: installing posts; connecting perforated rail sections to the posts; inserting palings through the perforated rail sections; and assembling covering rail sections adjacent the perforated rail sections.

Optionally, the rail sections are raked relative to the palings so that the palings remain relatively vertical over sloped ground, and wherein the covering rail sections cover distal ends of the palings. Further features and advantages of the present invention will become apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect, preferred embodiments of the invention will be described by way of example only with reference to the accompanying drawings, in which:

FIG. 1 is a schematic diagram showing a top view of a perforated rail section according to an embodiment of the present invention; FIG. 2 is a schematic diagram showing a cross sectional view of a perforated rail section and a covering rail section according to an embodiment of the present invention;

FIG. 3 is a schematic diagram of an end view of an assembled fence system according to an embodiment of the present invention;

FIG. 4 is a schematic diagram of a portion of a front view of a fence system showing rectangular palings raked at an angle alpha according to an embodiment of the present invention;

FIG. 5 is a schematic diagram showing a cross section view of perforated and covering rail sections according to a further embodiment of the present invention designed to minimize rattling of palings;

FIG. 6 is a schematic diagram showing a cross section view of alternative perforated and covering rail sections according to a further embodiment of the present invention designed to minimize rattling of palings; FIG. 7 is a schematic diagram of a top view of a perforated rail section used to create a traditional picket fence style having a single row of palings with gaps between the palings according to an embodiment of the present invention;

FIG. 8 is a schematic diagram of a top view of a perforated rail section used to create a barrier fence having no gaps between the palings according to an embodiment of the present invention;

FIG. 9 is a schematic diagram of a top view of a perforated rail section used to create a privacy fence having staggered palings that enables air to move through the fence but does not enable one to look orthogonally through the fence according to an embodiment of the present invention; FIG. 10 is a perspective cross-sectional view illustrating a perforated rail section 100 connected to a covering rail section 200, according to some embodiments of the present invention; and

FIG. 11 is a general flow diagram illustrating a method of installing a fence system according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Embodiments of the present invention are presented as apparatus components and method steps related to a fencing system and method of fencing installation. Elements of the apparatus are illustrated in concise outline form in the drawings, showing only those specific details that are necessary to

understanding the embodiments of the present invention, but so as not to clutter the disclosure with excessive detail that will be obvious to those of ordinary skill in the art in light of the present description.

In this patent specification, adjectives such as first and second, left and right, top and bottom, upward and downward, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as "comprises" or "includes" are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

Referring to FIG. 1 there is a schematic diagram showing a top view of a perforated rail section 100 according to an embodiment of the present invention. The section 100 includes an L-shaped cross section and perforations 105 in a perforated plate 110.

Referring to FIG. 2 there is a schematic diagram showing a cross sectional view of a perforated rail section 100 and a covering rail section 200 according to an embodiment of the present invention. The cross sectional view is magnified relative to the top view shown in FIG. 1. The covering rail section 200 is designed to lock or snap-fit into the perforated rail section 100 using, for example, notch and hook elements 205.

Referring to FIG. 3 there is a schematic diagram of an end view of an assembled fence system 300 according to an embodiment of the present invention. Two sets of perforated rail section 100 and covering rail section 200 are connected to a vertical post 305. Pickets or palings 310 are positioned between the two sets of rail sections 100, 200, and are inserted through the perforations 105 in the perforated plates 110. The perforated rail sections 100 include holes for receiving fasteners 315 that connect to the post 300. The covering rail sections 200 can be locked into place using a simple snap fit mechanism after the fasteners 315 are installed. Thus the covering rail sections 200 cover the fasteners 315 and the ends of the palings 310 and provide for a clean final look and finish to the completed fence system 300.

Those skilled in the art will appreciate the significant advantages of the fence system 300. For example, in addition to the clean final look of the system 300, the perforations 105 in the perforated rail sections 100 enable the palings 310 to be raked or angled with respect to the rail sections 100, 200. Referring to FIG. 4 there is a schematic diagram of a portion of a front view of a fence system 300 showing rectangular palings 310 raked at an angle alpha according to an embodiment of the present invention. Depending on the relative widths of the palings 310 and the height of the rail sections 100, 200, the palings 310 can be raked at very steep angles alpha relative to the rail sections 100, 200. That enables a fence system 300 to be installed on sloping ground but without requiring any special cutting or adjustments of the ends of the palings 310. Raked palings 310 do not require cutting because the covering rail sections 200 hide distal ends 400 of the palings 310 — providing a clean and professional finished look. Referring to FIGS. 5 and 6 there are schematic diagrams showing cross section views of perforated and covering rail sections 100, 200 according to a further embodiment of the present invention designed to minimize rattling of palings 310. FIG. 5 illustrates a single row of clamping tabs 500 into which the ends of palings 310 are engaged, thus securing the palings 310 to the rail section 200. Such secured palings 310 are less likely to rattle or make other objectionable noise in, for example, high wind conditions. Further, the clamping tabs 500 ensure that little or no welding is required to assemble a fence system 300 according to an embodiment of the present invention. FIG. 6 is a schematic diagram illustrating a double row of clamping tabs 500 used to secure staggered palings 310, which are described in more detail below.

Those skilled in the art will appreciate that the components of the present invention including the posts 305, perforated rail sections 100, covering rail section 200 and clamping tabs 500 can be manufactured using various techniques, such as, for example, combinations of stampings, extrusions and welding. Further, the above components of the present invention can be made of various materials such as, for example, aluminium, steel and various polymers or composites.

The present invention is thus an improved fencing system and method of fencing installation that enables aesthetically appealing metal fences to be quickly installed without the need for welding or excessive cutting of components. Further, manufacturers and suppliers of a system 300 can offer alternative forms of perforated rail sections 100 that provide very different styles of fences. For example, referring to FIGS. 7, 8 and 9 there are schematic diagrams of top views of perforated rail sections 100 including various patterns used to create different fence styles. Sample dimensions in millimetres are also shown. FIG. 7 illustrates a traditional picket fence style having a single row of palings 310 with gaps between the palings 310. FIG. 8 illustrates a barrier fence having no gaps between the palings 310. Finally FIG. 9 illustrates a picket fence having two staggered rows of palings 310. The fence style in FIG. 9 thus creates a privacy fence that enables air to move through the fence but does not enable one to look orthogonally through the fence. Those skilled in the art will further appreciate the useful adaptability of a fence system 300 according to an embodiment of the present invention. For example, identical palings 310, posts 305, fasteners 315 and covering rail sections 200 can be used to create all of the various fence styles illustrated in FIGS. 7 through 9. Only the perforated rail sections 100 are changed to completely change a fence style. That results in considerable economies of scale and cost reductions for mass produced fence products according to the present invention. Further, fence retailers can maintain lower levels of inventory of fence components, thus further reducing costs, while still offering customers a wide range of fence styles. The palings 310 can be U-shaped channels in all of the fence embodiments shown in FIGS. 7 through 9. In FIGS. 7 and 9 a single U-shaped channel paling 310 is inserted through each perforation 105 in the same or in alternating directions. If alternating directions are used, a fence system 300 will have an identical look from either side of the fence. That presents a further significant advantage of the present invention, as it avoids common disputes between neighbours over the look of traditional picket fences that have only one smooth side, where the other side, viewed by a neighbour, displays the back of

wooden rail sections. In FIG. 8 the palings overlap and are also inserted in alternating directions to create a complete visible barrier that has an identical look on either side.

Referring to FIG. 10, a perspective cross-sectional view is illustrated of a perforated rail section 100 connected to a covering rail section 200, according to some embodiments of the present invention. Alternative embodiments of the clamping tabs 500 are illustrated as clamping tabs 505, where one clamping tab 505 is connected to the perforated rail section 100 and another clamping tab 505 is connected to the covering rail section 200. The use of the clamping tabs 505 in both the perforated rail section 100 and in the covering rail section 200 provide a further mechanism for securing palings 310 that are inserted through the perforations 105.

The perforations 105 also can be located in both the perforated rail section 100 and in the covering rail section 200 so as to receive the palings 310. That enables the palings 310 to extend through both the perforated rail section 100 and the covering rail section 200, such as, for example, where the perforated rail section 100 and the covering rail section 200 together form a middle horizontal rail, positioned between a top horizontal rail and a bottom horizontal rail, of a fence. Referring to FIG. 11 , a general flow diagram illustrates a method 1000 of installing a fence system 300 according to an embodiment of the present invention. First, at step 1005 posts 305 are installed. The posts 305 can include various materials and shapes including thin walled rectangular metal stock. At step 1010 perforated rail sections 100 are connected to the posts 305. Those skilled in the art will appreciate that connecting the rail sections 100 to the posts 305 can be done using various types of fasteners 315 such as bolts or screws or using various other types of connection means such as clips. At step 1015 palings 310 are inserted through perforations 105 in the rail sections 100. Finally, at step 1020, covering rail sections 200 are assembled adjacent to the perforated rail sections 100. The covering rail sections 200 can be connected to the perforated rail sections 100 using for example notch and hook elements 205.

Those skilled in the art will further appreciate that the fencing system and method of fencing installation of the present invention are not limited to exterior commercial and residential fencing. Interior walls and barriers also can be constructed according to the teachings of the present invention. Further, the fence system 300 can be inverted so that the posts 305 and palings 310 are relatively horizontal and the rail sections 100, 200 are relatively vertical. Thus the posts 305 can include various types of end supports for the rail sections 100, 200 and are not limited to conventional heavy gauge fence posts.

In summary, the present invention therefore enables an improved fencing system 300 that provides a high quality and professionally finished appearance with a minimum of installation labour. Palings 310 of the present invention are easily raked relative to rail sections 100, 200 to provide an attractive fence over sloped ground. Further, covering rail sections 200 can be used to hide fasteners 315 and the ends of the palings 310. Symmetrical features of the present invention also can create a fence system 300 having an identical look from either side. Various styles of perforated rail sections 100, which create fences of dramatically different looks and functions, can be used with standard posts 305, covering rail sections 200, and fasteners 315-thus providing significant economies of scale and reduced storage costs for manufacturers and vendors. The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.

Limitations in the claims should be interpreted broadly based on the language used in the claims, and such limitations should not be limited to specific examples described herein. In this specification, the terminology "present invention" is used as a reference to one or more aspects within the present disclosure. The terminology "present invention" should not be improperly interpreted as an identification of critical elements, should not be improperly interpreted as applying to all aspects and embodiments, and should not be improperly interpreted as limiting the scope of the claims.