Extruded Aluminum Rail

Abstract

An integrally formed rail for use with a fence panel. The rail is formed to define a top platform, first and second side walls, and a bottom platform. The side walls extend from the top platform and past the bottom platform. The top platform and the bottom platform define the boundaries of a rail channel. The top platform and the bottom platform define picket openings. The rail is formed by extruding the platforms and side walls from an extrudable material such as aluminum. The picket openings can be formed by inserting a mandrel in the rail channel and stamping the openings. Fence pickets are inserted through the picket openings to construct the fence panel. A retaining rod is inserted in the rail channel and through openings in the pickets to retain the pickets in the panel.

1 . A rail for use with a fence, the rail comprising:
 a top platform having opposed first and second lateral edges;   a first side wall which depends from the first lateral edge of the platform;   a second side wall which depends from the second lateral edge of the platform; and   a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform;   wherein the top platform and the bottom platform define boundaries of a rail channel; and   wherein the rail is integrally formed.   
     
     
         2 . The rail of  claim 1  further comprising:
 a first flange at an end of the first side wall remote from the top platform; and   a second flange at an end of the second side wall remote from the top platform.   
     
     
         3 . The rail of  claim 1  wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein. 
     
     
         4 . The rail of  claim 1  wherein the top platform defines a plurality of longitudinally spaced picket openings formed therein; and
 wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein;   such that each picket opening of the top platform is aligned with a corresponding picket opening in the bottom platform.   
     
     
         5 . A fence panel comprising a plurality of rails as defined in  claim 4 , and further comprising:
 a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails.   
     
     
         6 . The rail of  claim 4  further comprising an elongate retainer element receivable within the rail channel. 
     
     
         7 . A fence panel comprising a plurality of rails as defined in  claim 6 , and further comprising:
 a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails; and   wherein each picket defines at least one retainer passage; the retainer element of each rail positioned within the rail channel such that it passes through the retainer passages of the pickets.   
     
     
         8 . A fence comprising a plurality of fence panels as defined in  claim 7 , and further comprising:
 a plurality of vertically disposed posts, each adjacent pair of posts supporting opposite ends of a plurality of rails.   
     
     
         9 . A kit comprising a plurality of rails as defined in  claim 1 , and further comprising: a plurality of posts; and a plurality of pickets. 
     
     
         10 . A kit comprising a plurality of rails as defined in  claim 4 , and further comprising: a plurality of posts; and a plurality of pickets. 
     
     
         11 . A method of making a rail as defined in  claim 1 , comprising: forming the rail from an extrudable material by an extrusion process. 
     
     
         12 . A method of making a rail as defined in  claim 4 , comprising the steps of:
 forming the rail from an extrudable material by an extrusion process;   inserting a mandrel into the rail channel;   stamping the plurality of picket openings in the top platform; and   stamping the plurality of picket openings in the bottom platform.   
     
     
         13 . The method of  claim 12  in which the extrudable material comprises aluminum. 
     
     
         14 . A method of making a rail as defined in  claim 2 , comprising the steps of:
 forming the rail from an extrudable material by an extrusion process;   inserting a mandrel into the rail channel; and   stamping the plurality of picket openings in the bottom platform.   
     
     
         15 . The method of  claim 14  in which the extrudable material comprises aluminum. 
     
     
         16 . A fence comprising a plurality of rails, including at least one rail as defined in  claim 15 , and further comprising: a plurality of vertically disposed posts, with each adjacent pair of posts supporting the opposite ends of a plurality of rails; and a plurality of pickets, with each picket being laterally traversed by at least one retainer passage; in which the retainer element is positioned within the retainer channel such that it passes through the aligned retainer passages of the pickets. 
     
     
         17 . A rail for use with a fence, the rail comprising:
 a channel element comprising:   a top platform having opposed first and second lateral edges;   a first side wall which depends from the first lateral edge of the platform;   a second side wall which depends from the second lateral edge of the platform; and   a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform;   wherein the top platform and the bottom platform define a rail channel; and   wherein the bottom platform is characterized by a plurality of longitudinally spaced picket openings formed therein; and   wherein the channel element is formed from extruded metal.   
     
     
         18 . The rail of  claim 1  further comprising:
 a first flange at an end of the first side wall remote from the top platform; and   a second flange at an end of the second side wall remote from the top platform.   
     
     
         19 . The rail of  claim 1  wherein the top platform is characterized a plurality of longitudinally spaced picket openings formed therein. 
     
     
         20 . A method of making a rail for use in a fence, the method comprising the steps of:
 forming a channel element by extrusion, the channel element comprising:
 a top platform having opposed first and second lateral edges; 
 a first side wall which depends from the first lateral edge of the platform; 
 a second side wall which depends from the second lateral edge of the platform; and 
 a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform; 
   inserting a mandrel in the channel element between the top platform and the bottom platform;   stamping a plurality of picket openings in the bottom platform.   
     
     
         21 . The method of  claim 18  further comprising stamping a plurality of picket openings in the top platform.