Spring clip and method of use for installing railings

A spring clip that has a first portion and a second portion. The first portion has a base with at least one aperture and a resilient flange portion that extends away from and above the base and faces a first direction. The second portion has at least one tubular extension that extends through the at least one aperture of the first portion beyond the base and engages the first portion. The at least one tubular extension has an aperture such that the at least one aperture in the first portion and the aperture in a second portion have a common axis. In addition, the flange portion can be compressed from a first position to a second position over the base and when the flange portion will move toward the first position when it is released from the second position. An installation tool is provided for inserting the spring clip into a longitudinal cavity of a railing section.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to improvements in fastener systems. More particularly the invention relates to a spring clip used in conjunction with railing systems.

2. Description of the Related Art

In many cases brackets and retainer systems are used as a replacement for or in addition to traditional fasteners such as screws and nails. Brackets and retainers allow for more options during construction and may even allow for simpler construction of many types of structures. Furthermore, newer building materials such as those formed from composite materials have increased the applicability of brackets and retainers.

Composite materials such as extruded plastic and PVC members have gathered attention because they can be formed a variety of shapes and sizes and have lower maintenance and simpler installation at a lower cost than traditional wood construction applications. Composite materials are nearly impervious to moisture and therefore will not rot or decay like natural wood. During the manufacture of these assemblies, composite materials can be tinted with dyes or other materials to provide a specific color to a component, thus removing the need for surface preparation and painting prior to or subsequent to installing the trim assembly.

One application of these composite materials is in railing systems. Composite railing systems can be formed in a variety of shapes and styles and can manufactured such that installation of a railing system can be undertaken by a novice. An example of such a railing system is a railing assembly provided in U.S. Pat. No. 6,702,259. U.S. Pat. No. 6,702,259 discloses a guard rail system that includes a handrail, a top retainer, and a bottom rail that may be manufactured through an extrusion process. The handrail/retainer combination forms an integrated rail section and may be combined with the bottom rail to form an aesthetically appealing railing for a deck, porch, or stairs.

Since these railing systems can be formed in a variety of shapes and sizes that were not previously available, traditional fasteners may not provide an efficient and secure mechanism for fastening such a railing system. Thus, there is a need for a fastener system that is easy to manufacture and install, and allows for installation of modern railing systems.

SUMMARY OF THE INVENTION

A spring clip is disclosed herein that comprises a first portion and a second portion. The first portion has a base with at least one aperture and a resilient flange portion that extends away from and above the base and faces a first direction. The second portion has at least one tubular extension that extends through the at least one aperture of the first portion beyond the base and engages the first portion. The at least one tubular extension has an aperture such that the at least one aperture in the first portion and the aperture in the at least one tubular extension of the second portion have a common axis. In addition, the flange portion can be compressed from a first position to a second position over the base and when released from the second position, the flange portion will move toward the first position.

In a preferred embodiment of the spring clip, an inner surface of the aperture defined within the at least one tubular extension of the spring clip has threads.

In another preferred embodiment of the spring clip, the at least one aperture of the first portion further comprises a notch.

In still another preferred embodiment of the spring clip, the first portion of the spring clip is formed from a piece of sheet metal.

In a further preferred embodiment of the spring clip, the flange portion of the first portion of the spring clip comprises a U shape.

In yet a further preferred embodiment of the spring clip, the second portion of the spring clip is formed as a casting.

In still a further preferred embodiment of the spring clip, the second portion of the spring clip is plastic.

In another preferred embodiment of the spring clip, the flange portion extends at an angle from the base of the first portion, wherein the angle is 60° or less relative to the base.

In still another preferred embodiment of the spring clip, the at least one aperture of the first portion comprises two apertures and the at least one tubular extension comprises two tubular extensions.

In a further preferred embodiment of the spring clip, an installation tool comprises a mouth portion and a handle portion. The mouth portion has a notch that is sized and configured to hold the spring clip in a second position and the at least one tubular extension extends through the notch and away from the mouth of the installation tool.

Further disclosed herein is a method of connecting a bracket to a tubular railing section having a longitudinal cavity using the spring clip disclosed herein.

The method requires creating at least one aperture in the tubular railing section that extends from an outside surface of the tubular railing section to the longitudinal cavity, placing the flange portion of the spring clip in the second position, and inserting the spring clip into the longitudinal cavity of the tubular railing section through an open end of the tubular railing section.

In addition, the method requires aligning the at least one tubular extension of the spring clip with at least one aperture in the longitudinal cavity of the tubular railing section such that the at least one tubular extension of the spring clip engages the at least one aperture in the longitudinal cavity and releasing the spring clip from the second position such that the flange contacts the longitudinal cavity of the tubular railing section and fixedly engages the spring clip within the longitudinal cavity of the tubular railing section.

In a preferred embodiment, the method requires that placing the spring clip into the second position comprises compressing the spring clip into the second position and inserting the spring clip into the mouth of a tubular installation tool. The mouth of the tubular installation tool has a notch and the spring clip is held while in the second position by the mouth of the installation tool. The at least one tubular extension of the second portion aligns with and is located within the notch of the mouth while the spring clip is in the second position.

In another preferred embodiment, the method requires that releasing the spring clip from the second position comprises removing the spring clip from the mouth of the tubular installation tool by moving the tubular installation tool in the first direction while the at least one tubular extension of the spring clip is engaged in the at least one aperture defined on the inner surface of the longitudinal cavity.

In still another preferred embodiment, the method requires aligning at least one aperture of a railing bracket with the at least one aperture on the outside surface of the tubular railing section and inserting at least one fastener through the at least one aperture in the railing bracket to the at least one tubular extension of the spring clip and fastening the railing bracket to the tubular railing section via the fastener.

Additionally disclosed herein is a kit for a spring clip system that comprises a plurality of spring clips and an installation tool.

In a preferred embodiment, the kit contains a plurality of railing brackets.

In another preferred embodiment, the kit requires at least one tubular railing section that is an extrusion.

Other details, objects, and advantages of the invention will become apparent as the following description of certain present preferred embodiments thereof proceeds.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown inFIGS. 1-11, a spring clip1has a first portion3and a second portion5. The first portion3has a base7with at least one aperture9and a resilient flange portion11that extends away from and above the base7and faces a first direction. The second portion5has at least one tubular extension13that extends through the at least one aperture9of the first portion beyond the base7and engages the first portion3. The at least one aperture9of the first portion may comprise a notch39that allows the at least one aperture9to expand to better accommodate the at least one tubular extension13of the second portion5.

In addition, the at least one tubular extension13has an aperture15such that the at least one aperture9in the first portion3and the aperture15in the second portion3have a common axis. An inner surface of the aperture15defined within the at least one tubular extension13of the spring clip may have threads. As shown in the embodiment ofFIGS. 1-10, the first portion may have two apertures9and the second portion may have two corresponding tubular extensions13. Further, the number of apertures9in the first portion3and the number tubular extensions13of the section portion5may be selected based on the desired application.

Additionally, the flange portion11can be compressed from a first position17to a second position19over the base7such that when the flange portion11is released from the second position19, the flange portion11will move toward the first position17. In one embodiment, the flange portion11of the first portion3of the spring clip1may have a U-shape. The flange portion11extends at an angle α from the base7of the first portion3, and as shown inFIG. 3, the angle α of the flange portion11may be 60° or less relative to the base7.

Further, the first portion3of the spring clip1may be formed from a piece of sheet metal or any other suitable material that allows the flange portion11to be flexible in relation to the base7. In addition, the second portion5of the spring clip1may be formed as a casting that is made from a suitable material, such as for example plastic, aluminum, resin, or fiberglass.

In addition, an installation tool21may be provided with the spring clip1. As shown inFIGS. 8-10, the installation tool21comprises a mouth23and a handle portion24. In the embodiment shown inFIGS. 8-10the mouth23has a notch25and is sized and configured to hold the spring clip1while the spring clip is in the second position19. The at least one tubular extension extends through the notch25and away from the mouth23of the installation tool21. The installation tool21is shown as having a tubular configuration inFIGS. 8-10, however the installation tool may comprise a set of tongs or similar device for holding the spring clip1in the second position19so that it can be inserted into an appropriately sized space.

Furthermore, the spring clip1may be used to connect a bracket to a tubular railing section27that has a longitudinal cavity29by inserting the spring clip1into the longitudinal cavity29as shown inFIGS. 9-11. The tubular railing section27may be a bottom rail section as provided in U.S. Pat. No. 6,702,259. Further, the tubular railing section27may be formed as an extrusion. At least one aperture33is created in the tubular railing section27that extends through an outside surface of the tubular railing section27to the longitudinal cavity29. The spring clip1is placed in the second position19and is inserted into the longitudinal cavity29of the tubular railing section27through an open end of the tubular railing section27in a second direction that is generally opposite the first direction which the flange portion11faces. If the installation tool21is used, the spring clip1is compressed into the second position19and is inserted into the mouth23of the installation tool21such that the at least one tubular extension13is located in the notch25at the mouth23. The installation tool21holds the spring clip1in the second position19while it is inserted into the longitudinal cavity29of the tubular railing section27in the first direction. The two-headed arrow shown inFIG. 10illustrates the directions of insertion and removal of the installation tool within the cavity29.

The at least one tubular extension13of the spring clip1is aligned with at least one aperture33in the longitudinal cavity29of the tubular railing section27such that the at least one tubular extension13of the spring clip1engages the at least one aperture33in the longitudinal cavity29. This engagement holds the spring clip1in place while the installation tool is pulled out of the cavity29, releasing the spring clip. Upon release, the flange portion11moves away from the base such that the flange portion11contacts the longitudinal cavity29of the tubular railing section27and fixedly engages the spring clip1within the longitudinal cavity29of the tubular railing section27.

Although we prefer to use the installation tool21shown inFIGS. 8-10, a different installation tool can be used to insert the spring clip1. Indeed, it may be possible to insert the spring clip1into some cavities manually without using a tool.

We anticipate that a railing bracket47will be attached to the railing section for attaching the end of the railing section to a wall or post. One aperture of that railing bracket47may be aligned with the at least one aperture29on the outside surface of the tubular railing section27. The railing brackets47should have a corresponding number of apertures to match the number of tubular extensions of the spring clip. At least one fastener49, such as a screw, may be inserted through the at least one aperture in the railing bracket47to the at least one tubular extension13of the spring clip1and the railing bracket may be fastened to the tubular railing section13via the fastener.

Furthermore the spring clip may be sold in a kit that includes a plurality of spring clips and the installation tool. The kit may also include a plurality of railing brackets. The railing brackets of the kit should have a corresponding number of apertures to match the tubular extension of the spring clip. In another embodiment, the kit may include at least one tubular railing section that is an extrusion.

While we have shown and described certain present preferred embodiments of our spring clip and have illustrated certain present preferred methods of making and using the same, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.