Abstract:
A method of using a rail clip assembly to connect a horizontal fence rail to a vertical fence post. The rail clip assembly includes a housing that is slidably engaged with at least one mounting spacer and a first leg of an L-shaped mounting bracket until a second leg of the bracket abuts the underside of the housing. A first fastener is screwed through the first leg and mounting spacer and into the side wall of the fence post. An end of the rail is inserted into the housing and a second fastener is screwed through the second leg, the housing and the end of the rail. The rail clip assembly aids in preventing the rail from disengaging from the housing when a lateral force is applied to the rail.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This is a continuation of U.S. patent application Ser. No. 11/485,849, filed Jul. 12, 2006, now U.S. Pat. No. 7,568,680, which is a continuation-in-part of U.S. patent application Ser. No. 11/405,840, filed Apr. 18, 2006, now abandoned, the entire specifications of which are incorporated herein. 

   BACKGROUND OF THE INVENTION 
   1. Technical Field 
   This invention generally relates to fencing systems. More particularly, the invention relates to a method of using a rail clip assembly for securing a fence rail to a fence post. Specifically, the invention relates to a method of securing a fence rail and post together with a rail clip assembly that reduces the tendency of the rail from disengaging from the fence post when a lateral force is applied to the rail. 
   2. Background Information 
   A variety of rail clips have been proposed in the prior art for connecting vinyl fence rails to vinyl fence posts. These clips have typically included a mounting base portion that is secured to the rail and which includes a rail-end shaped receptacle to receive the end of the rail therein. One of the reasons these rail clips have been used is to provide a neat, finished connection between the two components. The clips hide incorrectly cut rail ends, evidence of previous attempts to connect the rail and post together and the apparent elimination of gaps between the connected rail ends and the posts. In order to provide a more aesthetically-pleasing device, it is common for the rail clip to be in the magnitude of one to two inches deep. Rail clips that are deeper than this tend to give the rail a cumbersome appearance. 
   A second consideration when connecting fence rails to fence posts is the existence of rules and regulations governing building standards. In recent years, building codes have required that the rail clip provided must ensure that the end of the rail cannot pop out of the rail clip when a lateral force is applied to the rail. In other types of rail connectors, the rail clip itself is slidably engaged with a mounting base that is first secured to post. In this type of situation, the rail clip has tended to pop off the mounting base, thereby releasing the rail. 
   There is therefore a need in the art for a rail clip assembly that will connect a horizontal rail to a vertical post and that will resist the tendency for the rail to pop out of the clip when a lateral force is applied to the rail. 
   SUMMARY OF THE INVENTION 
   A method of using a rail clip assembly to connect a horizontal fence rail to a vertical fence post is disclosed. The rail clip assembly includes a housing that is slidably engaged with at least one mounting spacer and a first leg of an L-shaped mounting bracket until a second leg of the bracket abuts the underside of the housing. A first fastener is screwed through the first leg and mounting spacer and into the side wall of the fence post. An end of the rail is inserted into the housing and a second fastener is screwed through the second leg, the housing and the end of the rail. The rail clip assembly aids in preventing the rail from disengaging from the housing when a lateral force is applied to the rail. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
       FIG. 1  is a perspective view of a fence rail connected to a fence post using the rail clip assembly of the present invention; 
       FIG. 2  is a partial cross-sectional bottom view of the fence rail and rail clip assembly of  FIG. 1 ; 
       FIG. 3  is a cross-sectional side view of a fence rail being engaged with the rail clip assembly of the present invention; 
       FIG. 4  is a bottom view of the rail clip assembly through line  4 - 4  of  FIG. 3 ; 
       FIG. 5  is a rear view of the rail clip assembly, mounting bracket and mounting base taken through line  5 - 5  of  FIG. 3 ; 
       FIG. 6  is cross-sectional side view of the rail being inserted into the rail clip assembly; 
       FIG. 7  is a cross-sectional side view of the rail secured to the rail clip assembly; 
       FIG. 8  is a rear view of the rail clip assembly engaged with the rail and taken through line  8 - 8  of  FIG. 7 ; 
       FIG. 9  is top view through line  9 - 9  of  FIG. 7 ; 
       FIG. 10  is a cross-sectional side view of a second embodiment of the rail clip assembly in accordance with the present invention; 
       FIG. 11  is a rear view of the rail and rail clip assembly through line  11 - 11  of  FIG. 10 ; and 
       FIG. 12  is a top view of the rail and rail clip assembly through line  12 - 12  of  FIG. 10 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIG. 1 , there is shown a rail clip assembly in accordance with the present invention and being generally indicated at  10 . Rail clip assembly  10  is shown in  FIG. 1  securing a substantially horizontal fence rail  12  to a substantially vertical fence post  14 . Both rail  12  and post  14  are preferably manufactured from vinyl or fiber composite fencing materials. 
   Referring to  FIGS. 2-4 , rail clip assembly  10  preferably includes a housing  11  having a perimeter wall that comprises a top wall  16 , a bottom wall  18 , and side walls  20 . Walls  16 ,  18  and  20  extend outwardly away from a rear wall  22 . These walls preferably are integrally manufactured with each other by a process such as molding. The walls  16 - 22  surround and define an interior chamber  24  that is adapted to receive an end of rail  12  therein. Chamber  24  is complementary sized and shaped to snugly receive the end of rail  12  therein. 
   Housing  11  of rail clip assembly  10  is designed to be secured to post  14  by two components, namely a mounting base  26  and an L-shaped mounting bracket  28 . Base  26  is a substantially planar member having a front surface  26   a  and a back surface  26   b  and a peripheral wall  26   c . As shown in  FIGS. 3 &amp; 5 , peripheral wall  26   c  tapers from front surface  26   a  to back surface  26   b . Base  26  preferably is manufactured from the same material as housing  11 . Bracket  28  comprises a substantially L-shaped member having a first leg  30  and a second leg  32 . Preferably, bracket  28  is manufactured from a suitable metal. Housing  11  is designed to engage both base  26  and bracket  28 . Housing  11  includes a complementary tapered first recess  34  that is configured to tightly receive base  26  therein. Rail clip assembly further includes a second recess  36  that is differently shaped to first recess  34 , and is configured to receive the first leg  30  of bracket  28  therein. First and second recesses preferably are substantially continuous with each other. Furthermore, second recess  36  is also substantially continuous with interior cavity  24  of housing  11 . An opening  38  ( FIG. 4 ) to both of first and second recesses  34 ,  36  is provided in bottom wall  18  of housing  11 . Recess  34  preferably also has an opening  40  ( FIG. 5 ) in rear wall  22  of housing  11 . Opening  40  is smaller than the back surface  26   b  of base  26  so that base  26  cannot pass through opening  40 . 
   Referring to  FIG. 3 , rail clip assembly  10  is used in the following manner to secure rail  12  to post  14 . Back surface  26   b  of base  26  is placed into abutting contact with the outer surface  14   a  of post  14 . The first leg  30  of the L-shaped bracket  28  is placed into abutting contact with front surface  26   a  of base  26 . Fasteners  42  are used to secure both first leg  30  of bracket  28  and base  26  to post  14 . It will be understood that both the first leg  30  and base  26  preferably are provided with appropriate holes for receiving fasteners  42  therethrough, so that the correct positioning of the two components is ensured. Alternatively, however, holes may be drilled through first leg  30  and base  26  during installation of rail clip assembly  10 . When bracket  28  and base  26  are secured to post  14 , the second leg  32  of bracket  28  extends outwardly away from the exterior wall of post  14  and substantially at right angles thereto. 
   Rear wall  22  of housing  11  is then placed in abutting contact with outer surface  14   a  of post  14  and is slid downwardly in the direction of arrow “A” ( FIGS. 3&amp;5 ). This downward movement causes the uppermost ends of base  26  and first leg  30  of bracket  28  to enter first and second recesses  34 ,  36 . Housing  11  is moved downwardly until bottom wall  18  abuts second leg  32  of bracket  28 . An end of rail  12  is then inserted into cavity  24  of housing  11  ( FIG. 6 ). Once the outermost end  12   a  abuts a portion of rear wall  22  of housing  11  and first leg  30  of bracket  28 , a second fastener  44  is inserted through hole  46  in bracket  28  and is screwed through bottom wall  18  of housing  11  and into rail  12  ( FIG. 7 ). This securement substantially prevents rail  12  from being withdrawn from cavity  24 . Furthermore, the fastener  44  also prevents rail  12  from being moved laterally and causing rail  12  and rail clip assembly  10  to be dislodged from base  26 . 
     FIGS. 10-12  show an alternative embodiment of a rail clip assembly in accordance with the present invention and generally indicated at  210 . Rail clip assembly  210  is substantially identical to clip  10  in that it includes a housing  211  having a perimeter wall that comprises a top wall  216 , a bottom wall  218 , side walls (not shown) and a rear wall  222 . The walls  216 - 222  surround and define an interior chamber  224  that is adapted to receive an end of rail  212  therein. Rear wall  222  is provided with a tapered first recess  234  and a second recess  236  that is contiguous therewith. First recess  234  is smaller in area than is second recess  236 . Bottom wall  218  of housing  211  includes a first aperture  238  therein that is sufficiently wide enough to receive both first leg  230  of mounting bracket  228  and mounting spacer  280  therethrough as shown in  FIG. 12 . 
   Housing  211  is designed to be secured to post  214  by one or more mounting spacers  280  and an L-shaped mounting bracket  228 . Mounting spacers  280  are used in the place of base  26  and are washer-like members that are sized to be received within the tapered first recess  234  in housing  211 . First recess  234  has a depth “R” ( FIG. 12 ) and each mounting spacer  280  has a substantially equal thickness “R”. First recess  234  further has a narrowest width “S” and each mounting spacer has a diameter that is substantially equal to that width “S”. Mounting spacers  280  preferably are manufactured from the same material as housing  211  and have a back surface  280   a , a front surface  280   b  and a central aperture  282  therein. Bracket  228  is substantially identical to bracket  28  and is complementary shaped to be received within second recess  236  in housing  211 . 
   Rail clip assembly  210  is used in the following manner to secure rail  212  to post  214 . Back surface  280   a  of each mounting spacer  280  is placed into abutting contact with the outer surface  214   a  of post  214 . The first leg  230  of the L-shaped bracket  228  is placed into abutting contact with front surfaces  280   b  of mounting spacers  280 . Fasteners  242  are used to secure both first leg  230  of bracket  228  and mounting spacers  280  to post  214 . It will be understood that both the first leg  230  and mounting spacers  280  preferably are provided with appropriate holes, such as central aperture  282  in mounting spacers  280 , for receiving fasteners  242  therethrough. This ensures the correct positioning of the components. Alternatively, however, holes may be drilled through first leg  230  and mounting spacers  280  during installation of rail clip assembly  210 . When bracket  228  and mounting spacers  280  are secured to post  214 , the second leg  232  of bracket  228  extends outwardly away from the exterior wall of post  214  and substantially at right angles thereto. 
   Rear wall  222  of housing  211  is then placed in abutting contact with outer surface  214   a  of post  214  and is slid downwardly in the direction of arrow “X” ( FIG. 10 ). This downward movement causes mounting spacers  280  and first leg  230  of bracket  228  to enter first and second recesses  234 , 236 , respectively. Housing  211  is moved downwardly until bottom wall  218  abuts second leg  232  of bracket  228 . An end of rail  212  is then inserted into cavity  224  of housing  211 . Once the outermost end  212   a  abuts a portion of rear wall  222  of housing  211  and first leg  230  of bracket  228 , a second fastener  244  is inserted through hole  246  in bracket  228  and is screwed through bottom wall  218  of housing  211  and into rail  212  (FIG.  10 ). This securement substantially prevents rail  212  from being withdrawn from cavity  224 . Furthermore, the fastener  244  also prevents rail  212  from being moved laterally and causing rail  212  and housing  211  to be disengaged from base  226 . 
   Fence rail  212  may be connected to fence post  214  in a different manner. In this second manner mounting spacer  280  is inserted into vertical slot  234  in rear wall  222  of rail clip housing  211  and first leg  230  of L-shaped mounting bracket  228  is inserted into aperture  238  in peripheral wall  218  of the rail clip housing  211 . Mounting bracket  228  is slid upwardly into interior cavity  224  of rail clip housing  211  such that the rear surface of first leg  230  is in abutting contact with both an interior surface of the rear wall  222  of the rail clip housing  211  and with the interior surface  280 b of mounting spacer  280 . Mounting bracket  228  is slid upwardly until second leg  232  thereof abuts an exterior surface of the peripheral wall  218 . At this point, an aperture in said first leg  230  is aligned with aperture  282  in mounting spacer  280 . A rear surface of rail clip housing  211  is placed in abutting contact with outer surface  214   a  of the side wall of fence post  214 . A first fastener  242  is inserted through the aligned apertures in the first leg mounting spacer  280  and is screwed into the side wall of fence post  214 . The end  212   a  of rail  212  in inserted into interior cavity  224  of rail clip housing  211  and a second fastener  244  is inserted through aperture  246  in second leg  232  of mounting bracket  228 , and is screwed through the peripheral wall  218  of rail clip housing  211  and into rail  212 . 
   The step of sliding the mounting spacer  280  into slot  234  in rear wall  222  preferably also includes the steps of aligning aperture  236  in the rear wall  222  over an end of mounting spacer  280  and then sliding mounting spacer  280  inwardly into the slot  234  until the end of mounting spacer  280  abuts an interior end surface of rear wall  222 . 
   As discussed previously, more than one mounting spacer  280  may be used to abut a rear wall of first leg  230  and be thereby interposed between first leg  230  and the side wall of fence post  214 . In this instance, a second aperture in the first leg  230  of mounting bracket  228  is aligned with an aperture  282  in the second mounting spacer  280  and an additional first fastener  242  is inserted through the aligned second aperture in the first leg  230  and aperture  282  in second mounting spacer  280  and is screwed into the side wall of the fence post  214  a distance away from the first fastener  242 . 
   In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
   Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.