Patent Publication Number: US-2010108969-A1

Title: Unitary rail clip assembly for connecting a fence rail to a fence post

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a Continuation-in-Part of U.S. patent application Ser. No. 12/500,670, filed Jul. 10, 2009, which 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 all 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 rail clip assembly for securing a fence rail to a fence post. Specifically, the invention relates to a rail clip assembly that includes an L-shaped connector bracket having an integral detent that engages in a recessed area in the rear wall of the assembly&#39;s housing when a first leg of the bracket is received through a slot in the housing&#39;s perimeter wall. 
     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 rail clip assembly for connecting a fence rail to a fence post. The assembly comprises a housing slidably engaged with an L-shaped connector bracket that is securable to the post. The bracket has a first leg with a second leg extending outwardly therefrom, and a detent integral with the first leg and extending outwardly therefrom in the opposite direction to the second leg. The first leg is received through a slot in a perimeter wall of the housing and the detent engages in a recessed area in the housing&#39;s rear wall. The second leg abuts an exterior surface of the perimeter wall and a fastener secures the second leg to both the perimeter wall and the rail retained within the housing. 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 ; 
         FIG. 12  is a top view of the rail and rail clip assembly through line  12 - 12  of  FIG. 10 ; 
         FIG. 13  is a cross-sectional side view of a third embodiment of a rail clip assembly in accordance with the present invention incorporating a unitary connector bracket for securing the rail clip to a fence post; 
         FIG. 14  is a rear view of the rail clip assembly and connector bracket of  FIG. 13 ; 
         FIG. 15  is a front perspective view of the connector bracket of  FIG. 13 ; 
         FIG. 16  is a rear perspective view of the connector bracket of  FIG. 13 ; 
         FIG. 17  is a rear perspective view of an alternative embodiment of the unitary connector bracket showing a pair of spaced apart detents thereon. 
     
    
    
     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 a 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 a 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 . 
     Referring to  FIGS. 13-15  there is shown a rail clip assembly in accordance with the present invention in which a unitary mounting connector bracket  390  is utilized. The rail clip assembly is generally indicated at  310  and is substantially identical to the rail clip assembly  10  shown in  FIGS. 1-9 . 
     Rail clip assembly  310  comprises a housing  311 , having a top wall  316 , a bottom wall  318 , side wall  320  and rear wall  322 . Top, bottom, and side walls  316 ,  318 ,  320  comprise a perimeter wall of the housing  311 . The perimeter wall together with the rear wall  322  surrounds and defines an interior chamber  324  configured to receive an end  312   a  of a fence rail  312  therein. Rail clip assembly  310  is designed to secure rail  312  to fence post  314  in such a manner that lateral forces on the rail  312  will not tend to disengage assembly  310 , and therefore rail  312 , from post  314 . 
     Referring to  FIGS. 13-16 , housing  311  is substantially identical to housing  11  and includes a tapered first recess  334  and a second recess  336 . Second recess  336  is differently shaped to first recess  334 . First and second recesses  334 ,  336  are defined in rear wall  322  and preferably are substantially continuous with each other. Second recess  336  is also substantially continuous with interior cavity  324  of housing  311 . A slot  338  in bottom wall  318  is continuous with each of first and second recesses  334 ,  336 . First recess  334  also has an opening  340  in rear wall  322  of housing  311 . 
     In accordance with the present invention, a unitary, integrally formed L-shaped connector bracket  390  is provided to aid in securing rail clip assembly  310  to both of rail  312  and fence post  314 . Connector bracket  390  has a first leg  392  and a second leg  394  that are integrally formed and are disposed substantially at right angles to each other. First leg  392  has a front surface  392   a , a rear surface  392   b , first and second sides  392   c ,  392   d , a top end  392   e  and bottom end  392   f . Extending outwardly and rearwardly from rear surface  392   b , is a detent  396  that is integral with first leg  392  and extends outwardly therefrom in the opposite direction to second leg  394 . Detent  396  is complementary in shape and size to first recess  334  in rear wall  322  of housing  311  while first leg  392  is complementary in shape and size to second recess  336  in rear wall  322 . Detent  396  preferably is smaller in size than first leg  392  and is disposed intermediate, and preferably equidistant from first and second sides  392   c ,  392   d  of first leg  392 . Consequently, a portion of the rear surface  392   b  of first leg  392  extends outwardly for a distance beyond detent  396  in at least one direction. This portion of the rear surface  392   b  engages the front surface  322   a  of rear wall  322  when first leg  392  is received through slot  338 . 
     Detent  396  has a side wall  396   a  and a back surface  396   a . Back surface  396   a  is substantially parallel to rear surface  392   b  of first leg  392 . Detent  396  preferably includes a pair of shoulders  397  on its side wall  396   a  that are designed to interlockingly engage a complementary pair of shoulders  341  ( FIG. 14 ) on rear wall  322  when detent  396  is frictionally engaged in recessed area  344 . Back surface  396   b  of detent  396  is of a width W 1  from these shoulders  397  upwardly toward top end  396   c  of detent  396 . Back surface  396   b  is narrower than width W 1  from shoulders  397  downwardly toward bottom end  396   d  of detent  396 . Additionally, side wall  396   a  of detent  396  preferably tapers from proximate rear surface  392   b  of first leg  392  outwardly toward the detent&#39;s back surface  396   a . In other words, side wall  396   a  of detent  396  is disposed at an acute angle relative to the rear surface  392   b  of first leg  392 . The width W 2  of detent measured where side wall  396   a  joins rear surface  392   b  of first leg  392  is greater than W 1 . First leg  392  is of a width W 3  that is greater than both of W 1  and W 2 . Furthermore, second leg  394  preferably has a width W 4  that is even greater than the width W 3  of first leg  392 . As can be seen from the attached figures, detent  396  is smaller in size than first leg  392  and is specifically of a smaller width than first leg  392 . It will be understood, however that connector bracket  390  could be differently formed and that the detent could be larger in size than the first leg. 
     At least one, and preferably two apertures  398  are provided through first leg  392  and detent  396  so that the apertures  398  extend from front surface  392   a  of first leg through to rear surface  396   b  of detent  396 . Apertures  398  are spaced vertically apart from each other. Second leg  394  is also provided with at least one and preferably two apertures  399  therein. Apertures  399  extend between an interior surface  394   a  and exterior surface  394   b  of second leg  394  and preferably are spaced horizontally apart from each other. 
     Connector bracket  390  may be engaged with rail clip assembly  310  in a number of ways. In a first way, connector bracket  390  is first secured to fence post  314  and then rail clip assembly  310  is slidably engaged with connector bracket  390 . In this instance, rear surface  396   b  of detent  396  is placed into abutting contact with the outer surface  314   a  of post  314 . Fasteners  342  are inserted through apertures  398  in first leg  392  of connector bracket  390  and are screwed into post  314 . Thus, second leg  394  of connector bracket  390  extends outwardly away from outer surface  314   a  of fence post  314  and substantially at right angles thereto. Rear wall  322  of housing  311  is then placed in abutting contact with outer surface  314   a  of post  314  and rail clip assembly  310  is moved downwardly in the direction of arrow “A” ( FIG. 14 ). This downward movement causes first leg  392  of connector bracket  390  to enter the slot  338  in bottom wall  318  of housing  311 . The top end  396   c  of detent  396  moves into first recess  334  in housing  311  and top end  392   e  of first leg  392  enters second recess  336  therein. Housing  311  is moved downwardly in the direction of arrow “A” until the bottom wall  318  thereof abuts the interior surface  394   a  of second leg  332  of connector bracket  390 . At this point, first leg  392  of connector bracket  390  is disposed within the interior cavity  324  of rail clip assembly  310  with the rear surface  392   b  of first leg  392  in abutting contact with a portion of the front surface  322   a  of rear wall  322  of housing  311 . Detent  396  of connector bracket  390  is retained within first recess  334  with rear surface  396   a  of detent being substantially flush with rear surface  322   b  of rear wall  322  of housing  311 . Second leg  394  of connector bracket  390  is disposed outside of housing  311  with the interior surface  394   a  of second leg  394  in abutting contact with exterior surface  318   a  of bottom wall  318 . 
     A second way in which connector bracket  390  and housing  311  can be secured together is by first inserting first leg  392  of connector bracket  390  through slot  338  in bottom wall  318  of housing  311 . The connector bracket  390  is then pushed inwardly toward housing  311  until second leg  394  of connector bracket  390  abuts exterior surface  318   a  of bottom wall  318 . At this point, first leg  392  of connector bracket  390  is disposed within cavity  324  of housing  311  with detent  396  engaged in first recess  334 . Rear wall  322  of housing  311  is then placed in abutting contact with the outer surface  314   a  of fence post  314 . Fasteners  342  are then inserted through the apertures  398  in first leg  392  and are screwed into fence post  314 . 
     Once housing  311  with connector bracket  390  is secured to fence post  314 , the end  312   a  of rail  312  is then inserted into cavity  324  of housing  311 . Rail  312  is pushed inwardly until end  312   a  abuts a portion of front surface  322   a  of rear wall  322  and a portion of front surface  392   a  of first leg  392  of connector bracket  390 . Second fasteners  344  are inserted through apertures  399  in second leg  394  of connector bracket  390  and are screwed through bottom wall  318  of housing  311  and into rail  312 . This securement substantially prevents rail  312  from being withdrawn from cavity  324 . Furthermore, the fasteners  344  also prevent rail  312  from being moved laterally and causing rail  312  and rail clip assembly  310  to be dislodged from connector bracket  390 . 
       FIG. 17  shows an additional embodiment of an L-shaped connector bracket in accordance with the present invention and generally indicated at  490 . In this instance connector bracket  490  is substantially identical to connector bracket  390  and is designed for use with a housing that is substantially identical to housing  311 . Connector bracket  490  is a unitary L-shaped member having a first leg  492  and a second leg  494 , where the second leg  494  is disposed substantially at right angles to the first leg  492  and extends outwardly therefrom in a first direction. Connector bracket  490  differs from connector bracket  390  in that instead of having a single detent  396  extending outwardly and rearwardly from the rear surface  392   b  of first leg  392 , a pair of detents  496  extend outwardly away therefrom in a second direction relative to the second leg  494 . Detents  496  are spaced a distance vertically apart from each other. Each detent  496  has a tapered side wall  496   a  and a back surface  496   b . Back surface  496   b  is substantially parallel to the rear surface  492   b  of the first leg  492 . In other words, the side wall  496   a  is disposed at an acute angle relative to the rear surface  492   b  of the first leg  492 . 
     An aperture  498  is defined generally through the center of each detent  496  and extends from the front surface  492   a  of first leg  492  through to the rear surface  496   b  of detent  496 . Detents  496  have a width that is complementary to the width of the opening in the rear wall of the rail clip assembly such that detents  496  frictionally are engaged in the rear wall&#39;s recessed area. Second leg  494  of connector  490  defines at least two apertures  499  therein that are designed to receive fasteners therethrough. Connector bracket  490  is used in substantially the same manner as connector bracket  390  to secure the rail clip assembly to the rail and fence post. 
     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 are an example and the invention is not limited to the exact details shown or described.