Patent Publication Number: US-7216855-B2

Title: Fence rail mounting clip

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This is a continuation of U.S. application Ser. No. 10/967,403, filed Oct. 18, 2004, now U.S. Pat. No. 7,125,002 the entire specification of which is incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Technical Field 
   This invention generally relates to fences. More particularly, the invention relates to a clip for mounting vinyl fence rails to vertical fence posts. Specifically, the invention relates to a clip that includes a rail support which projects from its front surface and is receivable within the bore of a hollow fence rail. 
   2. Background Information 
   Fences are used in today&#39;s society for a variety of reasons and are available in a variety of different styles and types. For example, farmers use fences to contain their livestock, to prohibit entry of predators and to protect their crops. Businesses use fences to keep thieves and trespassers off of the premises. Residents use fences to keep their children and pets within their property limits or for ornamental or aesthetic purposes. 
   Conventionally, these fences are constructed of wood, rock or wire, each of which has its advantages and disadvantages. Wooden fences frequently need painting. Additionally, wooden fences are assembled by forming a slot in a vertical fence post through which a slatted end of the fence rail extends to mount the fence rail to the post. These slots allow water to enter and sit therein, subjecting the fence posts to water damage and rotting. Furthermore, wooden rails are heavy and dangerous to assemble. Rock fences are difficult to construct and are dangerous if the heavy fence wall begins to crumble. Wire fences rust, making them unpleasing to the eye and impractical for residential use. 
   Alternatives to these conventional fencing materials are plastic or vinyl fences. Vinyl fences are aesthetically pleasing, are relatively easy to install and never rot or need painting. The problem with vinyl and plastic fencing is that it is difficult to connect the horizontally extending fence rails to the vertically extending fence posts. 
   This problem has been previously addressed by the present inventor in U.S. Pat. No. 5,788,244, which issued Aug. 4, 1998. The patent discloses a fence rail clip for connecting a hollow fence rail to a vertical fence post. The fence rail clip includes a base mountable to the fence post and a locking bracket which is securable to the hollow fence rail. The locking bracket has a front surface with a peripheral wall extending outwardly at about ninety degrees from the front surface and a fence rail receptacle is formed between the front surface and the peripheral wall. The peripheral wall is sized and shaped to be complementary to the cross-section of the end of the fence rail. The end of the fence rail slides into the rail receptacle and the bracket is interlocked with the base. The peripheral wall of the locking bracket tends to prevent lateral movement of the end of the rail. The end of the rail may accidentally be pulled out of the rail receptacle during installation of the fence or the rail may be accidentally knocked out of the receptacle after the fence has been assembled. 
   There is therefore a need in the art for an improved fence rail mounting clip that resists the tendency of the rail end to be pulled out of the locking bracket when the opposite end of the rail is being handled. 
   SUMMARY OF THE INVENTION 
   A fence rail mounting clip for connecting a hollow fence rail to a vertical post. The mounting clip includes a base that is selectively interlockable with a bracket. The base is attachable to the vertical fence post and the bracket is adapted to receive and end of the hollow fence rail and to secure thereto. The bracket has a front surface with a peripheral wall extending normal to and outwardly therefrom to define a fence rail receptacle for receiving an end of the rail therein. A rail support extends normal to and outwardly from the front surface of the bracket from a position within the rail receptacle. The rail support has an outermost edge that extends beyond the outermost edge of the peripheral wall. The rail support is separated from the peripheral wall by a gap. When the rail is received in the rail receptacle, the walls of the rail are received within the gap between the rail support and the peripheral wall and become wedged therebetween and the rail support extends into the bore of the hollow rail to aid in supporting the rail and preventing lateral movement of 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 fragmentary perspective view of a first embodiment of a fence rail clip in accordance with the present invention and shown attaching a fence rail to a fence post; 
       FIG. 2  is perspective view of the fence rail clip of  FIG. 1 , with the fence rail removed; 
       FIG. 3  is an exploded fragmentary perspective view similar to  FIG. 1 ; 
       FIG. 4  is a rear elevational view of the locking bracket of the clip shown in  FIG. 1 ; 
       FIG. 5  is a front elevational view of the locking bracket of  FIG. 4 ; 
       FIG. 6  is a rear elevational view of the base of the clip of  FIG. 1 ; 
       FIG. 7  is a front elevational view of the base of  FIG. 6   
       FIG. 8  is a side elevational view of the base; 
       FIG. 9  is a side elevational view of the locking bracket; 
       FIG. 10  is a bottom view of the base of  FIG. 8 ; 
       FIG. 11  is a bottom view of the locking bracket of  FIG. 9 ; 
       FIG. 12  is a front elevational view showing the locking base moving into engagement with the base; 
       FIG. 13  is a front elevational view showing the locking bracket engaged with the base; 
       FIG. 14  is a partial cross-sectional side view of the locking bracket mounted on the post and holding a fence rail therein; 
       FIG. 15  is a perspective view of a second embodiment of the fence rail clip in accordance with the present invention; 
       FIG. 16  is a perspective view of a third embodiment of the fence rail clip in accordance with the present invention; and 
       FIG. 17  is a front view of a fourth embodiment of the fence rail clip in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIGS. 1–7 , the fence rail clip of the present invention is indicated generally at  10  and is shown in  FIG. 1  attaching a fence rail  12  to a fence post  14 . Fence rail  12  preferably is a hollow member molded from vinyl and is connectable to a substantially rectangular or square vinyl fence post  14  by clip  10 . Clip  10  is molded from a resilient plastic material and includes a base, generally indicated at  16  ( FIG. 3 ), and a locking bracket generally indicated generally at  18 . Base  16  is secured to post  14  and locking bracket  18  engages base  16 . 
   Base  16 , shown particularly in  FIGS. 3 ,  6 – 8  and  10 , preferably is rectangular-shaped and has front and rear surfaces  20  and  22 , respectively. Two pairs of circular holes  24  are formed through base  16 , with each hole  24  having an enlarged counterbore  26  formed in front surface  20 . Two pairs of screws  28  may be inserted through holes  24  and into two pairs of holes  30  drilled in post  14  which are axially aligned with holes  24 . Screws  28  include a screw head  32  which sits within counterbore  26  in base when base  16  is mounted on fence post  14 , as described below. A peripheral outer edge  34  of base is chamfered inwardly from front,surface  20  to rear surface  22  ( FIG. 8 ) so that rear surface  22  is smaller than front surface  20 . When base  16  is viewed from the side ( FIG. 10 ) it may be seen that base is formed so as to have narrowed portion  23  proximate rear surface  22  and a wider portion  25  proximate front surface  20 . Base  16  further has an upper edge  36  and a lower edge  38 . 
   In accordance with the present invention and referring to  FIGS. 1–11 , locking bracket  18  includes a flat, generally rectangular-shaped panel  40  having a front surface  42  and a rear surface  44 . A peripheral wall  46  extends outwardly from front surface  42  and substantially at ninety degrees thereto. Peripheral wall  46  has ends  48  and sides  50 . Peripheral wall  46  and front surface  42  define a fence-rail receptacle  52  ( FIG. 2 ) for receiving an end of rail  12  therein. Peripheral wall  46  extends outwardly for a distance from front surface  42  and terminates in an outermost edge  54 . A pair of rail supports  56 ,  58  extend outwardly from front surface  42  of bracket  18  and from within receptacle  52 . While the preferred embodiment of the invention is shown with two supports  56 ,  58 , it will be understood that only one rail support or more than two supports may be provided. Supports  56 ,  58  are structurally and functionally substantially identical to one another and are separated from each other by a space  60 . The structure of support  56  will be hereinafter described in greater detail, but it will be understood that the description applies equally to support  58 . Support  56  comprises an elongated rib  62  which extends normal to and outwardly from front surface  42  of bracket  18 . Rib  62  terminates at an outermost edge  64 . Outermost edge  64  lies at least the same distance, and preferably at a greater distance, from front surface  42  than does outermost edge  54  of peripheral wall  46 . Rib  62  has an outer wall  66 , an inner wall  68  and side walls  70 . Rib  62  also includes a number of chambers  72  separated from each other by connecting walls  74 . Chambers  72  are provided to reduce the weight of the fence rail clip. Connecting walls  74  increase the structural strength of rail clip  10 . Rib  62  has a longitudinal axis which is disposed normal to front surface  42  of bracket  18 . At least one, and preferably two, first flanges  76  extend outwardly from outer wall  66  of rib  62 . Flanges  76  are disposed normal to the longitudinal axis of rib  62  and extend outwardly from outer wall  66  of rib  62  toward peripheral wall  46  of bracket  18 . Flanges  76  run the entire length of rib  62  from front surface  42  to outermost edge  64 . Flanges  76  each terminate in a ridge  76   a  and at least a front portion of ridge  76   a,  proximate outermost edge  64 , is tapered to allow for easier sliding engagement of rail  12  with flanges  76 . A pair of spaced second flanges  78  preferably extend outwardly from and normal to inner wall  68  of rib  62  and into space  60 . Second flanges  78  run the entire length of rib  62  from front surface  42  to outermost edge  64  and are preferably spaced further apart from each other than are first flanges  76 . Second flanges  78  provide additional strength to rail support  56 . Side walls  70  of rib  62  are tapered proximate outermost edge  64  so as to allow for easier sliding engagement with rail  12 . 
   As may be most clearly seen in  FIG. 5 , a gap  80  is formed between side walls  70  of rib  62  and sides  50  of peripheral wall  46 . A gap  82  is formed between ridges  76   a  of flanges  76  and ends  48  of peripheral wall  46 . Gaps  80  and  82  are sized to respectively receive side walls  84  and end walls  86  of rail  12  therein, as will be described hereinbelow. Gaps  80  and  82  are complementary sized and shaped to received side and end walls  84 ,  86  of rail  12 . Gaps  80 ,  82  are wide enough to allow side and end walls  84 ,  86  to enter gaps  80 ,  82 , but are sufficiently narrow to cause side and end walls  84 ,  86  to be wedged between the rail supports  56 ,  58  and peripheral wall  46  and to therefore be interferencely fitted therein. 
   Referring particularly to  FIGS. 4 ,  10  and  11 , rear surface  22  of panel  40  includes a recessed portion  88  for engaging base  16 . Recessed portion  88  has an inner, substantially rectangular slotted section  90  and an outwardly angled section  92 . Section  92  opens proximate the lower edge  94  of bracket  18  to slidably receive base  16  therein. Section  90  is complementary sized and shaped to receive wider portion  25  of base  16  therein, as described below. Panel  40  forms a leg  96  on either side of recessed portion  88  and an elbow  98  is formed at the junction of sections  90  and  92 . The inner peripheral edges  100  of legs  96  are chamfered ( FIG. 11 ) so that they are complementary shaped to the outer peripheral edges  34  of base  16 . 
   Referring to  FIGS. 4 ,  5  and  14 , a catch  102  is formed in panel  40  within recessed portion  88  and between elbows  98  when bracket  18  is viewed from the back. Catch  102  lies between flanges  76  when bracket  18  is viewed from the front and comprises a segment of panel  40  around which a U-shaped section of material has been removed. Catch  102  includes a detent  104  that extends outwardly from the rear surface  44  of bracket  18 . Detent  104  includes an angled face  106  that enables base  16  to slide over catch  102  and force it to swing out of the way when base  16  and bracket  18  engage, as will be described hereinafter. In its rest position, catch  102  lies coplanar with rear surface  44  of bracket  18 . 
   Referring to  FIGS. 12–14 , in use, a fence installer drills holes  30  in fence post  14  to axially align with holes  24  of base  16 . The installer positions rear surface  22  of base  16  against fence post  14  and aligns holes  24  with holes  30 . The installer inserts screws  28  through holes  24  and  32  and tightens screws  28  until each heads  32  sits within its respective counterbore  26  and thereby firmly secure base  16  to post  14 . 
   The installer connects locking bracket  18  to base  16  by positioning rear surface  44  of locking bracket  18  above upper edge  36  of base  16  and snap-fits or operatively interlocks locking bracket  18  with base  16  by sliding bracket  18  downwardly over base  16  in the direction of the arrow “A” ( FIG. 12 ). Outwardly angled section  92  of recessed portion  88  guides bracket  18  over base  16 . Front surface  20  of base  16  slides along rear surface  44  of panel  40  and complementary tapered edges  34  and  100  of base  16  and recessed portion  88 , respectively, cam against one another as bracket  18  is pushed downwardly in the direction of arrow “A”. As base  16  slides over face  106  of catch  102 , catch  102  is forced out of alignment with rear surface  44  and allows base  16  to slide into recessed portion  88 . Wider portion  25  of base  16  is received in slotted section  90  of locking bracket  18  and locking bracket  18  is pushed downwardly until the upper edge  36  of base  16  abuts the inner edge  108  of locking bracket  18  ( FIG. 14 ). Once lower edge  38  of base  16  slides past detent  104 , catch  102  springs back into coplanar alignment with rear surface  44 . Detent  104  lies below lower edge  38  of base  16  and substantially secures bracket  18  and base  16  together. 
   The end of fence rail  12  is secured to locking bracket  18  by sliding rail  12  over rail supports  56 ,  58  in the direction of arrow “B” ( FIG. 14 ) thereby causing rail supports  56 ,  58  to enter bore  110  of rail  12 . As end walls  86  of rail  12  slide over flanges  76  of rail supports  56 ,  58 , supports  56 ,  58  flex into space  60  and slightly toward each other as indicated by the arrows “C” and “D” in  FIG. 14 . This slight inward movement of supports  56 ,  58  allows end walls  86  of rail  12  to slide over ridges  76   a  of flanges  76 . Simultaneously, side walls  84  of rail  12  engage sides  70  of ribs  62 . Rail  12  is moved in the direction of arrow “B” until the front edge  112  of rail  12  enters gaps  80  and  82  in bracket  18 . Rail  12  is moved in direction of arrow “B” until front edge  112  of rail  12  abuts front surface  42  of locking bracket  18 . When rail  12  is in this position, supports  56 ,  58  extend a distance “X” into the bore  110  of rail  12  and end and side walls  86  and  84  of rail  12  are wedged between rail supports  56 ,  58  and peripheral wall  46  of locking bracket  18 . 
   It will be understood that base  16  and recessed portion  88  in locking bracket  18  need not be rectangular in shape, but may be oval or any other suitable shape that allows base  16  and bracket  18  to interlock with each other. Furthermore, bracket  18  and peripheral wall  46  may be differently shaped so as to accommodate rails that are not rectangular in cross-section. For example, if rail is circular in cross-section, at least the peripheral wall may be circular in cross-section to define a substantially circular cross-sectional rail receptacle. It will further be understood that while two supports  56 ,  58  are shown extending outwardly from front surface  42  of panel  40 , a lesser or greater number of supports may be provided without departing from the spirit of the present invention. Flanges  76  are adapted to contact the end walls  86  of rail  12  and side walls  70  of ribs  62  are adapted to contact side walls  84  of rails. Flanges  76  could, however, be made to contact side walls  84  of rail  12  and side walls  70  of ribs  62  could contact end walls  86  without departing from the spirit of the invention. Furthermore, the order of connection of the locking bracket  18  to base  16  and connection of the rail  12  to the locking bracket  18  may be reversed. 
   Referring to  FIG. 15 , there is shown a second embodiment of the rail clip in accordance with the present invention and generally indicated at  210 . As with the first embodiment, clip  210  is adapted to be mounted to a post (not shown) and to receive a rail (not shown) therein. Clip  210  includes a locking bracket  218  having a peripheral wall  246  extends outwardly from front surface  242  thereof. Peripheral wall  246  and front surface  242  define a fence-rail receptacle  252  for receiving an end of rail therein. A plurality of rail supports  256 ,  257  and  258  extend outwardly from front surface  242  of bracket  218  and from within receptacle  252 . Supports  256 ,  257  and  258  are separated from each other and from peripheral wall  246 . Peripheral wall  246  terminates in an outer edge  254  and supports  256 ,  257 ,  258  each terminate in an outer edge  256   a  which extend at least as far from front surface  242  as does outer edge  254  of peripheral wall  246 . Preferably, outer edges  256   a,    257   a  and  258   a  extend further outwardly from front surface  242  than does outer edge  254  of peripheral wall  246 . Rail clip  210  functions in essentially the same manner as does rail clip  10 . 
   A third embodiment of rail clip in accordance with the present invention is shown in  FIG. 16  and generally indicated at  310 . Rail clip  310  includes a bracket  318  having a front surface  342  and a peripheral wall  346 . A pair of rail supports  356  and  358  extend outwardly from front surface  342  and from within the perimeter of peripheral wall  346 . Rail supports  356  and  358  are separated from each other and from peripheral wall  346 . The outer edges  356   a  and  358   a  of supports  356 ,  358  lie further from front surface  342  than does the outer edge  354  of peripheral wall  346 . Rail supports  356 ,  358  include tapered flanges as at  359  which allows for easier engagement with a rail (not shown). The third embodiment of rail clip  310  functions in essentially the same manner as the first and second embodiments thereof. 
   Referring to  FIG. 17 , there is shown a fourth embodiment of rail clip in accordance with the present invention and generally indicated at  410 . This embodiment includes rail supports  456  and  458  which are essentially identical to rail supports  356  and  358  shown in  FIG. 16 . The bracket  418  and associated peripheral wall  446 , however, are not rectangularly shaped as with the previously described embodiments. Rail supports  456 ,  458  are separated from each other and separated from peripheral wall  446  as with previous embodiments. The rail (not shown) is complementary sized and shaped to interlock with bracket  418  and the rail is received in the gap formed between rail supports  456 ,  458  and peripheral wall  446 . 
   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.