Patent Publication Number: US-2005127346-A1

Title: Bracket system for attaching elongated members

Description:
BACKGROUND OF THE INVENTION  
      The invention relates to attachments of elongated members at an angle, particularly joints between elongated rails and posts. The invention is applicable, for example, to stair, deck or balcony railings and to fences of various types, and also can join rails and rail-like elements to adjacent walls as well as line posts, end posts and corners, porch posts, newels and the like.  
     PRIOR ART  
      Joints between elongated members are made in various indoor and outdoor contexts in which the members may lend structural support or may provide decoration, or both. An example is a joint between a vertical standing member (a post) and an elongated member that connects to the vertical one (a rail). In buildings, posts generally support beams that are exclusively horizontal and carry further structures whose weight is transferred to the posts. In open work structures such as fences and railings, rails may support elements with a decorative and/or confining function, such as spindles, pickets or fence panels, and the rails may join to the posts at various angles. In a joint comprising a rail and a post, either of the rail and the post could attach endwise to the lateral side of the other. For convenience, this disclosure generally refers to the rail as being the member that abuts endwise against the lateral side of the post, regardless of orientation.  
      Depending on the particular structure, a post may have rails attached endwise to the post on one or more places along and around the lateral sides of the post. A rail may pass over the end of a post such that the top end of the post attaches endwise to a surface along an underside of the rail. It is advantageous for appearance and structural strength if the end of whichever member abuts endwise is shaped to form-fit against the side of the member that abuts laterally, with no gap. Also, the two members need to be securely connected across the joint if the structure is to bear any appreciable load.  
      For convenience of explanation, all elongated members joined end-to-lateral-side are termed posts and rails in this discussion. This is in keeping with the primary application of the invention to railings, fences and related structures such as balustrades, banisters, handrails, trellises, lattices, arbors, pergolas and the like. One or another of the members (posts and/or rails) may be contribute structural strength and support, as in the example of a porch post, or manual assistance, such as a stairway banisters, or confinement for safety or otherwise, such as perimeter railings and fences. These and other similar uses are apt for the joint of the invention. Decorative appeal is another important aspect. Thus, there are aesthetic and strength considerations to how the structures are arranged and attached.  
      The vertical post is generally the basic founded structure of an attached post and rail, although that situation is not a necessity. One or more rails often connect between two spaced posts (or between a post and another structure) and may be supported exclusively by a post at one or both ends of the rails. Often two or more rails are attached between successive posts at vertically spaced points. Spindles, pickets, slats or panels may be affixed between or to the rails. The rails may be inclined, crossed and optionally affixed together in a cross-buck configuration. The rails and posts may be configured to carry panels or other elements. A post may be attached to a fixed structure at its base, or may be embedded for part of its length as in the case of many fences having posts set in the ground. Usually a post is vertical, although the absolute orientation of the post is not important to the present invention.  
      In a fence or railing, a given post can be a line post, an end post, a corner post, etc., considering the placement of the post along the route of the fence or railing. A line post has rails attached on both opposite sides of the post. If the rails are co-linear, the post and the rails generally are in a common plane with one another. Co-linear rails may have longitudinal axes oriented at an angle relative to the axis of the post. This is usually the case with a stair railing or a fence on a slope, because the rails are parallel to the surface of the passage, which may be inclined to horizontal, whereas posts are usually vertical. The slope can change, so that the rail between two posts is arranged at a different slope than the rail between the next posts, for example where a horizontal railing leads into a sloping banister. In addition to those possible orientations, the post can be at the corner where a line of fencing or railing follows an acute, obtuse or right angle in plan view.  
      As a result of these different possibilities, one or more rails can join with a post at various different angles. If the longitudinal axes of a rail and post intersect, the two axes define a plane, but two rails attached to the same post may be in divergent planes. The axes of the post and either rail in the respective plane can meet at various angles from near zero to near 180°.  
      In order to make a simple abutting joint between a rail and a post, it is necessary to take into consideration the shapes of the post and rail and the angle at which they are to meet. If the post is cylindrical, the end of the rail needs to have a semi-cylindrical channel formed across the end of the rail at the relative angle of the joint. If the post is a different shape (e.g., a polygon) the channel needs a different shape to make the end of the rail complementary with the surface of the post. For a polygonal post such as a square cross section, attention is needed as to whether the rail meets the post at a face or at an angle between faces. Curved or complex shaping of the end of a rail (or other elongated member), so as to complement the shape of the side of a post or other elongated member to which the rail is to abut, is known as a coping cut.  
      A coped shape on the end of a rail may contribute to fixing the attachment of the rail to the post, depending on the shape of the post. However some sort of fastener is also required, at least to hold the joint against separating from tensile forces. Compression forces are resisted insofar a the end of the rail abuts against the surface of the post. It would be advantageous if the necessary structural connections could be made using some sort of fitting disposed to connect the rail to the post, but such a fitting might disadvantageously space the end of the rail from the post or substantially complicate the problem of shaping the end of the rail to complement the surface of the post.  
      Conventional joints for attaching rails to posts are intended to bear nominal force, and can be more or less successful depending on the structure and the situation. Toe-nailing a rail to the post is one alternative, but is not highly resistant to tension. Shear forces can be borne by placing a cleat adjacent to the rail, for example under the rail to bear vertical forces, the cleat being attached to the post by a fastener. A cleat likewise can help to resist tension, if attached both to the post and the rail using suitable fasteners. However cleats and similar fittings are not visually appealing because they detract from the extent to which the rail seems to abut and join directly to the post.  
      Assuming that the post is rectilinear and the rail is to attach at a face on a side of the post, the rail needs to be cut at the required angle to provide face-to-face contact. In a simplest case, the angle could be a right angle cut normal to the axis of the rail. However, the cut might need to slant, e.g., if the axes of the rail and the post do not meet at a right angle. If the rail also is angled relative to the face of the post in plan view, then the cut needs to slant in two perpendicular planes. If the cross section of the post is not a regular polygon or if the rail is to join the post at a corner of a polygon, the cuts are even more problematic. Fitting the rail to the post can become complicated.  
      Skilled craftsmen deal with these and similar complications in wood structures, for example by coping the end of the rail to match the shape of the surface of the post at the angle at which the rail is to meet the post. It would be advantageous if similarly close fitting joints could be achieved without the need for a high level of skill in cutting the ends of the posts. Apart from appearance, a close fit joint is likely to be stronger than one with gaps. It would be advantageous to provide a good structural connection so as to bear loads.  
      As shown, for example, in U.S. Pat. No. 6,017,019—Erwin, it is possible to affix a socket on the post, having a depth sufficient to conceal an end of an adjoining rail that is not cut to a shape complementary with the post. Assuming, for example, that the rail is cut flush at a right angle to its axis of elongation and joins the post at a non-right angle, then the end of the rail can touch the post on the acute angle side of the joint and but is necessarily spaced from the post on the obtuse angle side.  
      The socket in Erwin &#39;019 is a hollow box with surface flanges that affix to the post with fasteners. The box has an opening that is complementary with the external cross section of the rail. However, if the rail is to meet the post at an angle, such as the connection of an inclined balustrade to a vertical newel post at the end of a stairway, the opening needs to be enlarged to admit the inclined rail. In Erwin, the box can have an opening for the rail that is exaggerated in size in one direction, namely parallel to the inclined rail. If this socket solution is applied to a rail of round cross section, for example, the opening into the socket box has a minor axis equal to the diameter of the rail, and a major axis that varies inversely with extent to which the angle of incidence differs from a right angle.  
      If the rail is flush cut perpendicular to its axis and joined to the post at an acute\obtuse angle using a socket box, the box needs to be as deep as the gap between the post and the end or the rail on the obtuse side of the angle. If the same inclined rail is slant cut, or if its end is coped to roughly complement the post, then the end of the rail can be concealed by a relatively shallower socket box. Deep socket boxes are not visually appealing.  
      U.S. Pat. No. 5,873,671—West teaches a socket fitting comprising a stub that protrudes from a mounting plate that is affixed on the surface of a post. The mounting plate is the bottom of a socket box as in Erwin &#39;019 and must itself be shaped to fit the surface of the post. West has a hollow rail (a tube) that may be slant cut. The stub on the mounting plate protrudes generally at a right angle from the post but the stub is slant cut, whereby the rail can be inclined relative to the stub. As a result, the stub does not fill the hollow of the rail, which has structural drawbacks, but a connection can be made.  
      Examples of posts and brackets for rails that attach at right angles are found, for example, in U.S. Pat. No. 4,280,686—Wack (a bracket receiving fasteners directed oppositely into the post and rail, respectively); U.S. Pat. No. 5,143,472—Reed et al. (a base bracket with a telescoping cover); and U.S. Pat. No. 6,039,307—De Zen (a post bracket that telescopically receives an end of the rail.  
      It would be advantageous to provide a structure for attaching a rail to a post such that there is a secure mechanical connection for resisting tension as well as shear. Such an attachment or joint should have a minimum of required parts, should be easily assembled, and should produce a substantially flush and gap-less connection of the parts, at a number of selectable connection angles.  
     SUMMARY OF THE INVENTION  
      One of two elongated members (such as a post or rail) is to be attached endwise to a lateral side along the other of such members. At least the member abutting endwise has an internal support structure enclosed in an outer hollow body, such as an aluminum channel in a polymer extrusion. A bracket makes a structural connection between the internal support structure and the lateral side of the other member, using fasteners. The bracket can be configured for various angles. An adapter sleeve fits over and extends the shape of the outer hollow body at the end, covering the bracket. The adapter sleeve can be cut at a slant, coped or similarly fit against the surface at the lateral side.  
      It is an object of the invention to provide a rail-and-post connection that is versatile for accommodating different construction situations such as different relative angles of the rail and post, structurally strong, easy to assemble and attractive in the finished state. Another object is to do so in elements that are inexpensive but durable and substantially maintenance free.  
      According to an aspect of the invention, elongated members such as the rail and post of a baluster are attached by a U-shaped bracket strip affixed on a surface of the post and received in an end of the rail, being attached to each by fasteners. A terminal fitting forms a sleeve that is provided or is shaped during installation to conform to the surface of the post. The terminal fitting sleeve extends over the end of the rail and over the bracket, to abut against the post, concealing the end of the rail. The rail can have a flush cut load bearing internal member such as an aluminum channel or rectangular tube. A polymer outer cover forms the surface of the rail. Either or both of the internal member and the polymer outer cover can be slant cut or coped, but the invention minimizes or eliminates the need for complex coping cuts. The bracket system makes convenient, useful and structurally strong rail-to-post connections at various angles and in situations where the rail needs to meet the post at a polygonal edge.  
      According to an inventive aspect, the U-shaped bracket strip fits snugly into the opening in the load bearing internal member, and the opposite ends of the bracket strip are folded to provide feet at angles that determine the relative orientation of the body of the U-shaped bracket relative to the post. This also determines the nominal angle of the rail. The bracket strips are inexpensive, and can be provided pre-formed to a number of angles from which the installer selects the appropriate angle. It may also be possible to shape the bracket on site, but this can be complicated in the same way as complex coping cuts, and therefore is not preferred.  
      According to another aspect, the terminal fitting sleeve and/or the bracket strip is provided in standard or incremental angles to accommodate nominal construction angles such as slant endwise abutting joints of rails to newel posts. Likewise and additionally, incremental or standard angle forms of bracket and terminal sleeve part can be provided, e.g., for 45, 30 or 22.5 degree divisions in angles as viewed in plan, and other standard forms. According to another aspect, the terminal fitting sleeve can be pre-coped for a given post shape and for meeting at the face of a polygonal side or at a corner between faces.  
      A number of further objects and aspects will be apparent from the following examples and the associated discussion of variations of which the invention is capable.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The foregoing features and advantages of the invention, as well as other aspects and routine extensions of the invention, are apparent from the following detailed description of examples and preferred embodiments, to be considered together with the accompanying drawings, wherein the same reference numbers have been used throughout to refer to the same functioning parts, and wherein:  
       FIG. 1  is an exploded partial perspective view showing an exemplary embodiment of the invention, applied to a perpendicular mid-face attachment of a post and rail.  
       FIG. 2  is an elevation view corresponding to  FIG. 1 , showing the completed assembly in the area of the joint.  
       FIG. 3  is an exploded isometric view in which the invention is applied to attaching the rail at a corner between faces on the post.  
       FIG. 4  is an exploded isometric view in which the rail is attached at a rounded surface.  
       FIG. 5  is an exploded isometric view in which the rail is attached to a face of the post as in  FIG. 1 , but is inclined downwardly, for example as an inclined banister along a stairway.  
       FIG. 6  is an exploded isometric view in which rails are attached on opposite sides of a post, in this example defining an obtuse angle of incidence.  
       FIG. 7  is a section view longitudinally through the rail as shown in  FIG. 6 , demonstrating the structural connections between the parts. 
    
    
     DETAILED DESCRIPTION  
      A number of exemplary embodiments of the invention are described herein with reference to the drawings. These embodiments are examples intended to demonstrate aspects of the invention in different forms or separately. Not all the aspects are required in all embodiments of the invention, and the illustrated embodiments should be regarded as exemplary rather than limiting.  
      Furthermore, this description is written to refer to examples that do not exclude comparable structures and functions. For example, the vertical member of a post and rail construction is often the thicker and more securely mounted of the two members that are joined, is most often vertical, and is generally called the “post.” The rail is likely to be more lightweight and less securely affixed to other structures. The rail is usually abutted endwise against the lateral side of a post at the joint. Although often horizontal, rails sometimes reflect the ground contour or the inclined slope of a stairway. Notwithstanding these conventional aspects, it is entirely possible that the “post” could be horizontal (or otherwise aligned) or that a “rail” could be a vertical or securely mounted larger structure, or the joint can involve a rail to which a post is abutted endwise at the joint.  
      The embodiments discussed herein as examples concern post and rail or railing arrangements that are most frequently encountered in exterior projects such as porches, decks, verandas, gazebos and the like. The subject matter is also applicable to other interior or exterior uses such as balconies, balustrades, pool enclosures, malls and other public access uses, or fences, barriers, and structures of various descriptions and functions.  
      Therefore, in this description, terms denoting relative directions and orientations such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” should be construed to refer to the orientation as then being described or as shown in the drawing under discussion. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein elements are integral parts of a whole, or are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise or as apparent in view of the described functions of such elements.  
      Referring to  FIGS. 1 and 2 , according to an inventive aspect, elongated members such as the rail  20  and post  30  are attached to one another using a U-shaped bracket strip  40 . The bracket strip  40  is affixed on a surface of the post  30  and generally defines a tenon have a shape that is complementary with and is received in the hollow internal contour of an end of the rail  20 . The bracket strip  40  is attached to each of the rail  20  and post  30  by fasteners  52 ,  53  such as sheet metal screws, rivets or similar fasteners.  
      A terminal fitting  60  comprising a sleeve or channel that fits over the rail  20  adjacent to the joint, provides a transition from the rail to the post. The terminal fitting  60  is shaped on its end facing the post  30  to conform to the surface of the post. That is, the terminal fitting conforms to the shape of the surface of the post at the point of attachment, which might be any of various shapes. The terminal fitting also is chosen, or might be trimmed, for the angle of incidence between the rail  20  and post  30 .  
      In  FIGS. 1 and 2 , the end of the transition fitting is flush, namely formed or cut on a plane normal to the longitudinal axis of rail  20 , so as to join perpendicularly to a face  32  of post  30 . According to an inventive aspect, the end of the rail  20  need not be carefully cut to conform to the post  30 , because the transition fitting  60  conforms to the surface of the post while enclosing over any gap between the end of rail  20  and the surface of post  30 .  
       FIG. 1  shows an exploded view and in  FIG. 2 , the joint is assembled, thereby concealing the bracket  40 . The bracket  40  provides a secure structural connection between the rail  20  and post  30 , and fixes the relative positions of the rail  20  versus the post  30 . During assembly, the terminal fitting  60  is moved to the end of rail  20  so as to extend from the end of the rail  20 , enclosing over the bracket  40  and any gap between the rail  20  and post  30 , to rest against the post  30 . Thus the rail is secured structurally and appears to abut closely against the post due to terminal fitting  60 .  
      The joint as shown is strong. The fasteners  52  that affix bracket  40  to post  30  fix the bracket rigidly to the post. In the embodiment shown in  FIG. 1 , the bracket  40  is oriented so that forces that would apply leverage in a direction tending to rotate the rail downwardly around the joint (such as the force of gravity on rail  20  and whatever the rail may carry) are borne in the plane of the material on the side legs of bracket  40 . The bracket  40  is most rigid in this direction.  
      Additional fasteners  53  affix the rail  20  to the bracket  40 . It is possible to arrange the joint so that the transition sleeve  60  is also captured in position by fasteners  53 , or sleeve  60  can be affixed using adhesive or a dab of silicone caulk or the like. Thus assembly is a simple process. The bracket  40  is aligned for the desired lateral orientation of rail  20  (normally horizontal) and attached to post  30  at the required height, using two or four sheet metal screws  52 . The rail is then pushed onto the protruding end of bracket  40 . With the rail held temporarily in position, fasteners  53  are inserted and tightened, so as to couple rail  20  to post  30 . The sleeve  60  is advanced along rail  20  to bear against the post  30 , either before inserting the fasteners, so that the fasteners also hold the sleeve, or afterwards, so that the sleeve  60  also covers and conceals the heads of the fasteners. This technique structurally engages rail  20  to bracket  40  and thus to post  30 , and also decoratively and structurally attaches the sleeve  60  to complete the joint and extend the rail precisely into complementary position against post  30 .  
      The inventive arrangement relieves the installer of the need to make finely measured or geometrically complex coping cuts at the end of the rail. Nevertheless, the end of the rail conforms neatly to the surface of the post, concealing any gap and forming a tight and strong joint. In the event that coping cuts are necessary, it is much easier to accomplish cuts on the polymer sleeve  60  than on the rail  20 .  
      In the embodiment shown in  FIG. 1 , the rail  20  has an internal load bearing member  22  such as an aluminum channel or length of rectangular tubing. The member  22  can be coextensive with the outer part  24  of rail  20  (i.e., cut flush with the end of part  24 ), or can protrude as shown by a short distance at the end of rail  20 . The outer part can comprise an extruded polymer tube forming cover  24 , shaped as shown in a conventional hand-rail cross section with a wider upper part and narrower lower part for gripping. Other shapes are also possible for defining a decorative or functional outer surface for rail  20 .  
      Assuming that the internal load bearing channel or similar structure  22  protrudes from the cover  24  as shown in  FIG. 1 , it is possible to attach the rail to the post structurally by passing a fastener through channel  22  or the like and into the bracket  40 , without involving the polymer cover part  24 . The polymer cover part  24  can be dimensioned and configured to slide on the load bearing member  22 , so that the cover can be moved toward or away from post  30  on the internal part  22  of rail  20 . In that case, the cover can be dimensioned to pass over the heads of fasteners  53 , before or when moving the transition sleeve part  60  into position against the post  30 . As another alternative, the load bearing member  22  can be coextensive with the polymer cover  24  rather than protruding, in which case the fastener  53  can pass through the transition sleeve  60 , through the cover  24  and then into the internal structural part  22 .  
      The internal structure of the polymer tube forming cover  24  can have one or more ridges  25  that are positioned to engage with the surfaces of the internal structural tube or channel  22 . This tends to further stiffen the rail structure. The bracket as shown in  FIG. 1  preferably is dimensioned substantially to fill or complement the inside contour of the opening at the end of the internal load bearing channel or similar part  22 . Thus the channel is held in position by bracket  40 , and bracket  40  generally supports the internal channel  22  against collapse, in the manner of tenon fit into the hollow end of rail  20 .  
      Advantageously, the bracket system as described is configured to make convenient, useful and structurally strong rail-to-post connections wherein the post presents various shapes. Thus, in  FIG. 3 , a similar structure is provided wherein the joint is aligned to an edge or corner  34  of post  30 . The sleeve member  60  in this case has an edge contour  62  that is generally a 45° vee shape, for fitting closely against the surface of the post  30 , namely against the face surfaces  32  and associated corner  34 . In the same manner in  FIG. 4 , the analogous post, shown as a cylindrically curved sheet port  35 , is complementary with an edge contour  62  of sleeve  60  that is in this case rounded. These examples show that the sleeve member  60  can be arranged on its end facing the post to complement the surface and provide a close fit.  
      As apparent from these embodiments, the invention provides a post and rail construction in which the post  30  has a lateral surface  32 ,  34 ,  35 , etc. to which an end of the rail  20  is to be affixed. Each of the post and the rail have longitudinal axes, but they are oriented at an angle to one another such that the end of one, namely rail  20  in the foregoing examples, has an end that abuts against the other, in these examples post  30 .  
      The structural part of the connection is made in large part by bracket  40 , which is securely affixed to the surface of the post  30  by fasteners  52 . The could be solid of otherwise shaped, but advantageously as shown comprises a strip of sheet material extending from the surface of the post  30  for a distance along the longitudinal axis of the rail  20 . As shown in  FIG. 3 , the bracket  40  comprises a strip bent in a U-shape, having two support feet  42  at the ends of the U-shape, spaced-apart leg parts  44  and a U-bottom web  46 , all of which are portions of an integral length of sheet metal strip.  
      In the embodiments shown in  FIGS. 1-4 , the feet, legs and bottom of the strip are bent at right angles along lines perpendicular to the elongation of the strip before bending. As a result, the bracket  40  provides a substantially rectilinear tenon shape protruding from post  30 . In the case of  FIGS. 1-3 , for example, the bracket forms a tenon that is aligned perpendicular to the axis of the post, but this is not a requirement, as will be apparent in connection with further examples. In any case, the strip that forms the bracket  40  is bent so that the edges of the strip reside along the edges of a rectilinear plug shape or tenon that protrudes along the axis of the rail  20 . This tenon is affixed securely to the post  30  by fasteners  52  that engage the post  30  through fastener holes in each foot part  42  of the bracket strip.  
      Two fastener holes are shown in the foot part  42  visible in  FIG. 3 , one such hole being occupied by a fastener  52  that in the example comprises a screw. It is likewise possible to place two or more fasteners per foot  42 . The size and type of fastener can be varied to correspond the expected loading, for example from a lightweight sheet metal screw or pop rivet for attachment to a hollow polymer or sheet metal post to a heavy lag bolt threaded into a solid wood post, or another similar arrangement.  
       FIGS. 1 and 2  illustrate examples wherein the post and rails are both hollow elongated members, such as sheet metal or hollow polymer tubes. In the example, shown in  FIG. 3 , the post comprises a polyvinyl chloride (PVC) polymeric square tube fit over a wooden core post  37  that fits snugly in the tube. The preferred fastener is a #10 by two inch stainless steel pan head screw with a square drive head.  
      The rail  20  is hollow for at least a short distance along the end of the rail, forming an opening complementary with the strip of sheet material, which as bent into the U-shape forms a tenon. The rail is affixed to the strip of bracket  40  at the opening, thereby structurally affixing the rail to the post. In an embodiment as in  FIGS. 1 and 2 , wherein the rail  20  is cut flush at an end affixed to the bracket  40  and is joined perpendicularly to post  30  at a flat face  32  and at right angle, the end of the rail  20  can be placed relatively close to the surface of post  30 . The terminal fitting slides up against the surface of post  30 , being telescopically slid down the rail  20  to reset against post  30 . A relatively flush fit is possible as shown in  FIG. 2 . The terminal fitting can be retained frictional, fixed in position with a dab of adhesive or caulk, or attached using the same or other fasteners.  
      In the event that the end of rail  20  is cut off at a right angle but joins to the post  30  at a corner as in  FIG. 3  or joins to a round post  30  as in  FIG. 4 , the right angle cut end of the rail does not complement the cross sectional shape of the post. However the terminal fitting can be shaped to complement the post as shown. Thus, for example, the cut end of the post  20  in  FIG. 3  may abut the post at the corner and be spaced from the post in the area of the supporting feet  42  of bracket  40 . By providing the vee shaped cutout  62  for the square post cross section shown in  FIG. 3 , or a rounded contour  62  as in  FIG. 4 , the terminal fitting  60  is brought flush against the post  30 . The terminal fitting matches the predetermined angle of the rail relative to an axis of the post, and the terminal fitting is pre-formed or trimmed to a shape that complements a surface of the post at said predetermined angle.  
      In the embodiments of  FIGS. 3 and 4 , an end of the rail  20  at the joint, and more particularly the portion of the rail surrounding the opening that receives the bracket  40 , is spaced from the surface of the post by a gap caused by the fact that the end of the rail is not cut to the same contour as the surface of the post  30 . In the case where the rail joins to the post at a right angle, the terminal fitting  60  is cut on a vertical line corresponding to the surface of the post, having a shape resembling part of a square in  FIG. 3  or part of a circle in  FIG. 4 . The rail can optionally also be cut or coped on the end abutting the post so as to provide less gap. The gap generally does not detract from the structural connection of the post and the rail, which is robust due to the attachment of the rail to the post through bracket  40  as opposed to attachment relying primarily on complementary end shapes. It is possible to make a careful coped cut but the invention makes an exact fit less crucial. The structural connection is made from the rail  20  to the bracket  40  and from the bracket  40  to the post  30 . The terminal fitting accurately complements the shape of the surface of the post, and can accommodate a predetermined angle relative to an axis of the post, the terminal fitting instead of the post or rail is trimmed, if necessary, to a shape that complements the surface of the post at said predetermined angle.  
      In the embodiment shown, the rail  20  comprises an inner load bearing member  22  that defines the an opening that fits over the bracket  40 , namely extending along the longitudinal axis of the rail from the end adjoined to the post  30 . In the embodiment shown, the inner member  22  is a channel that opens downwardly, having a rectangular contour for the opening between the channel walls. The inner load bearing member  22  could alternatively comprise another shape besides a channel, such as a closed tube of a rectangular or other cross section, a flanged shape such as a length of angle iron, an I-beam cross section wherein one or both sides of the I-beam shape receives a bracket  40 , a folded sheet metal shape such as that of a galvanized steel building stud, etc.  
      The rail member  20  comprises an outer covering  24  on the load bearing internal member. The outer covering can be adhered tightly on the internal member  22  or can be loose enough to slide longitudinally along member  22 . Preferably, the outer cover is at least snugly fitted to provide friction against sliding. The cover can be adhered by shrinkage onto member  22  or by adhesive or a similar technique. In the exemplary embodiments shown, the inner load bearing member  22  protrudes beyond the end of the outer covering  24  at the end of rail  20  to be affixed to the bracket. Such protrusion is not absolutely necessary but has the advantage of enabling the installer to concentrate on the mechanical attachment of the structural member  22  of rail  20  to the bracket  40  and thus to post  30 .  
       FIGS. 1, 3  and  4  show examples wherein the bracket  40  comprises a strip of sheet material bent into a U-shape at right angle bends between the legs  44  and the bottom web  46  of the U-shape, with the direction of elongation of the strip being perpendicular to the axis of the post  30 , laterally oriented relative to rail  20  and with the center line of the U-shape extending along the center line of rail  20 . This arrangement is preferred but other specific structures and orientations are also possible.  
      The U-shape of the bracket can be more or less rounded, for example having a circular arc instead of a flat web at the bottom  46  of the U-shape. The U-shape can be partly formed by two or more parts, such as two spaced L-shapes that each correspond to one of the feet  42  and sides  44 . The orientation of the bracket can be provided by a strip with a center line parallel to the post axis rather than perpendicular as shown in the examples. Although such arrangements are possible, the arrangement shown in the figures is advantageous in that the bracket  40  tends to align rail  20  perpendicular to post  30  because bracket  40  is stiffer in a direction parallel to the plane of the side legs  44  than perpendicular thereto. Of course, in a given installation, it may be desirable to stiffen the connection in one direction more than another, in which event the bracket  40  can be oriented accordingly.  
      Similarly, the strip forming bracket  40  as shown is formed in a U-shape having both ends  42  turned flat and attached to the surface of post  30 . In a structure that requires less load bearing capacity, a similar bracket  40  could have just one foot or could have the shape shown but only require that one foot be attached. Such choices can be made in a given installation to accommodate tradeoffs between structural strength versus ease of assembly and/or cost.  
      In each of the foregoing embodiments, the rail is shown as meeting the post at a right angle in the plane that includes both the post and the rail. (In the orthogonal plane, the orientation of the rail is variable around 360° by suitably placing bracket  40  at a flat face as in  FIG. 1  or a corner or curve as in  FIGS. 3 and 4 .)  FIGS. 5   a ,  5   b  show that the relative angles of the post and rail need not be a right angle. As also shown in  FIG. 8 , it may be desirable, for example, to provide a rail  20  that meets a newel post at an angle that is parallel to the pitch of a stairway, and in the same structure to provide another rail that meets one or more posts at a right angle.  
      An inclined rail arrangement as in  FIGS. 5   a ,  5   b  can be accommodated by providing a bracket  40  that is shaped as already described, from a strip of sheet metal that is bent into a U-shape wherein the feet portions are attached to the post and the body of the U-shape extends in the direction of the rail  20 , being received as a tenon or locating pin in the rail  20 , e.g., in a structural member  22  thereof. More particularly, the bracket extends such that the edges of the bracket, namely the opposite sides of legs  44  and end web  46  in  FIG. 5   b , fit into the opening in the end of rail  20 , particularly inside the load bearing channel or tubing member  22  thereof.  
      In  FIG. 5   a , if the channel or tube  22  is cut off flush at a right angle to the axis of rail  20 , then when the rail is mounted and moved along bracket  40  to abut endwise against post  30 , the edge of the flush cut rail can come into contact with post  30  only on the acute angle side of the post/rail joint (namely the underside of the rail in  FIG. 5   a ). On the opposite or obtuse angle side, there is a gap between the end of the rail  20  and the surface of post  30  (specifically between the end of flush cut channel or tube member  22  and the post). The gap is a function of the vertical thickness of rail  20  and of the acuteness of the angle at which the rail meets the post.  
      The terminal fitting  60  shown in  FIG. 5   a  has a terminal fitting  60  with a facing edge  62  that is inclined at a complementary angle so as to rest flush against the surface  32  of post  30 , and thereby to bridge over the gap between the rail  20  and the post  30  due to their meeting at an acute angle. Fitting  60  also has a sufficient dimension along the axis of rail  20  to cover over the protruding end of internal channel  22  in an embodiment wherein the channel protrudes from the decorative outer cover.  
      The terminal fitting member  60  can comprise a PVC, polypropylene or other polymer form, preferably injection molded so as to form fit on the outside of the outer part  24  of rail  20 . For example, the inside of the terminal member  60  can have a nominal clearance of 0.001 to 0.005 inch, such that the terminal member can slide easily over the surface of outer part  24 . The terminal member  60  has a facing edge  62  that can be is preformed to a nominal shape for standard building construction situations, and is also capable of being trimmed to fit substantially more easily than one might trim the end of the rail  20  comprising the internal channel  22  (or similar shape) and outer part  24  of rail  20 . As so provided or trimmed, the terminal fitting part  60  has at least one edge  62  that is parallel to a surface of the post  30  when the rail is installed. The associated fasteners  53  that affix the rail to the post can also affix the terminal member  60 , or a separate fastener (not show) can be placed in a manner substantially like fastener  53  as shown but used specifically to hold the terminal member  60  to the decorative rail part and/or to the internal structural member  22 . Thus the terminal sleeve member  60  can be affixed by screws  53 , or by separate screws (not shown) that extend into rail  20  or bear against rail  20  in the manner of set screws. As mentioned above, the sleeve members  60  can be adhered using adhesive or caulk.  
      The square post shape shown in  FIG. 1  is an example of a polygonal cross section. The post could have any number of sides, and the terminal fitting  60  can fit against the post at the sides and over the junction between sides, by forming the facing edge  62  to a shape that is complementary with one or more such faces of the polygonal cross section. The facing edge  60  thereby also conforms to any junction(s) between such faces, given the angle of incidence of rail  20  to post  30 . This same attribute also allows the surface of abutment to be curved and the terminal fitting edge  62  can nevertheless fit flush against post  30  by having a shape the is appropriately complementary.  
      Often, building constructions call for standard angles.  FIG. 1  illustrates an angle of 90° between the post and rail axes and 90° between the associated face of the post  30  and the rail axis.  FIG. 3  illustrates 90° between the post and rail axes but 45° for the faces of two adjacent faces  32  of post  30 . In the illustrated case, the angular location of the rail axis falls at a line  34  between post faces  32 , such that the complementary shape of the facing surface  62  of terminal part  60  is vee shaped. It is possible to make a similarly inclined junction with the rail  20  engaged at 45° relative to a face  32  but attached only to such face  32 , in which event the rail would not radiate.  
       FIG. 6  illustrates an embodiment in which two rails  20  meet a post  30  on opposite sides, each rail  20  having an axis oriented at 90° relative to the post axis and 22½° relative to the associated face  32 . In this case, the junction encompasses the edge between faces of the post, whereby surface  62  is an asymmetrical vee shape.  FIG. 7  illustrates how the parts of this construction can be arranged and connected by fasteners  52 ,  53 .  
      A limited number of standard shapes for bracket  40  and terminal part  60  are normally sufficient to accommodate many standard orientations, for example of a rail and banister arrangement as shown in  FIG. 8 , and further assuming that the posts  30  need not be round. The brackets  40  are made of sheet metal and thus are relatively easily deformable to orient a bracket  40  for a right angle connection of a rail to a post at the required angle of approach to a post that may have any number of polygonal sides. Thus the same form of bracket will usually suffice in the case of  FIGS. 1, 3 ,  4 ,  6 . In the case of  FIG. 5   a , the fold line between the feet  42  of the bracket  40  can be inclined relative to the edges of the bracket strip to make the bracket inclined as shown in  FIG. 5   b . The directions for assembling the post/rail joint can provide a guide for determining the angles needed for the respective bends at predetermined connection angles.  
      In standard sizes and angles, parts can be supplied as specified or in a kit that accommodates standard connection points and angles for building post and rail structures using the invention. Standard connections of right angle post/rail axes with connections at 90° relative to a post face  32 , or at a 45° or 22½° are common types. Connections at 45° to a face could need a symmetrical vee on the terminal part  60  or a lateral incline at that angle. Connections at other angles are altered as apparent for reasons of geometry. The complication of differing stair pitch angles can be provided by supplying incrementally different bracket  40  and fitting  60  shapes, for example with several choices between the usual stair and railing pitch angles (normally from 27° to 37° relative to horizontal). It would also be possible to provide the installer with instructions on the correct bend angles for the bracket  40  and coping cuts for edge surface  62  of terminal part  60 , to make a neat flush fitting connection by forming the bracket  40  and trimming the terminal part on site. However as discussed above, an aspect of the invention is to relieve the installer of such headaches, namely by providing pre-formed parts that meet most building construction situations.  
      The invention concerns the apparatus for the joint as described and also the associated method whereby an end of a rail is affixed to a post. This method includes providing a post  30  and a rail  20 , at least part of the rail adjacent to the end being hollow, and determining an angle at which the rail is to meet the post. A terminal fitting  60  is selected or made to be complementary with a surface of the post at the required angle. During assembly, the terminal fitting can be placed temporarily on the rail at a position spaced back from the end of the rail. For receiving the end of the rail on the post, a bracket  40  is provided comprising a strip of material with at least one foot  42 , the foot being bent so that the bracket extends at the necessary angle when the foot is placed against the surface of the post. The bracket is attached to the post using fasteners and the rail is then placed over the bracket so that the bracket is inserted into the hollow end of the rail. It is also possible to place the bracket in the rail first and attach the bracket to the post second. In any event, the foot is attached to the post at the surface of the post using fasteners  52 . The terminal fitting  60  is moved along the rail  20  up to the post  30 , thereby at least partly covering the bracket  40  and making a connection that appears closely direct from the rail to the post.  
      The rail  20  is attached to the bracket  40  by passing a fastener  53  through at least part of the rail into the bracket. The terminal fitting  60  can conceal the fastener thus passed through the rail. Alternatively, the terminal fitting  60  can be attached to the rail  20  by passing a set screw or penetrating fastener or by running the same fastener  53  through the terminal fitting  60  and well as through the wall of the rail  20 ,  22 , into the bracket  40  therein. These different alternatives are shown in several of the drawings, particularly in that right angle joints (e.g.,  FIGS. 1 and 2 ) are apt for concealing fasteners  53  under sleeve  60 . In round post contour or corner approach joints ( FIGS. 3 and 4 ) the fasteners go through sleeve  60 , etc.  
      The rail can be flush cut perpendicular to its extension, or can be cut at an incline. According to an inventive aspect, it is not necessary to go to great lengths to trim or cope the end of the rail. The terminal fitting is provided with a shape, either as supplied or as trimmed by the installer (more easily than trimming the rail) to complement the surface(s) of the post. The terminal fitting fits against the post at least at one of a flat face of the post, a flat face of the post at an angle of incidence, a rounded face of the post, a rounded face at an angle of incidence, a polygonal portion of the post, a polygonal portion at an angle of incidence, or another comparable arrangement whereby the end of the rail is to abut against a lateral side of the post.  
      The invention has been disclosed in connection with certain examples and embodiments but is not limited to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the appended claims.