The present invention relates generally to fence systems and, in particular, to mounting brackets for attaching fence rails to fence posts.
Typical fence systems include vertical posts, horizontal rails extending between the posts, and sometimes vertical pickets mounted to the rails. Fence systems with these components molded of vinyl or another plastic have become popular because of their durability and low cost. In such fence systems, plastic brackets are mounted to the posts to support the rails. The brackets are usually mounted to the posts by metal screws, and then metal screws are inserted through holes in the brackets and into the rails to secure the rails to the brackets. The bottom walls of the brackets support the weight of the rails, the sidewalls of the brackets hold the rails in place on the bottom walls, and the screws that secure the rails to the brackets keep the rails from being upwardly dislodged from the brackets. These screws are typically made of very high grade aluminum so that they will not corrode and stain the fencing. But such screws add significant costs to the fencing system—just one of the screws can cost more than the bracket.
Accordingly, it can be seen that there is a need in the art for a better way to mount fence rails to fence posts. It is to the provision of a solution meeting these and other needs that the present invention is primarily directed.
Generally described, the present invention in one aspect provides a fence rail bracket assembly for mounting a fence rail to a fence post. The bracket assembly includes a mounting bracket, post-mounting push fasteners, and rail-mounting push fasteners. The mounting bracket supports the weight of the rail, includes one or more post-mounting apertures, and includes one or more rail-mounting apertures. The post-mounting apertures receive the post-mounting push fasteners to mount the bracket to the post. And the rail-mounting apertures receive the rail-mounting push fasteners to secure the rail to the bracket. In this way, the rail can be mounted to the post without using any high-grade aluminum or other metal screws. Alternatively, the bracket assembly may be provided with the post-mounting push fasteners and with conventional screws or other fasteners for mounting the rail to the bracket, or with the rail-mounting push fasteners and with conventional screws or other fasteners for mounting the bracket to the post.
In a first example embodiment, the rail-mounting push fasteners are selected with a length such that they extend into, but not all the way through, the rail. In a second example embodiment, the rail-mounting push fasteners are similar to those of the first embodiment but instead they are selected with a length such that they extend all the way through the rail and out the other side of the bracket. For example, the rail-mounting push fasteners may have a segment with wing elements for restraining the push fasteners in place and a segment without wing elements adjacent the rail-mounting aperture on the other side of the bracket for aesthetics. And in a third example embodiment, the rail-mounting push fasteners are similar to those of the second embodiment but additionally they include a cross-sectionally square segment for engaging parallel opposing edges of the rail-mounting apertures of the brackets to prevent rotation of the push fasteners. In addition, these rail-mounting push fasteners include a threaded segment that extends out of the other side of the bracket and that engages with a rail-mounting nut to help hold the push fasteners in place.
In another aspect, the present invention includes a fence system including the fence posts, the fence rails, and the fence rail bracket assemblies described herein.
In still another aspect, the present invention provides a method of mounting a fence rail to a fence post using the fence rail bracket assemblies described herein. The method includes the steps of mounting the mounting bracket to the post, positioning the fence rail on the bracket, forming one or more rail-mounting apertures in the rail in alignment with the rail-mounting aperture in the bracket, and inserting the rail-mounting push fasteners into the aligned rail-mounting apertures of the rail and the bracket to secure the rail to the bracket. The step of mounting the mounting bracket to the post preferably includes drilling one or more post-mounting apertures in the post and inserting the post-mounting push fasteners through the post-mounting apertures in the bracket and into the post-mounting apertures in the post. In addition, the step of forming the rail-mounting apertures preferably includes drilling one or more rail-mounting apertures in the rail. In this way, the fence installer drills the apertures for the push fasteners and then manually pushes the push fasteners into the drilled apertures, instead of screwing metal screws into the rail and the post.
The specific techniques and structures employed by the invention to improve over the drawbacks of the prior art and accomplish the advantages described herein will become apparent from the following detailed description of example embodiments of the invention and the appended drawings and claims.
Referring to the drawings,
The bracket assembly 10 includes a mounting bracket 18, post-mounting push fasteners 20, and rail-mounting push fasteners 22. The mounting bracket 18, the post-mounting push fasteners 20, and the rail-mounting push fasteners 22 can be packaged together and sold as a kit, or they can be provided individually.
The mounting bracket 18 may be a conventional fence rail bracket 18 molded of vinyl or another plastic. Such conventional fence rail brackets are made by U.S. Fence and sold nationwide at The Home Depot. In the depicted embodiment, the mounting bracket 18 includes two generally vertical sidewalls 24, a rear wall 26 extending at least partially between the sidewalls, and a bottom wall 28 extending at least partially between the two sidewalls. The bottom wall 28 has a support surface 30 that supports the weight of the rail 14 and any vertical loading applied to the rail. The sidewalls 24 receive the rail 14 between them to hold the rail in place on the support surface 30. In addition, the rear wall 26 has two post-mounting apertures 32 and the sidewalls 24 each have two rail-mounting apertures 34. Preferably, the rail-mounting apertures 34 of each sidewall 24 are aligned with the rail-mounting apertures of the other sidewall.
In alternative embodiments, the mounting bracket has more or fewer of the rail-mounting and post-mounting apertures, the rail-mounting and post-mounting apertures are provided in other portions of the mounting bracket, the sidewalls and bottom wall of the mounting bracket form a curve or other shape for use in mounting a curved or other-shaped rail to it, the rear wall of the mounting bracket forms a curve or other shape for use in mounting to a curved or other-shaped post, and/or the mounting bracket is made of wood, metal, or another material. The depicted mounting bracket has dimensions of about 2 inches by 3 inches for use with a rail having cross-sectional dimensions of about 2 inches by 3 inches. (In practice, the rail and bracket have actual dimensions of about 1-¾ inches by 2-¾ inches, as is common in the industry). In other alternative embodiments, the mounting bracket has other shapes and sizes that are selected based on the shapes and sizes of the rails and posts the mounting bracket is to be used with.
The post-mounting push fasteners 20 and the rail-mounting push fasteners 22 may be provided by conventional “push-in,” “drive,” or “Christmas tree” fasteners (collectively referred to as “push” fasteners). Such conventional push fasteners are made by Illinois Tool Works (Glenview, Ill.) and Micro Plastics, Inc. (Flippin, Ark.), among others. One example type of conventional push fastener is disclosed by U.S. Pat. No. 4,728,238 to Chisholm et al., which is hereby incorporated by reference in its entirety. Preferably, the push fasteners 20 and 22 are molded of nylon or another plastic material. The post-mounting push fasteners 20 are sized to be received through the post-mounting apertures 32 of the mounting bracket 18 and into the post 16 to secure the bracket to the post. Similarly, the rail-mounting push fasteners 22 are sized to be received through the rail-mounting apertures 34 of the mounting bracket 18 and into the rail 14 to secure the rail to the bracket.
The push fasteners 20 and 22 have resilient wing elements 36 that deflect when pushed through the apertures 34 and 32, respectively, and into the rail 14 and the post 16, respectively, then resiliently return to their original positions. In the depicted embodiment, the rail 14 and the post 16 are hollow and have peripheral walls, and the push fasteners 20 and 22 are extended into, but not all of the way through, the rail 14 and the post 16, respectively. So when the push fasteners 20 and 22 have been pushed into place, the wing elements 36 engage the inside surface of the peripheral walls of the rail 14 and the post 16, respectively. For use with the depicted 2- by 3-inch mounting bracket 18, for example, the rail-mounting push fasteners 20 preferably have a length of about ½ to 1 inch.
The wing elements of conventional push fasteners will support some tension loading (loads parallel to the axis of the fastener shaft). But they are typically used primarily for supporting shear loads (loads perpendicular to the axis of the fastener shaft). The rail-mounting push fastener 20 generally only “locates” the rail 14 relative to the bracket 18, as the bottom wall support surface 30 of the bracket carries the vertical shear load on the rail. So there is almost no vertical shear load or tension load on the post-mounting push fasteners 22, and there is very little horizontal shear load (along the length of the rail) on the rail-mounting push fasteners. The post-mounting push fasteners 22 carry the vertical shear load of the brackets 18 and rails 14, and this can result in some tension loading on the post-mounting push fasteners. In order to help retain the post-mounting push fasteners 22 in place, the rails 14 may be solid, have solid end-pieces, have an internal blocking structure that runs substantially the length of the rail, or be provided with end caps that can be inserted onto the rail ends, to the block the push fasteners from “backing out” into the hollow rail ends under tension loading after the bracket assembly 10 has been installed.
In an alternative embodiment, the bracket assembly 10 is provided with the rail-mounting push fasteners 20 and with conventional screw-in or other fasteners for mounting the bracket to the post. In another alternative embodiment, the bracket assembly 10 is provided with the post-mounting push fasteners 22 and with conventional screw-in or other fasteners for mounting the rail to the bracket. And in still another alternative embodiment, the bracket 18 is provided without the bottom wall 28 for supporting the rail, and the number, position, and strength of the rail-mounting push fasteners 20 are selected for supporting the entire shear loading from the rail 14.
In this embodiment, however, the bracket assembly 10a includes rail-mounting push fasteners 20a having a length selected for extending all the way through the rail 14 and the aligned rail-mounting apertures 34 of the mounting bracket 18. For use with the depicted 2- by 3-inch mounting bracket 18, for example, the rail-mounting push fasteners 20a preferably have a length of about 2 inches. In some embodiments, the rail-mounting push fasteners 20a have a segment 38a with the wing elements 36 and a segment 40a without any of the wing elements. In the depicted embodiment, the segment 38a with the wing elements 36 is adjacent the head 42 of the push fastener 20a and the segment 40a without wing elements is adjacent the leading tip 44 of the push fastener. In this way, the wing-element segment 38a engages the rail 14 adjacent one of the aligned rail-mounting apertures 34 to retain the push fastener 20a in place, and the no-wing-element segment 40a extends through the opposite one of the rail-mounting apertures to help support the shear loading from the rail without any of the wing elements 36 being visible. In an alternative embodiment, the wing-element segment 38a and the no-wing-element segment 40a are switched with the no-wing-element segment adjacent the fastener head 42 and the wing-element segment adjacent the fastener leading tip 44. In some other embodiments, the rail-mounting push fasteners 20a have the wing elements 36 along substantially their entire lengths.
In this embodiment, the bracket assembly 10b includes innovative rail-mounting push fasteners 20b that are not known to be commercially available. The rail-mounting push fasteners 20b have a length selected for extending all the way through the rail 14 and the aligned rail-mounting apertures 34b of the mounting bracket 18, and have a segment 38b with the wing elements 36, similarly to the mounting push fasteners 20a of the second embodiment. In the depicted embodiment, the segment 38b with the wing elements 36 is adjacent the fastener head 42 to secure the push fastener 20b to the rail 14 once inserted into place. In addition, at least one of the rail-mounting apertures 34b is square, and the rail-mounting push fasteners 20b each include a segment 48b with a square cross-section that is received in the square rail-mounting aperture. This prevents rotation of the rail-mounting push fastener 20b once inserted into place. Furthermore, the rail-mounting push fastener 20b includes a segment 46b that is threaded, with the threaded segment adjacent the fastener leading tip 44. And the bracket assembly 10b further includes a rail-mounting nut 50b with threading that mates with the threaded segment 46b of the push fastener 20b. The nut 50b screws onto the threaded segment 46b of the push fastener 20b to better retain the fastener in place. Because of the engagement of the square segment 46b in the square aperture 34b, the installer does not need to hold the push fastener head 42 to tighten the nut 50b on it.
In an alternative embodiment, the rail-mounting aperture is not square but still has two parallel opposing edges that engage the fastener square segment. For example, the bracket may have slotted rail-mounting apertures with two opposing edges that are linear and parallel and with the other two opposing edges being curved, or with rectangular slotted rail-mounting apertures. In any case, the rail-mounting aperture 34b has two parallel opposing edges 35b that engage the fastener square segment 46b to prevent rotation of the push fastener 20b.
In another aspect, the invention includes the fence system 12 with one or more of the fence posts 16, one or more of the fence rails 14, and one or more of the fence rail bracket assemblies 10, 10a, and 10b described herein. These fence system 12 components, or only some of them, may be packaged together and sold as kits, or they may each be provided individually.
In still another aspect, the invention provides a method of mounting a fence rail 14 to a fence post 16 using the fence rail bracket assemblies 10, 10a, and 10b described herein. When using the fence rail bracket assembly 10 of the first embodiment, the method includes the steps of mounting the mounting bracket 18 to the post 16, positioning the fence rail 14 on the bracket, forming one or more rail-mounting apertures 52 in the rail in alignment with the rail-mounting apertures 34 in the bracket, and inserting the rail-mounting push fasteners 20 into the aligned rail-mounting apertures of the rail and the bracket to secure the rail to the bracket.
The rails 14 are typically cut to length during the installation of the fence system 12, and using conventional installation techniques the installer drills pilot apertures in the rails using a power drill, inserts metal screws through the rail-mounting apertures 34 in the brackets 18 and into the pilot apertures, and then uses a power screwdriver to drive the metal screws into the rails. The present method includes the step of forming the rail-mounting apertures 52 in the rail 14, preferably by drilling the apertures in the rail, without the need for a screwdriver. The rail-mounting push fasteners 20 are then manually pushed through the aligned rail-mounting apertures 52 and 34 of the rail 14 and the bracket 18, respectively, to secure the rail to the bracket, without the need for a screwdriver.
In addition, with conventional installation techniques the installer drills a pilot aperture in the posts 16 using a power drill, inserts metal screws through the post-mounting apertures 32 in the brackets 18 and the pilot apertures, and then uses a power screwdriver to drive the metal screws into the posts 16. In the present method, the step of mounting the mounting bracket 18 to the post 16 preferably includes drilling one or more post-mounting apertures 54 in the post and inserting the post-mounting push fasteners 22 through the post-mounting apertures in the bracket and into the post-mounting apertures in the post to secure the bracket to the post, without the need for a screwdriver.
When using the fence rail bracket assembly 10b of the second embodiment, the method is very similar. Differences include that the rail-mounting push fasteners 20a are only inserted into the bracket 18 and the rail 14 from one side and fewer of the rail-mounting push fasteners may be needed, as the push fasteners of this embodiment extend all the way through the rail 14 and bracket 18.
When using the fence rail bracket assembly 10b of the third embodiment, the method is similar to when using the bracket assembly 10b of the second embodiment. With this bracket assembly 10b, however, the method includes the steps of grasping the rail-mounting push fastener 20b, inserting the push fastener into the rail-mounting aperture 34b, all the way through the rail 14, and out the opposite side of the bracket 18b, releasing the push fastener, and installing the threaded nut 50b onto the push fastener without manually restraining the push fastener against rotation. With the rail-mounting push fasteners 20b inserted into place all the way through the rails 14 and the brackets 18b, the fastener square segment 48b is engaged by the parallel opposing edges 35b of the rail-mounting aperture 34b to prevent rotation of the push fastener, the fastener wing-element segment 38b engages the rail to secure the push fastener in place, and the fastener threaded segment 46b extends out of the opposite side of the bracket. So the installer can simply push the rail-mounting push fastener 20b into place from one side and then, without manually restraining the fastener head 42 against rotation, twist on the nut 50b from the other side until it is tight.
It is to be understood that this invention is not limited to the specific devices, methods, conditions, and/or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be unnecessarily limiting of the claimed invention. In addition, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, plural forms include the singular, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Furthermore, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein.
Moreover, while certain embodiments are described above with particularity, these should not be construed as limitations on the scope of the invention. It should be understood, therefore, that the foregoing relates only to exemplary embodiments of the present invention, and that numerous changes may be made therein without departing from the spirit and scope of the invention as defined by the following claims.
The benefit of the filing date of U.S. provisional patent application Ser. No. 61/172,052, filed Apr. 23, 2009, entitled FENCE RAIL BRACKET WITH PUSH FASTENERS, is hereby claimed, and the specification thereof is incorporated herein by this reference.
Number | Date | Country | |
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61172052 | Apr 2009 | US |