FOOT PLATE

A foot plate, a foot plate and post assembly and method of using. The post has a first exterior side, a second exterior side, a third exterior side, a fourth exterior side, and a bottom edge. The foot plate has a top surface, a bottom surface and an opening having a first interior side corresponding to the first exterior side of a post, a second interior side corresponding to the second exterior side of the post, a third interior side corresponding to the third exterior side of the post, and a fourth interior side corresponding to the fourth exterior side of the post, wherein the opening fits around the post such that the foot plate is unable to rotate around the post but the bottom edge of the post can be aligned with the bottom surface of the foot plate. One or more connections secure the bottom surface of the foot plate to the bottom edge of the post. A weld secures the top surface of the foot plate to the post.

BACKGROUND

Foot plates are utilized in connection with a variety of top-mounted posts. Such posts, depicted at200inFIGS.2-3, can provide foundational support for railing, fencing and other systems requiring a substantially vertical support structure. Foot plates provide stability to the post and allow for it to be anchored to a surface. Posts200are typically bolted to the top of a slab of concrete or wood surface and can be interconnected with one or more cross members102. Often such posts support swinging gates—which, because of their substantial weight, need a bolt plate or “foot” on the bottom allowing lag bolts or other known securing mechanisms to secure the post to the concrete, and thereby support the gate with rigidity and strength to last for years to come. Posts200can be a variety of cross-sectional shapes including but not limited to substantially square, rectangular or other polygonal shapes as well as substantially circular, oval or other rounded shapes. All of the foregoing are deemed suitable for use with the present invention in its various embodiments.

As seen inFIGS.1-3, one limitation with the prior art is the difficulty in proper placement of the foot plate100relative to the post200it supports. Specifically, in order for a foot plate to provide optimal stability to a post, it must be substantially centered and level. Using current foot plate solutions, a user must either just eyeball the positioning of the plate prior to securing it—typically with a weld or other strong bonding mechanism—utilizing a laborious trial and error exercise which is error-prone. Alternatively, current methodologies incorporate the use of jigs, measurements, and markings. In both cases, centering and leveling the foot plate is difficult to get right and failing to do so compromises the structural stability the foot plate is intended to provide. For example, an off-center foot plate does not provide as much lateral stability as a centered foot plate would. A foot plate that is not level can translate into an uneven post which, in addition to being aesthetically unappealing, adds a layer of difficulty in applying railings and other features to the posts because without a straight and plumb surface to mount to, finished product quality and integrity is diminished.

Another shortcoming of foot plates in the present state of the art is that they are prone to rusting. In particular, posts and associated structures such as railings are often hollow tubing and contain iron. Over time, water begins to accumulate inside the posts and railings through humidity and condensation. When a solid foot plate is affixed to the bottom of the tubing, it prevents such water from escaping. Rather, the water just pools at the bottom of the posts causing faster rusting and thereby decreasing the longevity of the post.

Equally problematic, in cold weather conditions, the water that accumulates can freeze and thus expand resulting in rupturing or fracturing of the tubing. The tubing has typically already been rusting from the water inside it. Upon freezing, the tubing expands with the ice and breaks, after this happens the rust continues at a rapid pace. Eventually, after the legs or posts are broken and rusted out, the railing needs to be fully replaced. Because the foot plate of the present invention in its various embodiments includes an opening, it allows water to drain from the tubing thus providing a significant advantage over the prior art.

Additionally, under the current state of the art, getting a good weld between the post and the foot plate can be problematic. The present device and methodology, with its largely self-centering and self-leveling feature, allows a user to apply one or more tack welds on a bottom surface of the foot plate that anchor the foot plate in place, leaving a clean and stable top surface on which a user can do a high quality, consistent weld line (rather than having periodic spot welds to weld over as would be required under the old methodology). This clean weld surface helps keep the weld largely free of contaminants or debris that could compromise its quality. Thus, the strength of the weld is improved thereby increasing the strength and longevity of the post and associated structure overall.

The present invention in its various embodiments addresses all of the foregoing issues as well as others as will be apparent in the present disclosure. Additionally, and not inconsequentially, the present device and methodology takes a fraction of the time to install compared to previously designed foot plates. The foot plate slides on the tube with a snug fit. Its self-centering and self-leveling feature means, once in place, the foot plate is already substantially squared with the leg or post. With a speed square the foot can be fully tacked on in under 30 seconds. This allows for a highly efficient process that is a significant improvement over the prior art and makes rapid production of railing systems feasible.

SUMMARY

The present invention in its various embodiments is an improved foot plate. The foot plate includes a top surface, a bottom surface, and an opening. The opening corresponds to a post having a bottom edge. The foot plate opening fits around the post in a manner that the foot plate is unable to rotate around the post, but the bottom edge of the post can be aligned with the bottom surface of the foot plate, thus allowing for a self-centering and self-aligning feature.

In certain embodiments, the opening is substantially centered in the foot plate. However, different positioning of the opening is also considered to be within the scope of the present invention. In certain embodiments, the foot plate is substantially square in shape but different shapes of the foot plate including polygonal, rectangular and circular are considered to be within the scope of the present invention.

The foot plate can provide foundational support to posts in railings, fencing and other systems requiring a substantially vertical support structure. In certain embodiments, the post has a first exterior side, a second exterior side, a third exterior side, a fourth exterior side, and a bottom edge. The foot plate in such embodiments has a top surface, a bottom surface and an opening having a first interior side corresponding to the first exterior side of a post, a second interior side corresponding to the second exterior side of the post, a third interior side corresponding to the third exterior side of the post, and a fourth interior side corresponding to the fourth exterior side of the post. When assembled, one or more connections can secure the bottom surface of the foot plate to the bottom edge of the post and a weld can secure the top surface of the foot plate to the post.

In certain embodiments, the one or more connections securing the bottom surface of the foot plate to the bottom edge of the post are tack welds. In certain embodiments, the bottom edge of the post can be aligned with the bottom surface of the foot plate such that the bottom edge of the post is substantially flush with the bottom surface of the foot plate. In other embodiments, the bottom edge of the post is aligned with the bottom surface of the foot plate such that the bottom edge of the post is separated from the bottom surface of the foot plate by a substantially uniform distance. This distance can vary but in certain embodiments, it is between approximately 1/16 inches and 7/16 inches.

A method of securing a foot plate to a post is also provided for in the present invention in its various embodiments. A post is provided having a first exterior side, a second exterior side, a third exterior side, a fourth exterior side, and a bottom edge. A foot plate is also provided, wherein the foot plate has a top surface, a bottom surface and an opening having a first interior side corresponding to the first exterior side of a post, a second interior side corresponding to the second exterior side of the post, a third interior side corresponding to the third exterior side of the post, and a fourth interior side corresponding to the fourth exterior side of the post.

The post is inserted through the opening, with the opening fitting around the post such that the foot plate is unable to rotate around the post, but the bottom edge of the post can be aligned with the bottom surface of the foot plate. The bottom surface of the foot plate is secured to the bottom edge of the post with one or more connections. In certain embodiments, these connections are tack welds. The top surface of the foot plate is also secured to the post. In certain embodiments, this securing is made with one or more welds. In one embodiment, a single line weld is utilized.

The bottom edge of the post can be aligned with the bottom surface of the foot plate such that the bottom edge of the post is substantially flush with the bottom surface of the foot plate. As noted previously, in other embodiments, the bottom edge of the post can be aligned with the bottom surface of the foot plate such that the bottom edge of the post is separated from the bottom surface of the foot plate by a substantially uniform distance.

DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Referring toFIG.4, an improved foot plate300is shown according to one embodiment of the present invention. In the present illustration, the top surface303of the foot plate300is shown. In subsequent drawings, the underside301of the foot plate300will be depicted.

The foot plate300includes a center opening302corresponding to the outer edge of a post200(FIG.5). In particular, the outside edge206of post200generally corresponds with the inside edge306of the center opening302of the foot plate300. Similarly, the outside edge208of post200corresponds with the inside edge308of the center opening302of the foot plate300. The outside edge210of post200corresponds with the inside edge310of the center opening302of the foot plate300. The outside edge212of post200corresponds with the inside edge312of the center opening302of the foot plate300. By lining up these respective edges, the center opening serves as a self-centering and self-leveling feature. Cross member317is also shown inFIGS.5-7.

Foot plate300includes one or more peripheral openings304through which the foot plate is secured to a surface. These peripheral openings are peripheral in the sense that they are generally positioned on the outside of plate300relative to the central opening302.

Referring toFIGS.6-12, the self-centering and self-leveling feature of the present invention is depicted. Initially, the foot plate300is slid onto the post200by inserting the post200through the center opening302of the foot plate300. Having center opening302slightly larger than, but conforming to, the outer surface of the post200allows a user to utilize edges in the center opening302to both center and level the foot plate300. Specifically, and as discussed further below, the plate300slides on and, when it is flush with the bottom of post200or having a uniform bottom gap, a user knows it is substantially level. Because the center opening302matches up with the external shape of the post200, a user can also know that the foot plate300is centered.

It is noted that, in certain embodiments, rather than having the plate300substantially flush with the bottom of the post200, it may be desirable to instead place the foot plate300slightly lower than the bottom edge of the post200so the foot plate300can still sit flat on its desired surface as seen inFIG.10. For example, if the post200is ⅛″ tubing, a bottom gap of roughly 1/16″ may be advantageous. In yet other embodiments, for example, if a ½″ plate300is being utilized, the bottom gap could be between approximately 1/16″ to approximately 7/16″. It depends on the preference and application of the plate300.

Once centered and leveled, the plate300is initially secured with one or more spot or tack welds. While tack welds are well-suited for use with the present invention, in certain circumstances, other mechanisms may be utilized to initially secure the plate300to the post200before final welding. For example, depending on the post200and plate300materials, in certain embodiments plastic welding, adhesives and tapes may be used alone or in combination instead of a tack weld.

As seen inFIG.9, markings313can be applied at the points (or substantially at the points) where tack welds can be utilized to initially anchor the foot plate300to the post200. The number of tack welds need not be four but could vary depending on need and circumstances. The tack welds are also depicted as being approximately in the four corners of the post200. However, other tack weld configurations could be utilized and are considered to be within the scope of the present invention.

The improved foot plates300are designed to fit just tight enough around the post200such that they do not allow for any rotational movement but remain loose enough to adjust the alignment of the plate on its X and Y axes in order to sure it up perfectly.

As each tack weld is applied, the user is able to sure up the foot plate300on the remaining unsecured sides. In so doing, the foot plate300is not only centered but also level. The foot plate300is also secured substantially flush with the bottom edge of the post200. This process allows the foot plate300to be affixed level, plumb and square (i.e., properly positioned along all three axes). As noted above, this method significantly improves production time.

FIG.10depicts the underside301of a foot plate300according to one embodiment of the present invention. Also depicted are the tack welds314that have been applied roughly at the marks313(not shown).

Referring now toFIGS.11and12, an additional advantage of the present device and methodology is illustrated. Specifically, under the current state of the art, getting a good weld between the post200and the foot plate300can be problematic. The present device and methodology, with its largely self-centering and self-leveling feature, allows a user to apply one or more tack welds314on a bottom surface301of the foot plate300(seeFIG.11) that anchor the foot plate in place, leaving a clean and stable top surface303on which a user can do a high quality, consistent weld line305(rather than having periodic spot welds as would be required under the old methodology) as seen in FIG.12. This clean weld surface helps keep the weld largely free of contaminants or debris that could compromise its quality. Thus, the strength of the weld is improved, thereby increasing the overall strength and longevity of the post and associated structure. It is also noted that for thicker plates, it may be advantageous to weld both sides of the plate300. In other words, a weld can be applied at both the top surface303and the bottom surface301of the plate300.

FIG.13depicts a foot plate300attached to a post200according to one embodiment of the present invention. Top rail316and middle rail318are also shown to illustrate one application of the present invention in the context of a railing system.

FIG.14depicts variations of the present invention in its different embodiments. As can be seen, the present invention can be adapted to a variety of post sizes and shapes as well as utilize a variety of mechanisms to secure the foot plate300to an underlying surface. In certain embodiments400, the peripheral openings304through which the plate300is secured to an underlying surface could be slots or rounded openings through which bolts or screws are inserted. Other peripheral opening304shapes could also be utilized alone or in combination accommodating vast numbers of securing mechanisms as would be apparent to one skilled in the art. Embodiment400also includes a more rectangular center opening corresponding to the outer edge of post tubing. Embodiments402,404,406,408,410,412and414depict different sized center openings corresponding to the outer edges of post tubing. Embodiment410utilizes slotted peripheral openings. Embodiment414utilizes six peripheral openings in contrast to the four openings in other embodiments (e.g., embodiment412).

In certain embodiments, the foot plate300is substantially square in shape—which allows for equal distribution of support in all directions. However, in other embodiments, it may be advantageous to have the foot plate300substantially circular in shape. Foot plates300could also be other shapes including, but not limited to rectangular, triangular or other polygonal shapes depending on need and circumstances.

The various embodiments are shown to illustrate that the present invention in its various embodiments contemplates a variety of foot plate sizes and shapes; a variety of center openings corresponding to a variety of post tubing sizes and shapes; and a variety of peripheral openings that can accommodate a wide variety of securing mechanisms known in the art to secure the foot plate to a surface.

Materials. The foot plate300is generally constructed from steel but could be other materials alone or in combination including but not limited to any metallic material including but not limited to aluminum, steel, stainless steel, titanium, copper, brass and bronze. In certain embodiments, the plate could also be made in whole or in part of plastic or wood.

The foot plates300are generally used with posts200comprising steel tubing. However, the present invention in its various embodiments could also be utilized with other substantially vertical posts. These posts could be made of numerous materials alone or in combination including but not limited to any metallic material including but not limited to aluminum, steel, stainless steel, titanium, copper, brass and bronze. In certain embodiments, the post200could also be made in whole or in part of plastic or wood.

The posts shown in the illustrated embodiments are substantially square in cross-section. However, posts of numerous other cross-sectional shapes, alone or in combination, could be utilized including, but not limited to substantially round, substantially triangular, or other polygonal shapes.

In one embodiment, 1″ square tubing is used for the post. In yet other embodiments, 10″ square tubing is used. For any thickness or size of post or tubing the concept is the same.

In an effort to assist in understanding the present invention, but without intending to limit the scope of the present invention, the following illustrative model is provided. A user would place a 3″ square tube post on a welding table. The bottom 12″ of the post is hanging off the edge of the table, but the post is securely clamped to the table. The length and dimensions of the post could vary depending on need and circumstances. The foot plate is square with outside dimensions of 6″×6.″ The foot plate has four ½″ holes placed near each corner to accommodate lag bolts to be screwed into the concrete slab and secure the bolt plate to the concrete or wood surface depending on circumstances. Wood is very common to mount to inside homes and buildings; metal surfaces can be bolted to as well, both giving the post the strength it needs.

The foot plate includes a square cut out of its center that measures roughly 3.072″×3.072″ that is designed to fit directly over the base of the post, without being too tight to fit over the bottom edge, or too loose to twist side to side (Z axis) when in place.

The outside edges of the foot plate are in line with the outside edges of the square tubing. With that, a user is ready to attach the foot to the post. In the illustrated embodiment, this involves the user adjusting the placement of the foot so that it sits approximately 1/16″ below the furthest bottom edge of the tubing, so the foot can sit flat on its desired surface. However, as noted above, in other embodiments, it may be desirable to have foot substantially flush with bottom edge of the tubing. For purposes of illustration only, the corners of the foot plate are assigned the following numbers: Top left=Corner #1; Top right=Corner #2; Bottom Right=Corner #3; and Bottom left=Corner #4.

In the illustrated embodiment, a user aligns the foot plate 1/16″ below the bottom edge of the tubing and “tack welds” the #1 corner of the foot to the tubing. Next the user will use a speed square to align the foot. This is done by placing the speed square on the tubing vertically (tubing laying horizontally with the end12″ off of the Top worktable) and sliding the speed square alignment edge down to corner #1 (where the user just tacked it). In this illustration, the Y axis is adjusted first. With the speed square alignment edge touching the horizontal edge of the tube, and the top face of the foot plate, a user can adjust the angle of the bolt plate to match the alignment of the speed square (e.g., this can be done with use the user's hand or a small hammer). Once it is aligned with the speed square, the user would make a second tack on Corner #4 to keep the foot plate in alignment with the speed square. The speed square is removed and laid horizontally on the top face of the tubing, with the short alignment edge of the speed square covering Corner #1, and the direction of the speed square running towards corner #2.

The speed square is then slid until it touches the top face of the bolt plate again. The top edge of the foot plate is then aligned to match the alignment of the speed square. Once aligned, Corner #2 is tacked to hold the foot plate in alignment with the speed square. The speed square is removed, and Corner #3 is tacked and the centering, leveling and anchoring process are complete. With that, the foot plate is aligned on the X, Y, and Z axis in respect to the direction of the post, and it is ready to be finish welded.

This technique for installing each foot plate works for sloped feet as well. If, for example, a user is mounting surface slopes 3*X, the user would simply use an angled alignment tool and position the foot to the correct orientation. Similarly, the present invention can also work on a diagonal slope (e.g., 3*X and 4*Y).

Certain embodiments of the present invention can be utilized on 40+ degree sloped railing feet to maintain a plumb post on a sloped mounting surface. This design and concept can be used for any size tubing, pipe, or item on which a user wishes to weld a bolt plate to, regardless of thickness or outside dimensions. It can be used on any mounting slope, or a level slope and allow for a slanted post if needed. As long as the hole is calculated correctly to accommodate for the mounting edge of the tubing or post.

Production of the Foot Plates According to One Embodiment.

The outside dimensions of the desired post tubing are measured. By way of illustration, if a foot plate for a 3″×3″ piece of square tubing is wanted, a center opening of 3.072″×3.072″ square is produced. This production can occur utilizing a variety of methods. In certain circumstances, CAD software is utilized. The center opening is placed substantially in the center of the foot plate. This opening can be created with a plasma or laser cutting tool.

It is understood that the above-described arrangements are only illustrative of the application of the basic principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention. The appended claims are intended to cover such modifications and arrangements.