Construction components, assemblies thereof, and methods of making and using same

A maintenance-free post or building structural member having longitudinal grooves therein for mating with complementary brackets, which brackets are also adapted to mate with other building structural members, and end-adapters for mounting such posts and for connecting one post to other such posts at predetermined angles. The post is hollow and has a constant wall thickness. Each groove has a curved portion and a flat portion. The brackets may be moved in the grooves adjustably, and may be locked to the post without causing any deformation of the post or bracket.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to construction components for 
buildings, and to methods of constructing and utilizing such construction 
components. 
In particular, the present invention relates to an extruded aluminum post 
having a tubular configuration with a substantially constant wall 
thickness, and a plurality of longitudinal grooves in its outer periphery 
wherein each groove has an arcuate wall portion and an intersecting 
substantially flat wall portion, adapted to retain mating brackets, and 
end-adapters for mounting such posts and for interconnection of posts. 
2. Description of the Prior Art 
Heretofore, posts and support assemblies for privacy fences, boat docks, 
cyclone fencing, highway signs, and the like, have utilized various 
devices which are cumbersome, and require relatively frequent maintenance 
and replacement. While it has been recognized that metallic posts avoid 
some of the wear and deteriorating properties of wooden posts, special 
attachments and hardware requirements of suggested metal posts have slowed 
the use of such posts in the applications mentioned hereinbelow. 
Various prior art attempts to solve or meliorate the aforementioned 
problems have proven unsuccessful. The prior art attempts are exemplified 
by the inventions disclosed in Moore U.S. Pat. No. 3,398,499; Cheslock 
U.S. Pat. No. 3,462,110; Kiefer U.S. Pat. No. 3,728,837; and U.S. Pat. 
No. 4,021,973. 
The present invention solves the aforementioned problems in a convenient 
and relatively inexpensive manner, and also provides various adapters, 
connectors and brackets enabling utilization of such posts as structural 
load-bearing members for use in structures such as buildings. 
SUMMARY OF THE INVENTION 
The present invention provides a post apparatus which includes an elongated 
support member having a major longitudinal central axis and an outer 
periphery which includes at least one groove therein. The elongated 
support member has a tubular configuration which has a substantially 
constant wall thickness. A groove is disposed substantially parallel to 
the major longitudinal central axis of the elongated support member, and 
the groove has an arcuate side wall portion and a substantially flat side 
wall portion. The groove includes a flat base portion which is disposed in 
a flat plane that is oriented substantially perpendicular to a radius 
emanating from the major longitudinal central axis of the elongated 
support member. The apparatus further includes interconnecting means for 
assembling a plurality of the elongated support members into a building 
frame structure. 
The present invention also provides a novel method of constructing and 
utilizing the aforementioned apparatus. 
It is an object of the invention to provide a maintenance-free anodized 
aluminum post structure with complementary mating brackets therefor. 
Another object of the present invention is to provide an improved support 
arrangement for adjustably and releasably supporting a bracket member or 
the like from a vertically extending support pole member. 
A further object of the invention is to provide a fence post having an 
auger or drive point at the bottom thereof for rotating the post into 
frozen or hard terrain, or driving the post into softer terrain. 
An additional object of the invention is to provide an extruded tubular 
post support member having a substantially constant wall thickness. 
A further object of the present invention is to provide a post apparatus 
having grooves provided with novel re-entry sections facilitating 
manufacture thereof and ease of adjustably securing therein external 
bracket members. 
Yet a further object of the invention is to provide a post support 
apparatus which is simply constructed and pleasing in appearance, and 
which is especially suited for connecting signs and the like, as well as 
for interconnection to conventional building structural members. 
An additional object of the invention is to provide a metallic post support 
member wherein brackets are interlocked therewith without the necessity of 
deforming either the post or the bracket, and without the necessity of the 
heads of any bolts entering any of the grooves of the post. 
Another object of the invention is to provide novel bracket members which 
may be interchangeably used on posts having different configurations and 
groove arrangements. 
Another object of the invention is to provide novel adapter members for 
mounting and interconnecting such posts. 
The foregoing and other objects and advantages of the present invention 
will become apparent from the ensuing disclosure in which several 
preferred embodiments of the invention are described in detail and 
illustrated in the accompanying drawings wherein like parts are designated 
by like reference numerals. It is contemplated that minor variations in 
structural features and arrangement of parts thereof may occur to the 
skilled artisan without departing from the spirit of the present invention 
and without sacrificing any of the advantages or objects of the present 
invention.

DETAILED DESCRIPTION 
Before explaining the present invention in detail, it is to be understood 
that the present invention is not limited in its application to the 
details of construction and arrangement of parts as illustrated in the 
accompanying drawings, because the present invention is capable of other 
embodiments and of being practiced or carried out in various other ways. 
In addition, it is to be understood that the phraseology and terminology 
employed herein is for the purpose of description and illustration only, 
and not for the purpose of restriction or limitation. 
With reference to FIG. 1, there is shown in cross-section an elongated 
support member or post 1 having a major longitudinal central axis 2 and an 
outer periphery 3 which includes one or more grooves 4 therein. The post 1 
has a tubular configuration, with a wall 5 of substantially constant 
thickness. 
Each of the grooves 4 is disposed substantially parallel to the central 
axis 2. Each groove 4 has an arcuate wall portion 6 and a substantially 
flat wall portion 7. The wall portion 7 is disposed in a plane which is 
oriented askew with respect to the axis 2. In other words, flat wall 
portion 7 is disposed in a plane to one side of the axis 2, and which does 
not intersect with axis 2. In particular, it should be noted that the 
first flat wall portion 7 is constructed to be oriented in a predetermined 
angle A. In a particular working embodiment of the invention the 
predetermined angle A has been fixed at approximately 30.degree.. 
The groove 4 further includes a base portion or base 8 which is disposed in 
a plane that is oriented substantially perpendicular to a radius emanating 
from axis 2. It should be noted that no surface or wall portion of the 
groove 4 is disposed substantially perpendicular to the plane within which 
the base 8 of that groove is disposed. It should also be noted that the 
arcuate wall portion 6 intersects the first flat wall portion 7 in an 
oblique dihedral angle. 
Each groove 4 also includes a second substantially flat wall portion 9 
which is disposed opposed to and substantially parallel to the first flat 
wall portion 7. The second flat wall portion 9 intersects the base 8 in an 
oblique dihedral angle. Although first flat wall portion 7 is parallel to 
second flat wall portion 9, wall portion 7 does not intersect base 8, but 
rather wall portion 7 is separated from base 8 by arcuate wall portion 6. 
However, because of the parallel arrangement of flat wall portions 7 and 
9, wall portion 7 is disposed in a plane which would intersect base 8 in a 
similar oblique dihedral angle. 
Bases 8, and geometric extensions thereof, geometrically define the outline 
of a square. The function of this configuration will become apparent from 
the description which follows. 
The configuration and dimensions of post 1 are critical to operability and 
interchangeability of the various components of the present invention. In 
this connection, attention is directed to the predetermined dimension B of 
an arcuate wall section 10 forming part of the outer periphery 3 of the 
post 1. The significance of dimension B of section 10 will become more 
apparent from the explanation set forth hereinbelow. 
FIG. 2 depicts in cross-section a first bracket member or bracket 11 for 
mating with and interconnection with the post 1. Bracket 11 has a first 
arm 12 which is shaped and dimensioned to fit within a groove 4 of the 
post 1. Bracket 11 also has a second arm 13 configured and dimensioned to 
fit within another groove 4 so that arms 12 and 13 fit within adjacent 
grooves 4 separated by a wall section 10. Arms 12 and 13 are oriented to 
converge toward each other. 
Bracket 11 includes straight members 14, 15, 17, 18, 19, 21 and 22, arms 12 
and 13, and arcuate members 16 and 20. The arms 12 and 13 and the arcuate 
members 16 and 20 are configured and dimensioned to permit a wall section 
10 of post 1 to fit therewithin in order to assemble post 1 and bracket 
11. The arcuate space 25 formed in bracket 11 is also formed in part by 
arcuate portions 23 and 24 at the ends of arms 12 and 13, respectively. 
The radius of curvature of arcuate portions 23 and 24 is slightly smaller 
than the radius of curvature of arcuate wall portion 6 of the grooves 4. 
As shown in FIG. 2, members 15 and 21 are not coplanar with arms 12 and 13, 
respectively. Arms 12 and 13 have a separate angular orientation with 
respect to members 15 and 21, respectively, in order to assure that arms 
12 and 13 are oriented to present the same predetermined angle A which is 
indicated in FIGS. 1 and 2. 
Also as shown in FIG. 2, a box-like cavity 26 is formed between members 17, 
18 and 19. Member 18 is provided with an unthreaded hole therethrough 
which communicates with cavity 26. A bolt (not shown) may be passed 
through hole 27 to threadedly engage with a nut (not shown) disposed in 
cavity 26 to rigidly secure bracket 11 to post 1. By tightening the bolt, 
the end of the bolt would bear against the wall section 10 of post 1. As 
an alternative, in order to eliminate the need for the nut or the 
formation of cavity 26, there could be provided a threaded hole (such as 
the one described hereinbelow in connection with FIG. 5) in a continuous 
arcuate member in lieu of the discontinuous arcuate members 16 and 20. 
FIG. 3 shows a modified post 28 having grooves 29 which are larger than and 
configured somewhat differently than grooves 4 of post 1. Groove 29 does 
not have any second flat wall portion 9 such as in groove 4, but groove 29 
does have a larger base 8 and diametrically-opposed and oppositely-facing 
arcuate wall portions 6. The radii of curvature of arcuate portion 6, the 
predetermined dimension B, and the angular orientation of flat surface 7 
in predetermined angle A are identical for posts 1 and 28. The purpose of 
having posts 1 and 28 configured in this somewhat similar fashion is to 
permit the bracket 11 to be used interchangeably as desired for post 1 or 
post 28. 
As in post 1, base portions 8 define the outline of a square. 
FIG. 4 shows an elevational view of bracket 11 secured to post 1 (or post 
28). 
FIG. 5 shows a second bracket member or bracket 30 for mating with and 
interconnecting with post 28 by fitting within and occupying substantially 
the entire space of a groove 29 on post 28. Bracket 30 has a first portion 
31 which is configured and dimensioned to fit within groove 29 of post 28. 
First portion 31 has diametrically-opposed and oppositely-facing arcuate 
surfaces 32 and 33 each of which conforms substantially to the shape of 
the arcuate wall portions 6 of groove 29. 
First portion 31 is also provided with angled surfaces 34 and 35 which 
conform to the angular orientation of first flat wall portions 7 of groove 
29. First portion 31 is integrally connected with lateral member 36 of 
bracket 30. Member 36 may be connected to or form part of a fence, wall, 
sign, etc. A threaded aperture 37 extends through first portion 31 for 
accommodating a threaded bolt (not shown) for securing bracket 30 to post 
28. 
FIGS. 6 and 7 show a modified third bracket member or bracket 40 for mating 
with post 1 or 28. Bracket 40 has an arm 41 with an arcuate portion 42 
which is configured and dimensioned similar to arm 13 and arcuate portion 
24 of bracket 11. 
Arm 41 is unitary with a second portion 43 having an unthreaded aperture 44 
therethrough and a cavity 45 formed therewithin, similar to the hole 27 
and cavity 26 of bracket 11. Portion 43 is unitary and integral with a 
lateral portion 46 of bracket 40. 
FIG. 7 shows a pair of brackets 40 and 40' which may be welded, or bolted 
by bolt 50 and nut 51, to a member 52, such as for example a sign, wall, 
board, metal plate, etc. The brackets 40 and 40' having the member 52 
sandwiched therebetween are shown assembled on and secured to post 28 by 
means of suitable fastening means, such as a pair of bolts 53 and nuts 54 
(only one of each of which is shown). 
FIG. 8 is an elevational view of the FIG. 7 apparatus as assembled. 
It should be borne in mind that the brackets 40 and 40' can be employed for 
use with either post 28 or post 1. 
It should also be borne in mind that the particular dimensions and 
configurations of the apparatus components described hereinabove are of 
particular importance to the ease of manufacturing of such components, and 
also to the adjustability and assembly of the various components. 
It should be noted that the bracket 11 permits the securement of planar 
members which are either extensions of members 14 and 22 or coplanar 
therewith, and whereby the post 1 or 28 used therewith is substantially 
tangent to such coplanar members. 
On the other hand, brackets 40 and 40' permit the assembly of a planar 
member, such as a sign or wall or fence, which is substantially coplanar 
with the major longitudinal central axis 2 of post 1 or 28. 
Bracket 30 permits the assembly of an extension of member 36 or a member 
coplanar therewith, with respect to a post 28 having its central axis 22 
offset from member 36 or any member coplanar therewith. 
The present invention also contemplates color coding the apparatus 
components mentioned hereinabove to coordinate with external members used 
therewith. For example, post 1 or 28 can be provided in a red color when 
used in conjunction with redwood boards for fencing or other purposes. 
FIG. 9 is a view of a post assembly configured as a side member of a 
building structure. In this illustration, a post 1, or 28, is fitted with 
an adapter 70 which can be fastened to a foundation member (not shown) in 
a conventional manner, such as with bolts and nuts. Adapter 70 is further 
described in FIGS. 23 and 24. At the upper end of post 1, a connector 60, 
further described in FIGS. 25 and 26, is interposed between the first post 
1 and a second post 1, which is part of a roof truss assembly. Posts 1 may 
be bolted to connector 60, if desired. Brackets 11 serve as attachment 
points for roof and wall members (not shown). Brackets 40, and brackets 
120 (described in FIGS. 16 and 17), serve as attachment points for other 
structural members, which may be adapter plates and steel L-shaped angle 
members. Plates 150 and 160 are interposed between brackets 120 and 40 and 
angle members 151, and connected thereto in a conventional manner. 
FIG. 10 illustrates a connector 100 interposed among three posts 1, serving 
as the central peak portion of a roof truss assembly. Connector 100, 
further described in FIGS. 27 and 28, may be connected to posts 1 by 
conventional means, such as bolts, if desired. In the illustrated 
embodiment, brackets 40 and plates 150 connect one post 1 to angle members 
151, and brackets 11 serve to attach roof members (not shown). 
FIG. 11 illustrates a connector 110, further described in FIGS. 29 and 30, 
interposed between posts 1, in a configuration that may be used to connect 
two roof truss assemblies to form a double-width building. As in the 
above, brackets 11 may serve to attach roof members, and brackets 40 and 
plates 150 attach angle members 151. 
FIG. 12 illustrates a post 1 fitted with a drive cap 80 and a drive point 
90, for inserting post 1 into relatively soft terrain. Cap 80 and point 90 
are further described in FIGS. 21, 22 and 18. 
FIG. 13 illustrates a vertical perspective cross-sectional view of FIG. 9, 
showing a bracket 11 attached to post 1, and showing particularly the 
manner in which post 1 is attached to adapter 70. As shown, square flange 
71 of adapter 70 is inserted onto post 1, and contacts post 1 at base 
portions 8. From FIG. 13 it will be apparent that drive cap 80, drive 
point 90, auger point 120, and connectors 60, 100 and 110 attach to post 1 
in a similar manner. 
FIG. 14 illustrates the manner in which a modified post 28 may be connected 
to flange 71 of an adapter 70, which also is typical of the manner of 
connecting a post 28 to a drive cap 80, drive point 90, auger point 120, 
or connectors 60, 100 and 110. 
FIG. 15 illustrates a perspective view of one embodiment of a bracket 11, 
having holes 54 in portions 14 and 22, and bolt 50 in hole 27. This figure 
is for illustration of the shortest possible embodiment of a bracket 11, 
since actual working embodiments vary in length as appropriate to support 
signs, and roof and wall members of buildings, and may have a plurality of 
holes 27 and 54, and bolts 50. 
FIGS. 16 and 17 illustrate the construction and use of a bracket 120 which 
is capable of attaching three members of the desired type to a common 
point on a post 1 or 28. As shown, symmetrical bracket portions 120 and 
120a have surfaces 124 to which plate-shaped members can be attached by 
means of fasteners (not shown) passing through holes 123, and surfaces 125 
which bear upon and retain a plate member 160. 
As shown, bracket 120a has an unthreaded hole 122, and bracket 120 has a 
threaded hole 121, to retain bolt 50, although it is apparent that 
brackets 120 and 120a could be identical, and a nut could be used to 
retain bolt 50. Both brackets 120 and 120a have portions 126 and 127, 
which mate with portions 6 and 7, respectively, of a post 1 or 28. 
FIGS. 18 and 19 illustrate drive point 90. Drive point 90 has a four sided 
pyramidal point 91, a flange portion 92, and a solid square connector 
portion 93, which fits into a post 1 or 28 in the manner described in 
connection with FIGS. 13 and 14. Connector portion 93, in an actual 
working embodiment, is an interference fit within a tube 1 or 28, and 
flange portion 92 is adapted to aid in removing drive point 90 from a post 
1 or 28. 
FIG. 20 illustrates the construction of drive auger 120, which, in an 
actual working embodiment, is used to removably emplace a post 1 or 28, 
for use with large signs and the like. Auger 120, in this embodiment, has 
cone portion 121, a helical screw portion 122, a flange portion 123, and a 
solid, square connector portion 124, identical to portion 93 of FIG. 19, 
which fits inside a post 1 or 28 as shown in FIGS. 13 and 14. In an actual 
working embodiment, portion 124 is an interference fit in a post 1 or 28, 
and flange 123 is adapted to aid in the removal of an auger 120 from a 
post 1 or 28. 
FIGS. 21 and 22 illustrate drive caps 80 and 80a according to the present 
invention. In this embodiment, drive caps 80 and 80a have solid, square 
connector portions 83, flange portions 82, and cylindrical drive portions 
81. Actual physical embodiments of caps 80 and 80a differ in that cap 80 
has transverse drive hole 84, and portion 83 is a loose fit within a post 
1 or 28, while portion 83 of cap 80a is an interference fit in a post 1 or 
28. In one actual application of the illustrated embodiment of this 
invention, an auger 120 and cap 80 are placed on opposite ends of a post 
1, and a rod is used through hole 84 to drive auger 120 into the ground. 
Then cap 80 is removed and replaced with a cap 80a, which cannot be 
removed without tools, and, lacking a hole 84, prevents unauthorized 
removal of the post 1 or 28. 
FIGS. 23 and 24 illustrate the construction of an adapter 70. Adapter 70 
has a base plate 75, which may be provided with apertures (not shown) to 
attach it to a surface (not shown) and is provided with ring portion 76, 
reinforced with buttresses 72 and 73, and square flange portion 71, 
adapted to fit within a post 1 or 28 in the manner shown in FIGS. 13 and 
14. An end of a post 1 or 28 may be received into space 77, defined by 
base plate 75, ring portion 76, and flange portion 71. 
In actual working physical embodiments of the invention, posts and brackets 
are extrusions, and all other components, such as adapters, connectors, 
caps, and drive or auger points, are made by casting. 
FIGS. 25 and 26 illustrate an embodiment of a connector 60, adapted to 
connect two posts 1 or 28 together at a predetermined angle. In an actual 
physical embodiment, the predetermined angle is approximately 120 degrees, 
and the connector 60 is used to connect a vertical side member post to a 
post forming the upper edge of a roof truss. In the embodiment 
illustrated, connector 60 as two end portions 62, which are hollow square 
flange portions identical in dimension to flange 71 of adapter 70, which 
fits within a post 1 or 28 as shown in FIGS. 13 and 14, and a solid curved 
cylindrical intermediate portion 61. 
Portions 62 can be provided with holes therethrough to enable fastening a 
post 1 or 28 to a connector 60 with bolts or the like, although this is 
not absolutely necessary to practice this invention. It should be noted 
that holes for fastening together with bolts or the like can be provided 
in any post or adapter or connector of this invention, if desired. 
FIGS. 27 and 28 illustrate a connector 100 for joining three posts 1 or 28 
according to the invention. In an actual working embodiment of this 
invention, connector 100 is used to form the peak member of a roof truss. 
Connector 100 is provided with three end portion flanges 101, identical in 
dimension to flange 71 of adapter 70, which interconnect with a post 1 or 
28 as shown in FIGS. 13 and 14, and a center portion 102, supporting 
flanges 101 in a predetermined relationship. In an actual physical 
embodiment, the angles between the three flanges 101 are multiples of 30 
degrees. It is preferred, although not necessary, that each flange 101 be 
provided with holes to facilitate fastening posts 1 or 28 to connector 100 
by means of bolts or the like. 
FIGS. 29 and 30 illustrate a third embodiment of a connector according to 
the present invention. Connector 110 is adapted to connect three posts 1 
or 28 together, with an angle of approximately 120.degree. between each 
post 1 or 28. In an actual working embodiment, connector 110 is used to 
connect the ends of two roof truss assemblies together to form a 
double-width structure. Connector 110 has, in this embodiment, a solid 
center section 112, and three end portion flanges 111, each identical in 
dimension to flange 71 of adapter 70, which also interconnects with post 1 
or 28 as shown in FIGS. 13 and 14. It is apparent that each flange 111 
could be provided with holes to facilitate fastening posts 1 or 28 to 
connectors 110 by the use of bolts or the like, although it should also be 
apparent that such holes are not necessary to practice this invention. 
FIG. 31 illustrates a third possible embodiment of a post according to the 
instant invention. Post 130 has a major longitudinal central axis 132 and 
an outer periphery 133 which includes at least one groove 134. The outer 
periphery 133 is generally tubular in configuration, with a wall 135 of 
substantially constant thickness. 
Each of the grooves 134 is disposed substantially parallel to the central 
axis 132. Each groove 134 has an arcuate wall portion 136 and a 
substantially flat wall portion 137. The wall portion 137 is disposed in a 
plane which is oriented askew with respect to the axis 132. In other 
words, flat wall portion 137 is disposed in a plane to one side of the 
axis 132, and which does not intersect with axis 132. In particular, it 
should be noted that the first flat wall portion 137 is constructed to be 
oriented at a predetermined angle A. In a particular working embodiment of 
the invention the predetermined angle A has been fixed at approximately 
30.degree.. 
The groove 134 includes a base portion or base 138 which is disposed in a 
plane that is oriented substantially perpendicular to a radius emanating 
from axis 132. It should be noted that no surface or wall portion of the 
groove 134 is disposed substantially perpendicular to the plane within 
which the base 138 of that groove is disposed. It should also be noted 
that the arcuate wall portion 136 intersects the first flat wall portion 
137 in an oblique dihedral angle. 
Wall portion 137 does not intersect the base 138, but rather wall portion 
138 is separated from base 138 by the arcuate wall portion 136. Wall 
portion 137 is disposed in a plane which would intersect base 138 in a 
similar oblique dihedral angle. 
The configuration and dimensions of post 130 are critical to operability 
and interchangeability of the various components of the present invention. 
In this connection, attention is directed to the predetermined dimension B 
of an arcuate wall section 140 forming part of the outer periphery 133 of 
the post 130. The significance of dimension B of section 140 should be 
apparent from the explanation set forth above regarding the 
interchangeability of brackets 11, 30, 40 and 120, which are useable with 
post 130, as well as with posts 1 and 28. Post 130, unlike posts 1 or 28, 
has strengthening member portions 139, radially disposed from axis 132 to 
intersect perpendicularily with bases 138 of grooves 134. Post 130 is 
adapted for higher stress applications than posts 1 or 28. In the 
embodiment illustrated, post 130 is capable of being mated with 
modifications of adapter 70, connectors 60, 100, and 110, points 90 and 
120, and cap 80, which have octagonal, rather than square, mating 
portions. Obviously, members 139 of post 130 must be removed for a short 
distance from an end of a post 130. This can be accomplished by the use of 
conventional means, such as a milling machine, or with hand tools such as 
a sabre saw. 
It is to be assumed that one skilled in the art may make numerous changes 
and modifications in the described embodiments of this invention without 
departing from the scope of the appended claims.