Abstract:
The present invention provides a support stands as well as kits and methods for manufacturing the support stand that holds an elongate pole. In one embodiment, the stand comprises container receives a dish and a plurality of handle molds with one of a plurality of molds selectively positioned on the dish to define a cavity for the pole, for receiving a curable mixture to form the support stand, and optionally, a release solution applied to interior surfaces and, optionally, a plurality of mesh screens disposed in spaced-apart relation in the container. In an alternative embodiment, the stand comprises a container capable of receiving a filler, a removable lid, and a sleeve positioned within the container and conforming in cross-section to a post for being supported by the container. A kit for each stand and a method of manufacturing the support stands are disclosed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priorty from provisional application No. 60/562,158 filed Oct. 19, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to holders for posts. More particularly, the present invention relates to support stands for posts as well as kits and methods for building support stands for posts. 
         [0004]    2. Description of Related Art 
         [0005]    Inserting a post into the earth can be a difficult task due to certain characteristics associated with various soil surfaces and substrates. For instance, some areas have soil that is not easily removed by manual labor due to the presence of aggregates such as rocks or stones. Other areas may have various obstructions that cause difficulty in forming holes. The obstructions include tree roots, plumbing and sprinkler systems as well as in-ground utility lines. Other soils have high sand content which is unsatisfactory for firmly supporting a post. As such, it may be difficult, if not impossible for a person to install a support for fencing, lighting, sports equipment, signage or other various applications where a support such as a post or pole is needed. 
         [0006]    To accommodate difficult post mounting conditions, various types of metal or plastic portable support stands have been employed. Unfortunately, these systems may require professional installation or be incapable of withstanding extreme weather such as high or low temperature or high winds. Over the years, the use of concrete has proven to be dependable for such applications. Concrete mix products are available generally at builder&#39;s supply stores. A laborer is thus presently relegated to digging a hole in the ground, placing the support in the hole, pouring a wet cementations mixture into the hole around the post, and waiting for the cement mixture to cure around the support, in order to secure the support on the post in the ground. However, to move the support, the laborer must dig the concrete support out of the ground. This often proves to be an arduous task. There exists a need in the art for an apparatus as well as a kit and method for a laborer to construct a support stand that allows posts to be set into the stand and selectively removed or placed in the ground. It is to such that the present invention is directed. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention meets the need in the art by providing a support stand for a post. In one embodiment the support stand comprises a container for receiving a curable material to form a support stand for a post with a dish for being disposed in a bottom portion of the container. A plurality of handle forms are selectively positioned within the container for defining recesses in the support stand. A mold is positioned within the container and conforming in cross-section to a post for being supported by the support stand. A curable material, cured within the container forms a molded support stand for holding the post. A kit for consumer purchase comprising the support stand is also provided. 
         [0008]    In another aspect, the present invention provides a method of building a support for an elongated member comprising the steps of:
   (a) providing a container;   (b) positioning a dish in a bottom portion of the container;   (c) positioning a mold on the dish;   (d) positioning a pair of handle molds on opposing perimeter portions of the dish;   (e) pouring a curable material into the container around the mold;   (f) allowing the curable material to cure to form a solidified support stand;   (g) removing the support stand from the container;   (f) positioning an elongated member in a cavity defined by removal of the mold; whereby the support stand, positioned on the ground, supports the elongated member.   
 
         [0017]    In an alternative embodiment, the present invention provides a support stand for a post, comprising a container capable of receiving a filler, a removable lid, and a sleeve positioned within the container and conforming in cross-section to a post for being supported by the container. In one aspect the filler is a curable material that, when cured within the container, forms a molded support stand for holding a post. In another aspect, the curable material comprises a mixable concrete material. The filler can also be at least one rock, sea shell, sand particle, marble, water, gold fish or a combination thereof. Alternatively, the removable lid and sleeve are one solid piece. The support stand can further comprise a sleeve holder or a sleeve plug. In one aspect, the container comprises a substantially rouinded bottom. A kit for consumer purchase comprising the support stand is also provided. 
         [0018]    In another aspect, a method of building a support stand for an elongated member is provided comprising the steps of:
   (a) providing a container;   (b) positioning a sleeve in a center portion of the container;   (c) pouring a filler into the container around the sleeve;   (d) positioning an elongated member in sleeve; whereby the support stand supports the elongated member.   
 
         [0023]    The method can further comprise the steps of pouring a curable material into the container, allowing the curable material to cure to form a solidified support stand, removing the curable material from the container, and positioning the support stand in the ground. In one aspect, the curable material comprises a cementations mixture. Alternative, the container can receive a filler. The filler can be at least one rock, sea shell, sand particle, marble, water, gold fish or a combination thereof. 
         [0024]    Objects, advantages, and features of the present invention will become readily apparent upon reading the following detailed description in conjunction with the drawings and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  illustrates a temporary fence using support stands. 
           [0026]      FIG. 2  illustrates in detailed perspective view a support stand having a mold exploded away from the stand. 
           [0027]      FIG. 3  illustrates in detailed perspective view an embodiment of a stand for an elongated post. 
           [0028]      FIG. 4  illustrates in detailed perspective view an alternate embodiment of the stand illustrated in  FIG. 3 . 
           [0029]      FIG. 5  illustrates in detailed perspective view yet another alternative embodiment of the stand. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    With reference to the drawings, in which like parts have like reference numerals,  FIG. 1  illustrates a temporary fence  10  using support stands  12 . In this embodiment, the support stands  12  are placed above ground and receive elongated posts  14  that are substantially rectangular in shape. The elongated posts  14  serve as fencing. In an alternate embodiment, the stand  12  holds an elongated post for the purpose of lighting, sports equipment, signage, or other post functions. 
         [0031]      FIG. 2  illustrates in detailed perspective view the support stand  12  having a mold  16  exploded away from the stand  12 . The mold  16  is substantially the same shape and size of the elongated post  14  received by the stand  12  as described below. The mold  16  defines a cavity  15  in the stand  12  to receive the post  14 . As illustrated, recesses  18  in a bottom portion of the support stand  12  provide gripping places for the hands and fingers during lifting. Alternatively, the recesses  18  may be formed intermediate a bottom and a top portion of the support stand  1   2  to facilitate lifting, rolling, or moving the support stand  12 . 
         [0032]      FIG. 3  illustrates in detailed perspective view of an embodiment of a resulting support stand  30  for on-site manufacture. The numeral “30” is understood to indicate the resulting support stand as indicated in  FIGS. 1 and 2  as “12.” The support stand  30  comprises a container  32  that receives a dish  34 . The container  32  can have a closed bottom, or an open bottom that is closed by the dish  34 . A plurality of handle molds  36  sit in a lower portion of the container  32  on the dish  34 . 
         [0033]    A mold holder  38  attaches to a center portion of the base and engages the post mold  16 . In one embodiment, a fastener extends through the dish  34  into the mold  16  to secure the mold within the container  32 . A concrete release solution  39  may be applied to the sides of the container  32 . These components are readily provided in a kit configured for purchase and manufacture of a stand  30 . 
         [0034]    The container  32  can have a standard capacity of five gallons; however, various capacities and shapes may be employed depending on the desired size and shape of the support to be manufactured. Preferably, the container  32  is made of plastic; however, it is within the scope of this disclosure to include a container  32  made of any material capable of holding a curable materials mix for manufacture of the stand  30 , such as cementations mix. Suitable container materials include polyvinylchloride, metal and metal alloys. The container  32  may contain a closed or open bottom that receives a dish  34  having structural dimensions adapted to the diameter and overall shape of the container  32 . An open-bottom container facilitates extraction of the stand and the dish once the stand  30  has cured as discussed below. The dish  34  is made of a metal or metal alloy capable of supporting the weight or pressure of the cementations mixture. 
         [0035]    In the illustrated embodiment, the two handle forms  36  rest on an outer peripheral edge of the dish  14 . When the cementations mix is poured into the container  32 , the forms  36  define the cavities or recesses  18  the forms  36 . The forms  36  are fabricated from foam rubber or wood blocks; however, the forms  36  may be comprised of any materials that can withstand the pressure and acidity of the concrete mix. The recesses  18  formed by these forms  36  allow the laborer to physically grip the support  12  to facilitate lifting, carrying, and moving the support. A mold holder  38  attaches to a center portion of the dish  34 . The mold holder  38  holds the mold  16  in position to define the receiving cavity that conforms to the cross-sectional shape of the elongated post  14  to be positioned in the stand  30 . A toggle bolt or other fastener used as the molder holder  38  accepts various sized molds  16 . 
         [0036]    In an alternative embodiment, the mold  16  is an elongaged block of wood positioned in a center portion of the dish  34 . The mold  16  slideably engages the mold holder  38  in a center portion of the dish  34 . The mold  16  is substantially the same length as the depth of the respective container. The mold  16  is made of waxed cardboard for easy removal. The mold  16 , however, may be fabricated from any durable material such as polyvinylchloride, metal and metal alloys. 
         [0037]    Once the cementatious mixture cures, the mold  16  is removed. The cavity defined by the mold  16  is dimensioned to slideably receive the post  14 , pole or other structure to be held by the support  30  (i.e,. “12” of  FIGS. 1 and 1 ). A commercial embodiment of the support stand  30  includes a plurality of molds  16 . Each mold  16  corresponds to a standard support such as a 2″×2″ or 4×4″ square  20  posts or a round post having a diameter of 1″, 1½″, 2″, 2½″, or 3.″ 
         [0038]      FIG. 4  illustrates an alternative embodiment of the support stand  30  of  FIG. 3 . In this embodiment, the support stand  30  includes a plurality of mesh screens  40  annularly surrounding the mold  16 . Preferably, a plurality of mesh screens  40  is placed at spaced positions along the interior of the container  32 . In one embodiment, the mesh screens  40  are fabricated from woven or welded galvanized aluminum. In the illustrated embodiment, ½″ mesh is utilized. The mesh screens  40  have a multi-function purpose. In one aspect, the mesh screens  40  act as a support strengthening agent for the concrete. In another aspect, slots cut out of a middle portion of the mesh screens  40  act as an alignment tool for the mold  16 . The release solution  39  coats the inner surface of the container. The release solution  39  for cementations mixtures is a silicon-based solution, such as Concrete Form Release Agent made by Encor in Nashville, Tenn. It is understood, however, that the release solution  39  could be any comparable coating solution known in the art. The release solution  39  allows the cured concrete formation to be easily removed from the container  32 . 
         [0039]    With reference to  FIGS. 3 and 4 , the support stand  12  is manufactured with the support stand  30 . The container  32  has a capacity substantially equal to the size of the support  30  needed. The mold  16  attaches with the fastener to the dish  34 . The dish  34  positions in a bottom portion of the container  32 . The handle forms  36  are placed on the perimeter portions of the dish  34 . As an optional step, a user engages at least one mesh screen  40  annular to the mold  16 . For further reinforcement, the user may arrange multiple mesh screens  40  spaced-apart in the container. With the components of the support stand  30  positioned, a user pours a curable material such as a pre-mixed cementatious mixture into the container  32  and around the mold  16 . With use of the mesh screens  40 , the mixture falls through the screens and fills the container  32 . The curable material cures within the container  32 . A cementation mixture typically cures in about twenty-four hours. The cure time depends on the weather conditions at pouring. After  15  curing, the user removes the mold  16  leaving the cavity adapted to receive the elongated pole or post  14 . 
         [0040]      FIG. 5  illustrates in detailed perspective view yet another alternative embodiment of the support stand  50 . In this embodiment, the support stand comprises a container  52  of substantially the same capacity of the containers previously described. The support stand further comprises a sleeve  54 , a removable lid  58  and, optionally, a sleeve holder  60  and a sleeve plug  56 . Preferably, the container  52  has a capacity of about  4  gallons. The sleeve  54  resides within a central portion of the container  52 . The removable lid  58  comprises a cavity  62  located substantially in a center region of the lid  58 . The removable lid  58  substantially engages the top rim of the container  52 . As illustrated, the interior of the container  52  has a substantially rouinded bottom or “bullet” shape. Should the user choose to pour concrete within the container  52 , this shape results in a rounded mold. The bullet shape up may be more appealing for above-ground applications, since sharp corners can be rough if the concrete is poured in a square-bottomed embodiment of the container  52 . However, it is within the scope and spirit of the invention that the bottom of the container be square in shape, especially for applications where the user places the container  52  in the ground and later chooses to pull the container out of the ground. A handle  51  is attached to help a user move the stand  50  from place to place. 
         [0041]    The sleeve holder  60  is preferably engaged in the cavity  62  to secure the sleeve  54 . The sleeve plug  56  is placed above the cavity  62  to cover the sleeve  54  when pouring a filler such as concrete, sand, water, etc. into the container  52 . The sleeve plug  56  also serves an aesthetic purpose (i.e., to conceal the sleeve when no post inserted in sleeve). The removable lid  58  covers the filler and gives a more pleasing appearance, especially when the container  52  is utilized above ground. 
         [0042]    Preferably, the removable lid  58 , sleeve  54  and container  52  are fabricated of a plastic, preferably clear plastic; however, it is within the scope of this disclosure to include a removable lid  58 , sleeve  54  and container  52  made of any material capable of holding a filler such as a curable cementatious mix. Both the removable lid  58  and container  52  are reusable. In one embodiment, the removable lid  58  is a clear plastic to allow viewing of a decorative filler, such as rock sea shells, colored sand, marbles, colored water, gold fish and the like. The removable lid  58  and container  52  can be fabricated in a variety of sizes to accommodate various sized posts. A complimentary sized sleeve  54  can be fabricated to selectively engage each removable lid  58  and container  52 . The advantage of this embodiment is that this embodiment eliminates the need for recesses and plugs. Furthermore, the need to separate the concrete from the container  52  is eliminated. 
         [0043]    In use, the user inserts the sleeve  54  within a center portion of the container  52 . Next, the pours a filler in the areas outside the sleeve  54  (i.e., within the container  52 ) up to a level found acceptable by the user. The amount of filler poured within the container  52  will vary based on the size of the container  52  and the weight needed to support the post. A post is then inserted within the sleeve  54  which is substantially adapted to receive the post. The overall shape of the container  52  and lid  58  allows both pieces to be pulled out of the ground by using a noose like rope or cable wrapped around the outside perimeter of the container  52 . For above-ground applications, the container  52  may be left in place such as when the filler is sand or water. For in-ground applications, the container can optionally be removed or placed in the ground as a whole. 
         [0044]    In an alternative embodiment, the sleeve  54  and removable lid  58  comprise one solid piece with an additional outside plastic corrugated sleeve  64  around the perimeter of the sleeve  54 . In use, the solid piece would be pushed down into the concrete and after the concrete hardens allowing the user to then pull the sleeve  54  and removable lid  58  piece out and leave the plastic outside sleeve behind thus defining a space capable of receiving a post. All embodiments are made available in the form of a kit for consumer purchase. 
         [0045]    While this invention has been described in detail with particular references to illustrated embodiments thereof, it should be understood that many modifications, additions and deletions, in additions to those expressly recited, may be made thereto without departure from the spirit and scope of the invention.