Abstract:
A post mounting system and method that includes individually adjustable angled gripping elements which contact the interior of a hollow post so as to hold the post firmly against a retaining wall of a base member surrounding the lower end of the post. One or more shim components having a surface area substantially the same as at least the surface area of the bottom of the base member is used to adjust the vertical angularity of a post secured to the base member. The shims may be circularly shaped with a slot extending to the center thereof for shim placement about a rod upon which the base member is mounted. There is a thicker portion of such a shim opposite the slot. Alternative embodiments include additional post reinforcing structures insertable into the interior of the hollow post to provide additional support for complying with building code requirements, such as second story dwelling uses, etc.

Description:
RELATED APPLICATIONS  
       [0001]     The present application is a continuation of prior pending U.S. patent application Ser. No. 10/426,442 filed Apr. 29, 2003, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/376,658 filed Apr. 29, 2002; each of these prior applications is fully incorporated therein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention is directed to a post mounting system and method, and more particularly, is directed to a post mounting system having individually adjustable angled clamping members which contact the interior of a hollow plastic or composite post so as to hold such a post firmly against a base member&#39;s retaining wall surrounding such post.  
       BACKGROUND  
       [0003]     Post retaining systems and methods are known in the art. For example, U.S. Pat. Nos. 5,404,682; Reissue No. 36,550; 5,458,428; 5,307,598; and 5,386,938, all to West, describe various devices for mounting posts, and in particular, hollow square vinyl posts, to secure the same. Difficulties exist, however, with respect to proper plumbing of such posts to ensure correct vertical alignment thereof and with respect to securing such posts in a stable fashion. Moreover, the method by which hollow vinyl posts are connected to a mounting assembly is often complicated and made difficult by the necessity of having various accessories required to perform such task. For example, in prior art post mounting systems and methods, a vice may be utilized to hold the post, a press is utilized to insert elements of the mounting assembly into the hollow interior of the post and a router rig is required to configure the interior and exterior portions of the post so that it can be properly configured for use with such prior art post mounting systems.  
         [0004]      FIG. 1  is illustrative of the components used in other prior art mounting assemblies for securing hollow posts in a vertical position. Specifically, there is a support base  12  having: (a) a vertically protruding interior pedestal  16  over which a hollow post (not shown here) is fitted, and (b) a surrounding recess  20  into which a lower end of the hollow post is fitted when secured to the support base  12 . The additional components shown in  FIG. 1  include mounting screws  24  that can be used to secure support base  12  to a wood deck or porch, a threaded mounting rod  28  that can secure the support base  12  to the deck or porch by attaching the rod  28  to, e.g., an underneath side of the deck or porch so that the rod extends through the deck or porch and then through the center hole  32  of the support base. During assembly the following steps are generally performed: (a) the rod  28  is fastened with nuts and washers to the deck or porch, (b) a hollow post is selected that mates tightly with the pedestal  16  (the post interior is expanded if necessary), (c) the post is positioned on the pedestal  16 , (d) the post is then vertically adjusted by various techniques such as: positioning shims underneath one or more of the four corners  36  of support base, reconfiguring the interior of the hollow post, and/or grinding the lower end of the post so that the post will be sufficiently vertical, (e) once the post is sufficiently vertical, screws  40  are threaded into the side of both the post and the support base  12  to secure the post to the support base, and (f) a trim ring  44  is provided over the exposed portion of the support base  12  to thereby cover the connection between the support base and the post.  
         [0005]     To secure the hollow post tightly onto the support base  12 , the interior pedestal  16  must tightly fit into the interior of the post. Accordingly, such pedestals  16  may be slightly larger than the interior of the post, and thus each pedestal must have its exterior dimensions reduced and/or each post must have its lower end interior dimensions increased so that: (a) the pedestal and its post tightly mate, and (b) when the support base  12  is secured to the ground (via the threaded bolts  24 ), the post will be (or at least appear to be) exactly vertical. Moreover, since the ends of such hollow posts may not be exactly perpendicular to the length of the post, a user can not always fully seat the lower end of the post into the recess  20 . Additionally, the ground upon which the support base  12  is to be attached may not be (and typically is not) completely horizontally level. Thus, there is no simple way to assure that the length of the post will be vertical when put in position. Moreover, once the post is secured to the pedestal, there is no simple means by which the post&#39;s orientation to the support base  12  can be adjusted short of disengaging the two customizing their fit.  
         [0006]     Thus, it would desirable to have an efficient and sturdy system and method for securely attaching and more easily vertically aligning posts without the need for expensive accessories when performing post mounting operations.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention is directed to a post mounting method and assembly wherein posts (and in particular, hollow posts) are more easily set in place. In particular, the present invention provides a method and assembly by which posts can be properly plumbed to a desired vertical orientation without undue expense or the need for expensive accessories in order to perform the post mounting operation.  
         [0008]     Further description of advantages, benefits and patentable aspects of the present invention will become evident from the accompanying drawings and description hereinbelow. All novel aspects of the invention, whether mentioned explicitly in this Summary section or not, are considered subject matter for patent protection either singly or in combination with other aspects of the invention. Accordingly, such novel aspects of the present invention disclosed hereinbelow and/or in the drawings that may be omitted from, or less than fully described in, this Summary section are fully incorporated herein by reference into this Summary. In particular, all claims of the Claims section hereinbelow are fully incorporated herein by reference into this Summary section. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a representation of a prior art device for mounting a hollow vinyl fence post.  
         [0010]      FIG. 2  is an exploded view of one embodiment of the present invention showing a shim plate  122 , an angled support structure  115 , four individual angled/wedge gripping element  118 , a slide-over decorative cap  128  and a hollow post  126 .  
         [0011]      FIGS. 3A-3C  illustrate various views of the angled/wedge gripping element  118  to grip and properly align the vertical vinyl fence posts  126 . In particular, referring to the vertically operative orientation ( FIG. 2 ) of the gripping elements  118 ,  FIG. 3A  shows an end view of the gripping element  118 ,  FIG. 3B  shows a top view of the gripping element  118 , and  FIG. 3C  shows a side view of the gripping element  118 , wherein this side contacts a face  116  of an angled support member  115  ( FIGS. 2 and 8 ).  
         [0012]      FIGS. 4A-4C  illustrate views of one particular embodiment of a base member  112  designed to accommodate the angled/wedge gripping elements  118  and an end of a hollow vinyl fence post  126  therein. In particular, referring to the vertically operative orientation ( FIG. 2 ) of the base member  112 ,  FIG. 5A  shows a side cross sectional view of the base member wherein the cross section is defined by the sectioning plane corresponding to the cross section viewing arrows A in  FIG. 4B ;  FIG. 4B  shows a top view of the base member  112 ; and  FIG. 4C  shows an exterior side view of the base member  112 .  
         [0013]      FIG. 5  is a representation of a shim member  122  suitable for use with the present invention, such a shim showing the thicker portion (t) at an area adjacent to a slot  124  formed therein.  
         [0014]      FIG. 6  is an illustration of one embodiment of the present invention where an elastic band  50  is provided that surrounds each gripping element  118  so as to maintain the gripping elements in a contacting position with an angled support member  115 , thus allowing placement of a vinyl hollow post  126  (not shown) within the post mounting system of the present invention.  
         [0015]      FIG. 7  is shows an embodiment of the bottom (i.e., ground facing) side of the base member  112 . In particular, this figure shows the threaded aperture/screw positions  154 , wherein Allen headcap screws  158  are threaded therein. More specifically, each such Allen headcap screw  158  extends through the base member  112  and then extends through a threaded bore  160  of a corresponding one of the gripping elements  118  when the element  118  is operably positioned to rest against a face  116  of the angled support member  115  on the opposite (top) side of the base member  112 .  
         [0016]      FIG. 8  illustrates a side perspective view of an embodiment of the present invention with three of four gripping elements  118  in their operative positions prior to the insertion of a hollow vinyl post  126 .  
         [0017]      FIG. 9  is a perspective top view of one embodiment of the base member  112  with all the gripping elements  118  in their operative positions so as to accept a hollow post  126  (not shown in this figure) prior to tightening the Allen headcap screws  158  (not shown in this figure, but shown in  FIGS. 7 and 10 ) on their threaded bolts  158  which, in turn, causes each of the gripping elements  118  to be forced downwardly and outwardly toward the interior walls of the hollow post  126  for securing the post to the base member  112 .  
         [0018]      FIG. 10  shows: (a) a partial view of the base member  112  with its interior angled support member  115 , (b) a gripping element  118  with its bore  160  running therethrough and a groove  170  running transversely to the bore, wherein the groove accommodates the elastic band or retaining member  150  ( FIG. 6 ), and (c) a threaded bolt  158  for use in threadably securing the gripping elements  118  in the base member  112 .  
         [0019]      FIG. 11  shows one embodiment of an internal support member  127  that fits within a hollow post  126  to provide additional structural support therefor. 
     
    
     DETAILED DESCRIPTION  
       [0020]     For the purposes of sufficient enabling written description, the entire contents of U.S. Pat. Nos. 5,404,682; Reissue No. 36,550; 5,458,428; 5,307,598; and 5,386,938 are incorporated herein in their entireties by this reference.  
         [0021]      FIG. 2  shows one embodiment of the post mounting assembly  100  of the present invention. The post mounting assembly  100  includes a base member  112  for attaching to the lower end  125  of a hollow post  126  (this post being substantially identical to the post  26  of  FIG. 1 ). The base member  112  includes a bottom plate  113  with an upper surface  130 . Attached to the upper surface  130  is a substantially vertical wall component  114  configured to surround the exterior of the post lower end  125  when the post  126  is attached to the base member  112 . The base member  112  also includes an angled support member  115  that has a truncated conical or pyramidal-shape with as many faces  116  as the hollow post  126  has. Note that although such a post  126  typically has four sides and may be manufactured from vinyl or a composite material (e.g., a wood flour polymer blend), it is within the scope of the invention for embodiments the assembly  100  to be configured to accept posts  126  having a smaller or larger number of sides. Indeed, there may be embodiments of the assembly  100  that are configured to accept cylindrical posts, such that there may be only a single conical face  116  circularly surrounding a top  117  of the angled support member  115 . Moreover, such posts  126  may include reinforcing structures within their interiors that extend most of the lengths of the posts. Such reinforcing structures may be integral with the interior of the posts  126 , or such reinforcing structures may be separate structures that are inserted into the interior of the posts prior to the posts being mounted to their base members  112 .  FIG. 11  shows one embodiment of such a reinforcing structure  127  for a post  126 . In particular, when the reinforcing structure  127  is a separate unit that slides into the interior of a post  126 , the reinforcing structure can be secured by suitable means, such as by attachment screws connecting the base member  112  to the attachment member  127 , etc. Of course, other configurations of such reinforcing structures may also be used. However, such a reinforcing structure  127  must not interfere with or block the insertion of the angled support member  115  into the interior of a post  126 . Accordingly, such a reinforcing structure  127  may be at least somewhat shorter than the interior of the post  126  in which the reinforcing structure resides so that when the reinforcing structure is positioned in the post interior (e.g., at a closed upper end of the post), the lower end  125  extends beyond the reinforcing structure a sufficient amount so that there is no blockage or interference with the insertion of the angled support member  115  into the lower end  125 . Note that such reinforcing structures are important in various uses of fences and railings, e.g., that may be mounted on a second story of a dwelling. In particular, such posts  126  must satisfy certain safety code regulations, for example, at least withstand the force of a 500 lb. man leaning against the post without the post breaking, etc. Moreover in one embodiment, such a reinforcing structure  127  may be placed inside the post  126 , via an open upper end of the post (which will subsequently be capped), after the post is connected to the base member  112  in a secure fashion.  
         [0022]     In the embodiment of  FIG. 2 , the top  117  of the angled support member  115  square and has dimensions that are substantially smaller than the inside dimensions of the post lower end  125 , and the faces  116  extend angularly downward from the top  117  to a post seating surface  120  ( FIG. 4B ), wherein this surface  120  has outer dimensions that are only slightly larger than the outer dimensions of the post lower end  125 . In some embodiments, these outer dimensions are 0.02 inches to 0.025 inches larger than the outer dimensions of the post lower end, and in at least some embodiments approximately 0.15 inches larger. Additionally, the inner dimensions of the post seating surface  120  are smaller than the dimensions of the hollow interior of the post lower end  125 , and in particular, these inner dimensions may be 0.275 inches to 0.300 inches smaller than the dimensions of the hollow interior of the post lower end.  
         [0023]     In general, the top  117  will have substantially the same shape as a cross section of the interior of the post lower end  125  into which it fits. Thus, if this interior is circular, then the top  117  may have a substantially circular perimeter.  
         [0024]     Each face  116  of the angled support structure  115  is configured to accept thereon a separate one of the angled/wedge gripping elements  118 , each such gripping element having at least one bore  121  passing therethrough (in the orientations of the gripping element of  FIG. 2 , such bores are directed generally perpendicularly to the upper surface  130  of the bottom plate  113 . Each of the bores  121  accepts an Allen headcap screw  158  ( FIG. 10 ) that also is intended to extend through an oval bolt hole  134  ( FIG. 4B ) in the bottom plate  113  of the base member  112 . Note that as the gripping elements  118  are forced toward the post seating surface  120  by tightening of the screws  158 , the gripping elements move away from the center bore  146  and toward the interior surface of the post lower end  125 . Thus, the oval configuration of the bolt holes  134  allows the screws  158  to remain substantially vertically oriented while such tightening causes them to move away from the center bore  146 .  
         [0025]     One or more circular shim members  122  each having a slot  124  provided therein are utilized beneath the base member  112  in order to adjust the angular orientation of the entire assembly  100  and (if attached) a post  126 , thus permitting a method for adjusting the vertical orientation of the hollow post  126  once secured to the base member  112 .  
         [0026]     Preferably, the shim member  122  has a circular shape, although any of various different shapes can be provided. Importantly, in a preferred embodiment, the shim member  122  is designed to substantially encompass the surface area below the base member  112 , as opposed to prior art shims which merely raise a corner or portion of a side of a component that functions as a base member. The shims  122  therefore provide a broad “footprint” for support beneath essentially the entire base member  112 . The slot  124  in the shim  122  provides for easy insertion beneath a base member  112  in order to change the angular orientation of the entire post mounting assembly  100 . Preferably, the shim member  122  may be thicker around the slot  124  portion (“t” in  FIG. 5 ) and is thinner at a portion  136  of the shim  122  directly across from the slot  124  opening. Additionally, the underside of the bottom plate  113  may have a recess or counterbore  135  ( FIG. 4B ) having a depth of approximately the thin portion  136  of a shim  122 . Thus, the thicker portion, t, about the slot  124  allows access to the slot for rotating the shim about a projection or rod  138  (such as a threaded bolt, a lag screw or a threaded shaft extending out of, e.g., concrete) shown in  FIGS. 4A and 4C  while the post mounting assembly  100  is positioned for attachment to a support platform or structure. Note, in at least some embodiments, the support platform includes the rod  138  extending substantially vertically out of an in-ground concrete anchor  142  ( FIG. 4A ). That is, by utilizing a tool having a thin edge and a width of the edge no wider than the slot  124 , such an edge may be placed in the slot for rotating the shim(s)  122  around the rod  138 .  
         [0027]     Although not shown, a plurality of such shims  122  can be stacked on top of each other (and underneath the base member  112 ) to achieve a desired angular orientation of the assembly  100 . The shims  122  are preferably made from a durable material such as plastic, vinyl, metal, etc., as will be appreciated by one of ordinary skill in the art. Moreover, as shown in  FIG. 6 , each shim  122  has a thicker portion “t” that is substantially adjacent to the shim&#39;s slot  124 . The thickness differences between the perimeter of the shim  122  adjacent the slot  124  opening and the perimeter of the shim substantially at t can vary. There may shims  122  that are effective for changing a substantially vertical orientation of a post  126  by, e.g., ¼ of an angular degree and/or multiples thereof. In some embodiments, where the shims  122  have a diameter of 6 inches, the thickness differences may be: (a) for a shim that changes the vertical orientation of a post  126  be ¼ of an angular degree, approximately 0.033 inches, and (b) for a shim that changes the vertical orientation of a post  126  be ½ of an angular degree, approximately 0.047 inches.  
         [0028]     A decorative cap  128  is typically used to provide a desired ornamental appearance of the mounted post once the post  126  is securely positioned within the base member  112 .  
         [0029]     In operation, the post  126  is positioned within the base member  112  by abutting the walls of the post  126  against the exterior supporting wall  114  of the base member  112 . The wedge members  118  are preferably held in contact with the pyramidal structure by an elastomeric retaining member  150 . The individual gripping elements  118  are then tightened by an appropriate adjustment of the screw  123  provided through the gripping element&#39;s bore  121  so that the gripping element is pulled toward the post seating surface  120  of the base member  112 . As each gripping element  118  moves toward the post seating surface  120 , the gripping element also increasingly presses outwardly against the interior walls of the post  126 . Once each of the individual gripping elements  118  is secured so as to tightly hold the walls of the post  126  against the exterior wall  114  of the base member  112 , the post  126  will be securely mounted therein and cannot be removed unless the gripping elements  118  are loosened by operation of the threaded screws  123 .  
         [0030]     Subsequently, a desired one or more shims  122 , having various angular configurations (e.g., ¼°, ½°, ¾°, etc.) can be slid below the base member  112  so as to adjust the vertical angular orientation of the post mounting assembly  100 —when it is mounted to a solid support such as the support platform described hereinabove. That is, once the rod  138  is inserted into the center bore  146  ( FIGS. 2 and 7 ) of the base member  122  and the bottom surface of the bottom plate  113  is allowed rest upon the top surface of, e.g., the anchor  142  (or another anchoring support), a determination is made as to whether the post  126  attached to the base member  112  is sufficiently vertical. If so, then the base member  112  is secured to the anchor  142  by any one of a variety of techniques, e.g., including: 
        (i) tightening a threaded nut (not shown) onto a threaded upper end  148  of the rod  138  ( FIG. 4A ), wherein the rod may be, e.g., a shaft having an opposite end fixed in concrete, or a bolt with its head secured to the underside of a floor, walkway, bridge, etc.; note that the nut may be tightened onto the rod  138  via an opening (not shown) in the side of the post  126 , wherein this opening is used to mount a railing into the post. Thus, the nut can be tightened onto the rod  138  after the post is secured by the gripping elements to the base member  112 ;     (ii) when the rod  138  is a lag screw, the opening for mounting a railing may be used as an access for tightening the lag screw down for securing the base member  112  to the support platform (such as wood or wood composite material);     (iii) bolting the base member  112  to the anchor  142  via bolt holes (not shown) in the bottom plate  113 ;     (iv) fixedly clamping the bottom plate  113  to the anchor  142  via clamps (not shown), wherein such clamps may be included as part of the support platform, and     (v) inserting fasteners or spikes into holes (not shown) in the bottom plate  113  and driving these fasteners or spikes into the anchor  142 .        
 
         [0036]     However, if the post  126  attached to the base member  112  is not sufficiently vertical, then a determination is made as to the approximate direction and amount that the post  126  is angled from vertical, and one or more of the shims  122  are positioned underneath the bottom plate  113  (with the rod  138  inserted into the slot  124  of each of the shims and, if necessary, rotating the shims about the rod) to thereby orient the post  126  more vertical. Subsequently, another step of determining whether the post  126  is sufficiently vertical, and either the base member  112  is fixedly attached to the anchor  142  (if vertical alignment is sufficient), or further vertical alignment adjustments are made using one or shims  122 . Accordingly, the above step of determining is iterated along with adjusting the post  126  vertical alignment until the post is sufficiently vertical and is then fixed to the anchor  142 .  
         [0037]     It should be understood that the above description is illustrative of how the assembly  100  may be utilized. Accordingly, instead of the base member  112  being attached to an in-ground anchor made of, e.g., concrete, the assembly  100  may be attached to a wooden foundation or another foundation material such as metal or brick.  
         [0038]     In another embodiment of the invention, the angled support member  115  can be angled so that the wider portion of the support member is at the top  117 , and faces  116  slope toward the center bore  146  as the faces come closer to the post seating surface  120 . Thus, in this embodiment, gripping elements  118  are inverted within the post lower end  125 , and the screws  158  (or, e.g., other threaded shafts) push (instead of pull) the gripping elements to engage the interior walls of a post  126 .  
         [0039]     In some embodiments of the invention, the Allen headcap screws  158  and their corresponding threaded portions within the bores  160  may be replaced by another mechanism for tightening the gripping elements  118  between the adjacent face  116  and the adjacent interior post wall. For example, spring activated levers (accessible via the underneath side of the bottom plate  113 ) attached to a non-threaded shaft extending through the bores  160  may be used wherein in an initial position such levers allow the gripping elements to fit loosely between the adjacent face  116  and the adjacent interior post wall, and in a second position cause the gripping elements to fit tightly and securely between the adjacent face  116  and the adjacent interior post wall. Thus, instead of the bores  160  being threaded, they are smooth and there is a hook or head on a portion of the shaft adjacent its bore  160  (e.g., an end of each shaft on the opposite side of the bore from that of the operably attached lever), so that when the lever is moved to its second position, the attached shaft mores the hook or head into contact with the operatively associated gripping element  118  for, in turn, urging the gripping element to securely wedge itself between its corresponding adjacent face  116  and its corresponding adjacent interior post wall.  
         [0040]     Of course, other tightening mechanisms are also within the scope of the present invention, such as providing a plate (not shown) that rests, e.g., on the surfaces  152  ( FIG. 2 ) of the gripping elements  118 , wherein threaded bolts or screws may be tightened into, e.g., the base member  112  (via the railing opening discussed above) thereby forcing the plate toward the base member and consequently forcing the gripping elements  118  to secure the post  126  to the base member.  
         [0041]     While various embodiments of the present invention have been described in detail, it will be apparent that further modifications and adaptations of the invention will occur to those skilled in the art. It is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention.