Patent Publication Number: US-9850683-B2

Title: Post caps

Description:
BACKGROUND 
     Technical Field 
     This disclosure generally relates to fence structures, and more particularly to post caps. 
     Description of the Related Art 
     Post caps are known which consist of a single, one-piece structure or a multi-piece structure, such as, for example, two post cap halves that may be fastened together to form a post cap. Example post caps are shown in U.S. Pat. No. 6,994,327. Such post caps, however, may suffer from a variety of drawbacks including poor durability, lack of versatility and/or inefficient space utilization. 
     BRIEF SUMMARY 
     Embodiments of the post caps described herein include robust form factors that may be stacked in a particularly efficient manner and provide enhanced versatility with respect to visual design elements thereof and/or with respect to installation of the post caps. 
     One embodiment of a post cap assembly for covering an upper end of a post may be summarized as including a post cap body having an internal post cavity that is sized and shaped to receive the upper end of the post and having a topper receiving aperture extending at least partially through the post cap body; and an interchangeable topper positioned within the topper receiving aperture and projecting from the top side of the post cap body. The interchangeable topper may include a decorative topper element that is configured to engage the topper receiving aperture with a snap fit or interference fit. The interchangeable topper may include a decorative topper element and a fastener to couple the interchangeable topper to the post cap body. In such instances, a threaded nut may be concealed within the decorative topper element to receive the fastener. The interchangeable topper may include a decorative topper element having a skirt portion that is shaped to nest with the top side of the post cap body. The skirt portion of the decorative topper element may be configured to divert rain water away from the topper receiving aperture. In some instances, the post cap body may be a single, one-piece body and may comprise cast concrete or injection molded plastic. The top side of the post cap body may be inclined downwardly away from a central apex, and, when a plurality of the post cap bodies are stacked, the central apex of a lower one of adjacent stacked post cap bodies may extend within the internal post cavity of an upper one of the adjacent stacked post cap bodies. In some instances, the topper receiving aperture may extend completely through the post cap body between the internal post cavity and the top side of the post cap body. 
     The post cap assembly may further include a post attachment device having one or more resilient coupling features removably engaged with a respective portion of the post cap body. The post attachment device may be readily separable from the post cap body for attachment to the upper end of the post apart from the post cap body. The post cap body may include at least one cavity that is sized and shaped to receive the at least one resilient coupling feature of the post attachment device. The at least one resilient coupling feature of the post attachment device may comprise a resilient tab that is sized, shaped and positioned to snap into the at least one cavity of the post cap body when the post cap body is urged into engagement with the post attachment device. The post attachment device may include a generally planar body with an array of apertures formed therein to receive fasteners for securing the post attachment device to an end face of the upper end of the post. The resilient coupling feature(s) of the post attachment device may project or extend downwardly from the generally planar body. The post attachment device may be sized to be insertably received and press fit within the internal post cavity of the post cap body. Each resilient coupling feature may be a resilient tab that is sized, shaped and positioned to flex in response to contact with a sidewall of the post cap body during insertion of the post attachment device into the internal post cavity of the post cap body. Another embodiment of a post cap assembly for covering an upper end of a post may be summarized as consisting of: a single, unitary post cap body having an internal post cavity that is sized and shaped to receive the upper end of the post and having a topper receiving aperture extending at least partially through the post cap body; and an interchangeable topper positioned within the topper receiving aperture and projecting from the top side of the post cap body. 
     Another embodiment of a post cap for covering an upper end of a post may be summarized as including a single, unitary body having an internal post cavity that is sized and shaped to receive the upper end of the post and having a partially spherical projection extending from a top side thereof. An outer maximum diameter of the partially spherical projection may be less than a maximum transverse dimension of the internal post cavity by no more than 0.50 inch, and in some instances, by no more than 0.25 inch. The internal post cavity may include a post receiving shoulder and a nesting portion adjacent thereto. The nesting portion may be shaped to nest with the partially spherical projection of an adjacent post cap when the post cap is stacked thereon and to assist in centering the post cap on the adjacent post cap. 
     According to another embodiment, an arrangement of post caps may be summarized as including a plurality of stacked post caps, each post cap having a single, unitary body with an internal post cavity that is sized and shaped to receive an upper end of a post and having a partially spherical projection extending from a top side thereof; and a plurality of liners, each liner positioned between a pair of adjacent post caps. The liner may have a lower portion configured to conceal an upper surface of a lower one of the pair of adjacent post caps. The liner may also have an upper portion configured to surround the partially spherical projection of the lower one of the pair of adjacent post caps and to prevent direct contact between the pair of adjacent post caps. The arrangement of post caps may further include a plurality of post attachment devices, each post attachment device being removably coupled to a respective one of the plurality of stacked post caps and being separable from the respective post cap for attachment to an upper end of a post apart from the post cap. 
     According to yet another embodiment, an arrangement of post caps may be summarized as including a plurality of stacked post caps, each post cap having a single, unitary body with an internal post cavity that is sized and shaped to receive an upper end of a post and having a tapered projection extending from a top side thereof; and a plurality of liners, each liner positioned between a pair of adjacent post caps. The liner may have a lower portion configured to conceal an upper surface of a lower one of the pair of adjacent post caps. The liner may also have an upper portion configured to surround an apex of the tapered projection of the lower one of the pair of adjacent post caps and to prevent direct contact between the pair of adjacent post caps. The arrangement of post caps may further include a plurality of post attachment devices, each post attachment device being removably coupled to a respective one of the plurality of stacked post caps and being separable from the respective post cap for attachment to an upper end of a post apart from the post cap. 
     According to yet another embodiment, a post cap assembly for installing on an upper end of a post may be summarized as including a post cap body having an internal post cavity that is sized and shaped to receive the upper end of the post and a post attachment device having at least one resilient coupling feature removably engaged with an engagement portion of the post cap body within the internal post cavity, the post attachment device being separable from the post cap body for attachment to the upper end of the post apart from the post cap body. The engagement portion of the post cap body may be a cavity that is sized and shaped to receive the at least one resilient coupling feature of the post attachment device. The at least one resilient coupling feature of the post attachment device may comprise a resilient tab that is sized, shaped and positioned to snap into the engagement portion of the post cap body when the post cap body is urged into engagement with the post attachment device. The post attachment device may include a generally planar body with an array of apertures formed therein to receive fasteners for securing the post attachment device to an end face of the upper end of the post. The post attachment device may be sized to be insertably received and press fit within the internal post cavity of the post cap body. The at least one resilient coupling feature of the post attachment device may comprise a resilient tab that is sized, shaped and positioned to flex in response to contact with a sidewall of the post cap body during insertion of the post attachment device into the internal post cavity of the post cap body. 
     According to yet another, a method of adorning a post with a post cap may be summarized as including coupling an interchangeable decorative topper element to a post cap base; and positioning the post cap base over the post such that an upper end of the post is received within a post receiving cavity thereof. The method may further include replacing the interchangeable decorative topper element with another different interchangeable decorative topper element. Coupling the interchangeable decorative topper element to the post cap base may include press-fitting or snap-fitting the decorative topper element within a topper receiving aperture formed in the post cap base. Coupling the interchangeable decorative topper element to the post cap base may include securing the decorative topper element to the post cap base with a fastener from within the post receiving cavity such that the fastener is concealed from view when the post cap base is positioned over the post. The method may further include, prior to positioning the post cap base over the post, securing a post attachment device to an upper end of the post and urging the post cap into engagement with the post attachment device. 
     Other aspects and features of the post caps and related systems and methods will be readily apparent to one of ordinary skill in the relevant art upon review of the drawings and detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is an isometric view of a post cap, according to one embodiment, installed on a post, such as, for example, a fence post. 
         FIG. 2  is an isometric exploded view of the post cap of  FIG. 1 , together with a plurality of interchangeable topper elements. 
         FIG. 3  is an isometric view of a plurality of the post caps of  FIG. 1  stacked on a pallet for shipping or storage. 
         FIG. 4  is front cross-sectional view of the post cap of  FIG. 1  shown stacked on another post cap of the same form. 
         FIG. 5  is an isometric view of a post cap, according to another embodiment. 
         FIG. 6  is an isometric view of a plurality of the post caps of  FIG. 5  stacked on a pallet for shipping or storage. 
         FIG. 7  is front cross-sectional view of the post cap of  FIG. 5  shown stacked on another post cap of the same form. 
         FIG. 8  is a front cross-sectional view of a post cap, according to another embodiment. 
         FIG. 9  is a bottom plan view of the post cap of  FIG. 8 . 
         FIG. 10  is a skewed bottom view of the post cap of  FIG. 8  with a portion of the post cap cut away to show details of a post attachment device received within the post cap. 
         FIG. 11  is front cross-sectional view of the post cap of  FIG. 8  shown stacked on another post cap of the same form. 
         FIG. 12  is a front cross-sectional view of the post cap of  FIG. 8  shown attached to an upper end of a fence post. 
         FIG. 13  is an isometric view of a multi-piece mold core kit for forming post caps, according to one embodiment. 
         FIG. 14  is a skewed bottom view of one combination of the multi-piece mold core received in one half of an outer mold form used to fabricate post caps, according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with fences, fence components and related accessories, such as post caps, have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. In addition, well-known structures and techniques associated with casting or molding processes have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
     Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.” 
     Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
       FIGS. 1 through 4  illustrate one embodiment of a post cap assembly  10  that includes a robust form factor, which may be stacked in a particularly efficient manner and which provides enhanced versatility with respect to visual appearance. The post cap assembly  10  includes a post cap body  20  and an interchangeable decorative topper  40  (e.g., a three dimensional fleur-de-lis, acorn, star, etc.). 
     The post cap body  20  has an internal post cavity  22  that is sized and shaped to receive an upper end  24  of a post  26 . The internal post cavity  22  may be generally rectangular, cylindrical or otherwise shaped to substantially reflect a corresponding shape of the upper end  24  of the post  26  on which the post cap assembly  10  may be installed. The internal post cavity  22  may include sidewalls with a slight draft to facilitate release of the post cap body  20  from a mold when utilizing a casting or molding process to form the post cap body  20 . A terminal end or shoulder portion of the internal post cavity  22  may define a stop against which an end surface of the post  26  may abut upon installation. 
     The post cap body  20  further includes a topper receiving aperture  30  that extends at least partially through the post cap body  20  and is configured to receive the interchangeable topper  40  with the topper  40  projecting from a top side  32  of the post cap body  20 . In some instances, the topper receiving aperture  30  may extend completely through the post cap body  20  between the internal post cavity  22  and the top side  32  of the post cap body  20 . In other instances, the topper receiving aperture  30  may be a blind hole. 
     The interchangeable topper  40  may be configured to engage the topper receiving aperture  30  with a snap fit or interference fit. In some instances, the interchangeable topper  40  may include a decorative topper element  42  and a fastener  44  ( FIG. 2 ) to couple the interchangeable topper  40  to the post cap body  20 . Additionally, a threaded nut  46  ( FIG. 2 ) may be concealed within the decorative topper element  42  to receive the fastener  44 . Alternatively, the topper element  42  may include internal threads to receive a corresponding fastener  44  or other coupling mechanisms, such as, for example, a detent mechanism, clips, snaps or other fastening devices. Preferably, the coupling mechanism of the interchangeable topper  40  is concealed from view upon installation into the topper receiving aperture  30 . 
     In some embodiments, the interchangeable topper  40  may include a decorative topper element  42  having a skirt portion that is shaped to nest with the top side  32  of the post cap body  20 . The skirt portion of the decorative topper element  42  may be configured to divert rain water away from the topper receiving aperture  30 . The interchangeable topper  40  may include decorative topper elements  42  having a variety of forms. Some example decorative topper elements  42 ,  42   a ,  42   b ,  42   c  (collectively  42 ) are shown in  FIG. 2 . Other decorative topper elements  42  may include sport team emblems, cartoon characters, geometric shapes, or other design elements. The decorative topper elements  42  may be interchangeably replaced as needed or desired. 
     In some embodiments, the post cap body  20  is a single, one-piece body. In other instances, the post cap body  20  may be a multi-piece assembly. The post cap body  20  may be formed of cast concrete or injection molded plastic or other suitable materials. 
     With reference to  FIGS. 3 and 4 , the top side  32  of the post cap body  20  may be inclined downwardly away from a central apex  48  and, when a plurality of the post cap bodies  20  are stacked, the central apex  48  of a lower one  20   a  of adjacent stacked post cap bodies  20  may extend within the internal post cavity  22  of an upper one  22   b  of the adjacent stacked post cap bodies  20 . In this manner, the post cap bodies  20  may nest together in a particularly efficient manner such that a plurality of stacked post cap bodies  20  can be stored or transported together with significant space savings. 
     With reference to  FIG. 4 , and according to one embodiment, a collection of post caps  20   a ,  20   b  may be provided wherein each post cap  20  has a single, unitary body with an internal post cavity  22  that is sized and shaped to receive an upper end  24  of a post  26  and which includes a tapered projection  48  extending from a top side  32  thereof. A liner  50  may be positioned between adjacent post caps  20   a ,  20   b . The liner  50  may include a lower portion  52  configured to conceal an upper surface of a lower one  20   a  of the adjacent post caps  20   a ,  20   b  and an upper portion  54  configured to surround the tapered projection  48  of the lower one  20   a  of the adjacent post caps  20   a ,  20   b  and to prevent direct contact between the adjacent post caps  20   a ,  20   b.    
       FIGS. 5 through 7  illustrate another example embodiment of a post cap  60  that includes a robust form factor and which may be stacked in a particularly efficient manner. The post cap  60  may comprise or consist of a single, unitary body  70  having an internal post cavity  72  that is sized and shaped to receive an upper end  24  of a post  26 . The unitary body  70  may further include a partially spherical projection  80  extending from a top side thereof  82 . An outer maximum diameter OD ( FIG. 7 ) of the partially spherical projection  80  may be less than a maximum transverse dimension TD ( FIG. 7 ) of the internal post cavity  72  by no more than 0.50 inch, or in some instances, by no more than 0.25 inch. 
     The internal post cavity  72  may include a post receiving shoulder  82  and a nesting portion  84  adjacent thereto. The nesting portion  84  may be shaped to nest with the partially spherical projection  80  of an adjacent post cap  60  when the post cap  60  is stacked thereon and to assist in centering the post cap  60  on the adjacent post cap  60 . 
     With reference to  FIGS. 6 and 7 , and according to one embodiment, an arrangement of post caps  60  may be provided which includes a plurality of stacked post caps  60 , each post cap  60  having a single, unitary body  70  with an internal post cavity  72  that is sized and shaped to receive an upper end  24  of a post  26  and having a partially spherical projection  80  extending from a top side  82  thereof. The arrangement may further include a plurality of liners  90 , with each liner  90  being positioned between a pair of adjacent post caps  60 . Each liner  90  may include a lower portion  92  configured to conceal an upper surface of a lower one of the pair of adjacent post caps  60  and an upper portion  94  configured to surround the partially spherical projection  80  of the lower one of the pair of adjacent post caps  60  and to prevent direct contact between the pair of adjacent post caps  60 . 
       FIGS. 8 through 12  illustrate another example embodiment of a post cap  160  that includes a robust form factor and which may be stacked in a particularly efficient manner, and which may operate with a separable post attachment device  200  for enabling efficient attachment of the post cap  160  to an upper end  124  of a post  126 . The post cap  160  may comprise or consist of a single, unitary body  170  having an internal post cavity  172  that is sized and shaped to receive the upper end  124  of the post  126 . The unitary body  170  may further include a partially spherical projection  180  extending from a top side  182  thereof or a wide variety of other regular or irregular shaped structures, such as, for example, an acorn shaped structure, extending from the top side  182 . 
     With reference to  FIG. 11  in particular, the internal post cavity  172  may include a post receiving shoulder  182  and a nesting portion  184  adjacent thereto. The nesting portion  184  may be shaped to nest with the partially spherical projection  180  or other regular or irregular shaped projection of an adjacent post cap  160  when the post cap  160  is stacked thereon. The nesting portion  184  may also assist in centering the post cap  160  on the vertically adjacent post cap  160 . 
     As shown best in  FIG. 10 , the post attachment device  200  may include a generally planar body  210  with an array of apertures  212  provided therein to receive fasteners  214  ( FIG. 12 ) for securing the post attachment device  200  to an end face of the upper end  124  of the post  126 . The post attachment device  200  may further include a pair of opposing resilient coupling features  220  for removably engaging opposing portions  186  of the post cap body  170  within the internal post cavity  172 . In this manner, the post attachment device  200  can be separated from the post cap body  170  for attachment to the upper end  124  of the post  126  apart from the post cap body  170 . More particularly, the post cap body  170  may include opposing engagement cavities  187  each sized and shaped to receive a respective one of the resilient coupling features  220  of the post attachment device  200 . In some instances, each resilient coupling feature  220  may comprise a resilient tab that is sized, shaped and positioned to snap into the respective engagement cavity  187  of the post cap body  170 . Each resilient tab may also be sized, shaped and positioned to flex in response to contact with the sidewalls  188  of the post cap body  170  during insertion of the post attachment device  200  into the internal post cavity  172  of the post cap body  170 . 
     In some embodiments, the post attachment device  200  is sized to be insertably received and press fit within the internal post cavity  172  of the post cap body  170 . More particularly, the opposing resilient coupling features  220  may be urged inwardly by the sidewalls  188  of the post cap body  170  during insertion of the post attachment device  200  and then may spring back outwardly into the cavities  187  when reaching the position shown in  FIGS. 10 through 12 . One or more of the resilient coupling features  220  may include a notch  221  or other feature to assist in prying the post attachment device  200  out of engagement with the post cap body  170 , and more particularly in prying the resilient coupling feature  220  out of the engagement cavity  187  in which it is received. The sidewalls  188  of the post cap body  170  may also include grooves  189  or other features to assist in receiving the post attachment device  200  and guiding the resilient coupling features  220  into proper engagement with the cavities  187 . This may facilitate efficient coupling and de-coupling of the post attachment device  220  from the internal post cavity  172  of the post cap  160 . 
     With reference to  FIG. 11 , and according to one embodiment, an arrangement of post caps  160  may be provided which includes a plurality of stacked post caps  160 , each post cap  160  having a single, unitary body  170  with an internal post cavity  172  that is sized and shaped to receive an upper end  124  of a post  126  and having a partially spherical projection  180  or other regular or irregularly shaped projection extending from a top side  182  thereof. The arrangement may further include one or more liners  190  positioned between vertically adjacent post caps  160 . The liner or liners  190  may include a lower portion  192  configured to conceal an upper surface of a lower one of the pair of vertically adjacent post caps  160  and an upper portion  194  configured to surround the partially spherical or other shaped projection  180  of the lower one of the pair of adjacent post caps  160  and to prevent direct contact between the pair of vertically adjacent post caps  160 . As shown in  FIG. 11 , the post caps  160  may also be stacked together with a post attachment device  220  installed within the internal post cavity  172  of the post cap body  170 . The post attachment device  220  installed within the internal post cavity  172  of the post cap body  170  to nest closely therewith so as to not interfere with the stacking of the post caps  160 . In this manner, each post cap  160  may be provided with means for securely attaching the post cap  160  to a post and may be stacked in a particularly space efficient manner for storage and transport. 
     To adorn posts  126  (e.g., fence posts) with such post caps  160 , a user can simply pry out or otherwise remove the post attachment device  220  from within the internal post cavity  172 , attach the post attachment device  220  to the upper end  124  of the post  126  with nails or other conventional fasteners  214  ( FIG. 12 ), and then snap the post cap  160  onto the upper end  124  of the post  126  until the resilient coupling features  220  of the post attachment device engage the respective engagement cavities  187  formed in the post cap body  170 . Advantageously, the caps  160  can be securely attached to posts  126  quickly and efficiently and with no fasteners being externally visible to those viewing the capped posts. As can also be appreciated from  FIGS. 8 through 12 , each post cap  160  may provide a unitary body  170  that completely conceals the upper end  124  of the post  126  and may lack any seams, gaps or other areas in which rain water could otherwise infiltrate the cap and deteriorate the upper end  124  of the post  126 . 
       FIG. 13  shows a multi-piece mold core kit  300  for forming post caps  10 ,  60 ,  160  according to one or more embodiments described herein, and  FIG. 14  shows one combination  312   b  of the multi-piece mold core kit received in one half of an outer mold form  350  used to fabricate post caps  10 ,  60 ,  160 . As can be appreciated from  FIG. 13 , the multi-piece mold core kit  300  may include a plurality of core tops  310   a ,  310   b  that are interchangeably coupleable to a core base  320  to fabricate post caps  10 ,  60 ,  160  having different configurations. For example, the core top  310   a  may be coupled to the core base  320  and then used to mold caps  160  having the form shown in  FIGS. 8 through 12 . As such, the assembled mold core  312   a  may have external surfaces that are identical to the internal surfaces of the formed caps  160 . As can be appreciated from  FIG. 14 , an assembled mold core  312   b  may be enclosed within an outer mold form  350  for molding post caps. The outer mold form  350  may comprise two identical mold halves (one shown). 
     Although only several different shaped post caps  10 ,  60 ,  160  are shown in the accompanying drawings, it is appreciated that post caps may be formed to include a wide variety of different aesthetic shapes and may be provided in a wide variety of sizes to fit many different sized posts. In addition, although the post caps  10 ,  60  and  160  are show as including an internal post cavity having a generally rectangular cross-section, it is appreciated that in some embodiments post caps may be provided with an internal post cavity having other regular or non-regular shaped cross-sections, such as, for example, a circular cross-section for receiving cylindrical posts. 
     Moreover, aspects and features and the various embodiments described above can be combined to provide further embodiments. In addition, U.S. Provisional No. 61/868,026, filed Aug. 20, 2013, is incorporated herein by reference for all purposes and aspects of the present invention can be modified, if necessary, to employ features, systems, and concepts disclosed in this application to provide yet further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.