Patent Publication Number: US-9850675-B2

Title: Post mount adapter

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to railing systems and relates more specifically to support hardware for use in railing installations. 
     BACKGROUND OF THE DISCLOSURE 
     Post mounts are frequently used in the construction of decks, porches, stairs, and other structures that include railings.  FIG. 1 , for example, is a schematic illustration of a portion of an exemplary railing system  100 , including a post mount  108 . The railing system  100  comprises a railing  102 , a support surface  104 , and a plurality of posts  106   1 - 106   n  (collectively referred to as “posts  106 ”). Generally, the rail  102  is supported in a spaced-apart relation relative to the support surface  104  by the posts  106 . 
     In order to mount the posts  106  to the support surface  104  in a substantially invisible manner (i.e., little or no outwardly visible hardware), post mounts may be first installed in the support surface  104 . For example, the post  106   1  is mounted to the support surface via a post mount  108  (illustrated in phantom). The post mount  108  may include a support pipe  110  supported between two support blocks  112   1  and  112   2  (collectively referred to as “support blocks  112 ”), for example as described in U.S. Pat. No. 7,546,720. The post mount  108  is fastened to the support surface  104  in a secure manner, and the hollow post  106   1  is then slipped over the post mount  108 . In this manner, the post  106   1  is supported securely by the support surface  104  and in turn provides secure support for the railing  102 . 
     In some applications, the interior dimensions of the post  106   1  may exceed the exterior dimensions of the post mount  108  (e.g., the exterior dimensions of the support blocks  112 ). In such a case, the post  106   1  will not fit over the post mount  108  snugly; it will be loose, and may undermine the stability of the railing system  100 . 
     SUMMARY OF THE DISCLOSURE 
     In one embodiment, an adapter for increasing exterior dimensions of a post mount support block includes a base having two sides that meet to form an angle of approximately ninety degrees, two legs, wherein each of the two legs extends from an outside edge of a different one of the two sides of the base, and two flanges, wherein each of the two flanges extends from an inside edge of a different one of the two sides of the base, such that each of the two flanges is positioned in a substantially parallel orientation relative to one of the two legs. 
     In another embodiment, an adapter for increasing exterior dimensions of a post mount support block includes a base having two sides that meet to form an angle of approximately ninety degrees, and two legs, wherein each of the two legs extends from an outside edge of a different one of the two sides of the base in a manner that avoids contact with the other of the two legs. 
     In one embodiment, a method for installing a post includes installing an adapter on each of two opposing corners of a support block of the post mount, wherein the adapter includes a base having two sides that meet to form an angle of approximately ninety degrees, two legs, wherein each of the two legs extends from an outside edge of a different one of the two sides of the base, and two flanges, wherein each of the two flanges extends from an inside edge of a different one of the two sides of the base, such that each of the two flanges is positioned in a substantially parallel orientation relative to one of the two legs, and subsequent to the installing, slipping the post over the post mount. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The teachings of the present disclosure can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a schematic illustration of a portion of an exemplary railing system, including a post mount; 
         FIG. 2A  is an isometric view of the exterior of one embodiment of a post mount adapter, according to the present disclosure; 
         FIG. 2B  is an isometric view of the interior of the post mount adapter of  FIG. 2A ; 
         FIG. 3  is a top view illustrating one embodiment of the post mount adapter of  FIGS. 2A and 2B , as installed; and 
         FIG. 4  is a flow chart illustrating one embodiment of a method for installing a post mount adapter onto a post mount. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. 
     DETAILED DESCRIPTION 
     In one embodiment, the present disclosure provides a post mount adapter that can be fastened securely to a support block to increase its exterior dimensions and allow for the support of larger posts. 
     As discussed above, in some applications, the interior dimensions of the post may exceed the exterior dimensions of the post mount (e.g., the exterior dimensions of the support blocks). The exterior dimensions of a post mount support block can be increased by slipping an adapter over the support block, like a sleeve. Conventional adapters tend to be formed as unitary items having hollow, substantially square-shaped cross sections. Embodiments of the present disclosure, by contrast, provide a two-piece adapter that allows the exterior dimensions of a post mount support block to be increased while minimizing the material usage, storage space, and shipping costs associated with the adapter. The post mount adapter of the present disclosure may be used, for example, in conjunction with a post mount that includes support blocks similar to the support blocks disclosed in U.S. Pat. No. 7,546,720, which is herein incorporated by reference in its entirety. 
       FIG. 2A  is an isometric view of the exterior of one embodiment of a post mount adapter  200 , according to the present disclosure.  FIG. 2B  is an isometric view of the interior of the post mount adapter  200  of  FIG. 2A . Collectively,  FIGS. 2A and 2B  may be viewed to enhance understanding of the present disclosure. 
     The post mount adapter  200  comprises a sleeve that is designed to slip over a corner of a post mount support block, in order to increase the exterior dimensions of the support block. As illustrated, the post mount adapter  200  generally comprises a base  204  from which two legs  202   1  and  202   2  (hereinafter collectively referred to as “legs  202 ”) extend. In one embodiment, the base  204  is substantially L-shaped (e.g., has two sides that meet to form an angle of approximately ninety degrees), with the corner of the “L” (i.e., the point where the two sides of the “L” meet) cut out to accommodate the corner of the support block, as discussed in greater detail below. 
     In one embodiment, each leg  202  comprises a planar, substantially rectangular appendage that extends away from the base  204 . In one embodiment, the legs  202  are coupled to the outside edge of the “L,” and one leg  202  is coupled to each side or segment of the “L”; thus, the legs  202  are positioned in a substantially perpendicular orientation (i.e., approximately ninety degrees, within a tolerance of a few degrees) relative to each other. Both legs  202  extend away from the base  204  in the same direction. In one embodiment, the legs  202  do not contact each other. 
     In a further embodiment, each leg  202  additionally comprises a pressure fin  206   1  or  206   2  (hereinafter collectively referred to as “pressure fins  206 ”). The pressure fins  206  comprise tabs formed in the planar surfaces of the legs  202 . The tabs are designed to flex when a certain amount of pressure is applied to them. In one embodiment, the tabs may include ribs or ridges. 
     In addition, two flanges  208   1  and  208   2  (hereinafter collectively referred to as “flanges  208 ”) extend from the base  204 . In one embodiment, the flanges  208  are coupled to the inside edge of the “L,” and one flange  208  is coupled to each side or segment of the “L”; thus, each flange  208  is positioned in an orientation that is substantially parallel (i.e., parallel, within a tolerance of a few degrees) to one of the legs  202 . In one embodiment, the flanges  208  are shorter than the legs  202 , extending only a fraction of the distance from the base  204  that the legs  202  extend. In one embodiment, the flanges  208  do not contact each other. 
     In one embodiment, the post mount adapter  200  may be formed from the same material as the support block. Thus, the post mount adapter  200  may be formed at least in part from a rigid polymer or composite, such as polypropylene, polyethylene, or the like. The post mount adapter  200  may be fabricated in a variety of sizes, each different size being capable of increasing the outer dimensions of a support block by a different amount. 
       FIG. 3  is a top view illustrating one embodiment of the post mount adapter  200  of  FIGS. 2A and 2B , as installed. In particular,  FIG. 3  illustrates two post mount adapters  200  fitted onto a single support block  300 . The support block  300  is mounted at one end of a support pipe  202 . In one embodiment, the support block  300  is configured in a manner similar to similar to the support blocks disclosed in U.S. Pat. No. 7,546,720. As illustrated, installation of the post mount adapters  200  on the support block  300  increases the outer dimensions of the support block  300 , such that the support block  300  is capable of snugly supporting a post having larger interior dimensions. 
     As illustrated, the post mount adapters  200  are fitted onto opposing (i.e., diagonal) corners  306   1  and  306   2  of the support block  300 . A post may subsequently be slipped over the post mount, as described above. In this way, two post mount adapters  200  that are, individually and collectively, smaller than a conventional post mount adapter may be used to increase the exterior dimensions of a post mount support block  300 . Thus, the same increase in dimensions can be achieved with less material. This reduces manufacturing costs by reducing the amount of material used. It also reduces storage and transportation costs, because the post mount adapters  200  of the present disclosure are smaller than conventional post mount adapters. In additional, unlike conventional post mount adapters, whose hollow interiors consume space that may not be able to be dedicated to other items, the post mount adapters  200  of the present disclosure have a configuration that allows the post mount adapters  200  to be stacked. Thus, more post mount adapters  200  of the present disclosure can fit in the same amount of space that is consumed by fewer conventional post mount adapters. 
       FIG. 4  is a flow chart illustrating one embodiment of a method  400  for installing a post mount adapter onto a post mount. In one embodiment, the method  400  is performed using a post mount adapter and a support block similar to the post mount adapter  200  and the support block  300  illustrated in the previous figures. As such, reference is made in the discussion of the method  400  to various elements of the previous figures. It will be appreciated, however, that the method  400  may be performed with post mount adapters having configurations that are not necessarily identical to the configuration of the post mount  200  and with support blocks having configurations that are not necessarily identical to the configuration of the support block  300 . 
     The method  400  begins in step  402 . In step  404 , a single post mount adapter  200  is positioned above a support block  300  of the post mount, such that each leg  202  of the post mount adapter  200  is aligned with one side of the support block  300 . The corner at which the two sides of the support block  300  meet will be aligned with the cutout in the L-shaped base  204  of the post mount adapter. 
     In step  406 , the post mount adapter  200  is slipped over the support block  300 , until the base  204  of the post mount adapter  200  is substantially flush with the top of the support block  300 . When the post mount adapter  200  is slipped onto the support block  300  in this way, the legs  202  of the post mount adapter will be flush with the exterior surfaces of the two sides of the support block  300 , as illustrated in  FIG. 3 . Depending on the dimensions of the support block  300 , this arrangement may cause the pressure fins  206  on the legs  202  to flex outward to accommodate the support block  300 . In addition, the flanges  208  of the post mount adapter  200  slide into recesses in the support block  300 , so that the support block  300  is gripped firmly between the legs  202  and the flanges  208  of the post mount adapter  200 , as illustrated in  FIG. 3 . 
     In step  408 , it is determined whether another post mount adapter  200  should be installed on the post mount. For instance, as discussed above, a support block  300  of the post mount may require two post mount adapters  200  in order to increase the outer dimensions of the support block  300  in an even and symmetrical manner. Additionally, if the post mount includes two support blocks  300 , then each of the support blocks  300  may require two post mount adapters  200 . 
     If it is determined in step  408  that no more post mount adapters  200  should be installed, then the method  400  ends in step  410 . 
     Alternatively, if it is determined in step  408  that another post mount adapter  200  should be installed, then the method returns to step  404 , and steps  404 - 406  are repeated until all of the necessary post mount adapters  200  have been installed. Once all necessary post mount adapters  200  have been installed, the method  400  ends in step  410 . 
     The result of the method  400  is a post mount whose support blocks are sized to support a larger post. As discussed above, the post may then be slipped over the post mount, like a sleeve. 
     Although various embodiments which incorporate the teachings of the present disclosure have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.