Patent Abstract:
A post securing system that secures a post in the ground, while allowing for a full range of vertical adjustment via a coupling assembly that includes an articulating ball joint element that is connected to a post support element secured within two clamp assemblies. The clamp assemblies each include an anchor assembly which, when assembled, secures at least three stake elements at a predetermined angle. The post securing kit includes both the coupling assembly and the anchor assembly to allow securing a post into a non-horizontal ground, while maintaining the desired vertical alignment of the post held therewithin.

Full Description:
FIELD 
       [0001]    The present system relates generally to post supports and anchor assemblies for posts, as well as to anchoring of structures and other physical objects and structures requiring anchoring. 
       BACKGROUND 
       [0002]    Post or pole fixation is most often seen in securing fence posts in the ground. These applications require that the pole or post be vertically aligned with great accuracy; however, the ground into which these are secured, may not be level or may be against the side of a slope or hill. Because the poles or posts being utilized are typically long in relation to their thickness, it can be difficult to accurately align them. 
         [0003]    One of the existing common methods utilized is to dig a hole and set the post in concrete. The post or pole can be aligned vertically with other posts or poles to keep the alignment while the concrete cures. In many cases, the position of the pole or post must also be constrained with additional posts or poles to maintain alignment during concrete curing. Generally, concrete must cure for several days, depending on weather conditions, before the post or pole is sufficiently fixed to be usable. This method, although labor intensive and time consuming, allows for exact vertical alignment of the pole or post. Thus, there is a need for a system that allows for the accurate alignment of posts or poles while requiring much less labor and time than the existing systems. 
         [0004]    In addition, many post or poles used currently for fencing deploy wood directly in the earth or encased in cement. Both of these methods result in failure in a relatively short period of time. In some environments where moisture, freezing temperatures and insects are prevalent the time period is extremely short. Frost heave is a common problem in cold weather climates, in which the frozen ground effectively pushes out of the ground the concrete block that is securing a post. Thus, there remains a further need to an improved system for anchoring posts that minimizes costs, and enables the use of materials having long-term durability in a ranges of environments. 
       SUMMARY 
       [0005]    The present system relates to post supports that can pivot at an angle sufficient to provide structural support for posts installed against a hillside or other non-level surface, as well as on level surfaces. The support may include an anchor assembly adapted to receive the pivotable post support, or other supports that may require secure anchoring. 
         [0006]    The present system is used for anchoring fence posts, sign posts, flag posts, flag poles, or a post for any purpose that requires anchoring. As used in this document, the term “post” refers to both posts and poles, including fence posts, sign posts, flag posts, and flag poles, that are rounded or includes one or more squared edges, or any post, pole, or other substantially elongate item used for any purpose that requires essentially vertical anchoring. The present system is used to fix poles or posts into the earth for permanent construction or temporary applications. 
         [0007]    An advantage of the present system is the ability to adjust the angular orientation of the post or pole after the stakes have been set into the earth. Another advantage of the present system is that a relatively small number of components are necessary to assemble the system, which conserves cost and reduces the amount of raw materials. A still further advantage of the present system is that the components are made of preferably galvanized steel for long life even in harsh conditions. 
         [0008]    Accordingly, the present system is a post support assembly for receiving a post, comprising a post support structure adapted to receive an end of an elongated post extending along a post axis, an anchor assembly adapted for stable fixation in the ground at a geographic location, and a coupling assembly for coupling the post support structure to the anchor assembly by way of a ball joint element and associated clamp assembly. In this system, a post received by the post support is adjustably positionable to establish the post axis to a desired angle with respect to local gravity at the geographic location. 
         [0009]    In an embodiment of the present system, the coupling assembly further comprises a ball joint element extending along a post axis between a support end and a post end, wherein the support end has an outer surface disposed about a center point CP on the post axis, and characterized by a radial distance from CP less than or equal to R 0 . The outer surface of the ball joint element includes an outer surface region that includes one or more spherical segments centered about CP and being a radial distance R 0  from CP, and the outer surface region extends between angle A 1  and angle A 2 . The spherical segments may be contiguous to form an outer surface having a solid spherical shape, or the surface may be striated or variegated with holes. In an embodiment, A 1  is an upper limit angle between an upper limit point of the spherical segment on a first side of a reference plane orthogonal to the post axis and passing through CP, wherein A 1  is greater than 0° and less than 90°, and A 2  is an lower limit angle between a lower limit point of the spherical segment on a second side of the reference plane, wherein A 2  is greater than 0° and less than 90°. 
         [0010]    The system further comprises a post support element extending between a ball end and the post end, wherein the ball end is affixed to the ball joint element at a point on the outer surface of the ball joint element at an angle greater than A 1  with respect to the reference plane. 
         [0011]    In another embodiment, the coupling assembly is a clamp assembly. The clamp assembly includes: (i) an upper clamp element, including a planar region having a central aperture therein disposed about an upper clamp axis orthogonal to the planar region, wherein the central aperture includes a circumferentially dispersed circular segment having a radius R UC  is greater than R UC  cos A 1 , and R UC  greater than or equal to R UC  otherwise; (ii) a lower clamp element, including a planar region having a central aperture therein disposed about a lower clamp axis orthogonal to the planar region, wherein the central aperture includes a circumferentially dispersed circular segment having a radius R LC  is greater than R LC  cos A 1 , and R LC  greater than or equal to R LC  otherwise; and (iii) a clamp coupler, including at least three bolt assemblies adapted to adjustably couple the upper clamp element to the lower clamp element with the upper clamp element disposed with its central aperture extending about a portion of the spherical regions on one side of the reference plane, and the lower clamp element disposed with its central aperture extending about a portion of the spherical regions on the other side of the reference plane. 
         [0012]    In this embodiment, the anchor assembly further comprises a plurality of elongated anchor elements extending from at least one of the upper clamp element and the lower clamp element and in a direction away from the upper clamp element. These anchor elements secure the anchor assembly into the ground, and preferably are elongate rigid stakes. 
         [0013]    Upon assembly, the post support system includes a post extending along a post axis between a support end and a distal end, wherein the support end of the post axis extends from and is integral with the support end of the post support element, and the post axis is coaxial with the post axis. Alternatively, the support end of the post axis is adapted to slidingly engage the support and of the post support element, whereby the post axis is coaxial with the post axis. 
         [0014]    The present anchor element for an anchor and support assembly, comprises a first anchor plate, wherein the plate is a sheet element having a uniform thickness D, and having a planar central portion with a nominal periphery P, and extending along and about a principal plane transverse to a central axis. The sheet element includes a coupling region disposed about the central axis and within the central region, and at least three elongated tab elements, each tab element extending along an associated tab axis from the nominal periphery P, from a proximal portion at a proximal end thereof to a distal end, wherein a principal plane of the proximal portion extends along and is parallel to the principal plane. The tab axes are co-planar and are transverse to and extend radially outward from the central axis, and each tab element includes, at its distal end, a capture bend region, whereby the tab axis of a distal portion of the tab element extends from an intermediate point, away from the principal plane in a first direction, and thereafter extends toward and across the principal plane in a second direction to the distal end. Each tab element includes a primary bend region between its proximal portion and the intermediate point, whereby a distal portion of the tab element extending from the intermediate point to the distal end extends transverse to the tab axis in a direction perpendicular to the principal plane, between a first lateral edge on one side of the principal plane and a second lateral end on the other side of the principal plane. Each distal portion includes a slot having a predetermined width D extending from the first lateral edge into the distal portion along an associated slot axis parallel to and a distance S from the central axis. 
         [0015]    In an alternative embodiment, the anchor element includes a structure for coupling the coupling region to an externally applied element. In an embodiment, the tab elements are equi-angularly disposed about the central axis. 
         [0016]    As described herein, the present anchor and support assembly kit comprises a first anchor plate, and a second anchor plate, as described above. The kit further includes a set of fastening elements adapted to clamp the first anchor plate to the second anchor plate with distal portions of opposite tab elements disposed within corresponding slots, and a set of elongated anchor elements, each anchor element being associated with a tab element, and wherein each anchor element extends from a proximal end to a distal end, wherein the proximal and is adapted for capture between oppositely positioned bend regions of the plus first anchor plate and the second anchor plate when positioned opposite each other with the fastening elements. 
         [0017]    These and other objects and advantages of the present invention will become apparent to those skilled in the art in view of the description of the best presently known mode of carrying out the invention as described herein and as illustrated in the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective representation of an embodiment of the present post anchor system. 
           [0019]      FIG. 2A  is a perspective view of an embodiment of the ball joint and post support elements of the present system. 
           [0020]      FIG. 2B  is a top cross-section view of an embodiment of the ball joint element of the present system. 
           [0021]      FIG. 3  is a side cut-away view of the ball joint and post support elements of the present system. 
           [0022]      FIG. 4  is a perspective view of an embodiment of the present system. 
           [0023]      FIG. 5  is a perspective view of an embodiment of the coupling assembly of the present system. 
           [0024]      FIG. 6A  is a side perspective view of an embodiment of an upper clamp element of the present system. 
           [0025]      FIG. 6B  is a graphic representation of the dimensions of an embodiment of an upper central aperture. 
           [0026]      FIG. 7  is a top perspective view of an embodiment of a lower clamp element. 
           [0027]      FIG. 8  is a top perspective view of an embodiment of a coupling assembly of the present system. 
           [0028]      FIG. 9  is a side perspective view of an embodiment of an anchor assembly of the present system. 
           [0029]      FIG. 10  is a side close-up view of an embodiment of an anchor assembly of the present system. 
           [0030]      FIG. 11  a side diagrammatic view of an embodiment of the anchor assembly of the present system. 
           [0031]      FIG. 12  is a perspective view of an embodiment of the present system angled for installation into non-level ground. 
           [0032]      FIG. 13  is a perspective view of an exemplary embodiment of the present system, having a post that is driven into the ground. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    The present post support assembly  100 , as shown in  FIG. 1 , includes a post support element  102  that is coupled to an anchor assembly  104  by coupling assembly  120  for fixing a post, as defined above, into the ground. One benefit of the present assembly  100  is that the post support element  102  is coupled to the anchor assembly  104  in such as way that the post support element  102  can rotate within the coupling assembly  120  in a manner that allows an attached post to be anchored into the side of a hill, while maintaining an accurate vertical orientation of the post. 
         [0034]    As shown in  FIG. 2A , the coupling assembly  120  includes a ball joint element  106  extending along a post axis PA between a ball distal end BDE and a ball support end BSE. The ball joint is integral with or otherwise attached to a post support element  102  that also extends along the post axis PA between the post proximal end PPE and the post distal end PDE. The ball joint element is attached to or integral with the post support element at the junction of the ball support end and the post distal end. The outer surface of the ball joint element  106  is disposed about a center point CP on the post axis PA, along a reference plane RP. As shown in cross-section in  FIG. 2B , the ball support end BSE has an outer surface  112  disposed about a center point CP on the post axis PA, and is characterized by a radial distance from the center point CP less than or equal to radius R 0 . 
         [0035]    In an embodiment, the outer surface of the ball joint element  106  includes an outer surface region, which preferably is a solid surface. In alternate embodiments, the surface may be formed from separate segments or may be striations or variegated with holes on the surface itself. The ball element may be a solid structure, or may be hollow, provided that the materials with which the ball joint element is manufactured is sufficiently strong to support a post of the desired dimensions. Thus, the thickness of the ball joint may vary from solid to several millimeters, depending on the intended use of the ball joint. The ball joint element  106  may be spherical, or may have an essentially spherical shape, depending on the specific application. Alternatively, the element  106  may include multiple segments that are manufactured from the same or different materials from the center of the element  106 . The ball joint element  106  may be integral with the post support element  102 , or may otherwise be affixed to the post support element  102 , for example by welding. The ball joint element  106  preferably is manufactured from a rigid material, such as steel or aluminum, and may be manufactured using standard manufacturing methods, such as die casting. 
         [0036]    As shown in the cut-away view of the present system  100  in  FIG. 3 , the outer surface region  112  is a spherical segment centered about CP and a radial distance from R o  from CP. The outer surface region extends between angle A 1  and A 2 , wherein A 1  is an upper limit angle between an upper limit point of the spherical segment on a first side of the reference plane RP that lies orthogonal to the post axis PA and passes through center point CP. Angle A 1  is greater than 0° and less than 90° with respect to the reference plane RP. In addition, angle A 2  is a lower limit angle between a lower limit point of the spherical segment on a second side of the reference plane RP, wherein A 2  is greater than 0° and less than 90° with respect to the reference plane RP. 
         [0037]    The coupling assembly  120  includes an elongate post support element  102  extending along the post axis PA between the post proximal end PPE and the post distal end PDE. The post distal end PDE is affixed to the ball joint element  106  at a point on the outer surface  112  of the ball joint element  106  substantially along the post axis PA. Such fixation may be achieved through welding, screws, or other secure method known in the field. The size, diameter, and shape of the post support element  102  varies depending on the size, diameter, and shape of the post element which mounts onto the support element  102 . Thus, the support element  102  may be adapted to accept a post of any diameter or shape, or example a round pole, or a square post. 
         [0038]    In the embodiment shown in  FIG. 3 , a hollow post  200 , such as a type used for installing cyclone fences and the like, may be inserted into or onto the post support element  102 . The ball joint element  106  is secured between two plates of a clamp assembly  120 , as described in further detail below, such that in practice, the post support element  102  can rotate as necessary to maintain the post  200  in an accurate, predetermined alignment relative to the ground. 
         [0039]      FIG. 4  shows an alternate embodiment of the present post anchoring system  100  wherein the post support element  102  further includes support brackets  110  attached to or integral with the support element  102 . The brackets  110  are spaced apart along and extend vertically parallel with the post axis PA to securely receive a post  200 . The number, height, thickness, and shape of the brackets  110  depends on the height, weight, and shape of the post  200 . The brackets  110  preferably are manufactured from a rigid material, such as steel or aluminum, and may be pressed and formed from a single sheet of material, or securely welded or otherwise attached to a base. Such a system can be used to secure solid posts, which cannot be inserted on top of the post support element described above. 
         [0040]    The present system  100  further includes a clamp assembly  122 , as shown in  FIG. 5 . The clamp assembly  122  has an upper clamp element  124  and a lower clamp element  126 , together with one or more fastening elements or clamp couplers  128 . The couplers  128  may be bolts, or other securing couplers as generally commercially available. 
         [0041]    As best shown in  FIG. 6A , the upper clamp element  124  includes a planar region PR having a central aperture  118 . In the illustrated embodiment, the central aperture  118  is contiguous and spherical in shape. In alternative embodiments, the aperture may be non-spherical due to manufacturing design, cost, and the like. In yet another embodiment, the aperture may be formed by segments or otherwise non-contiguous. As shown in  FIG. 6B , the aperture  118  has a radius R UC  that is greater than R UC  cos A 1 , such that the radius of a corresponding ball joint element  106  fits within the aperture  118  without passing fully through the aperture  118 . In this manner, the ball joint element  106  can be held by the aperture while being able to rotate freely within the aperture. 
         [0042]    The upper clamp element  124  preferably is made of a sheet of rigid material having a uniform thickness D, of about 3 mm, depending on the nature of the intended use. Larger posts will require greater thickness D. The element  124  includes a planar central portion  132  having a nominal periphery P, and extends along and about the planar region PR along an upper plate axis UPA transverse to the central axis CA. In an embodiment, the clamp assembly  122  includes an anchor assembly  104  for securing structural stake elements  114  (shown in  FIG. 4 ), which allows the clamp assembly to be used for securing posts in the ground. The anchor assembly  104  may be integrally formed from the planar central portion  132 , or may otherwise be welded, or attached to the planar central portion  132 . 
         [0043]      FIG. 7  shows a lower clamp element  126 , which includes a planar region PR having a central aperture  119 . As with the upper clamp element, it is possible for the aperture  119  to be non-spherical due to manufacturing design, cost, and the like. The central aperture  119  of the lower clamp element  126  is not required to be, but may be the same dimension as the central aperture  118  of the upper clamp element  124 . In different embodiments, the central aperture of the upper clamp element and the lower clamp element are the same and one or the other or both elements may include separate circular segments. Alternatively, one clamp element may have contiguous circular segments, while the other clamp element may include multiple separate circular segments. Each such segment has a radius R UC  that is greater than R UC  cos A 1 , such that the radius of a corresponding ball joint element  106  fits within the aperture  119  without passing fully through the aperture  119 . 
         [0044]    The lower clamp element  126  preferably is made of a sheet of rigid material having a uniform thickness D, of about 3 mm, depending on the nature of the intended use. Larger posts will require greater thickness D. The element  126  includes a planar central portion  133  having a nominal periphery P 2 , and extends along and about the planar region PR along an upper plate axis UPA transverse to the central axis CA. In an embodiment, the clamp element  126  includes an anchor assembly  104  for securing structural stake elements  114  (as shown in  FIG. 4 ), which allows the clamp assembly to be used for securing items in the ground. The anchor assembly  104  may be integrally formed from the planar central portion  132 , or may otherwise be welded, or attached to the planar central portion. The clamp element  126  includes one or more coupler holes  134  positioned adjacent the central aperture  118  and of sufficient size to receive fastening elements  128  therethrough. 
         [0045]    As shown in  FIG. 8 , the coupling assembly  120  includes an upper clamp element  124  that combines with a lower clamp element  126 , and are secured by clamp couplers  128 . When coupled as illustrated, the assembly  120  forms a central aperture  116  that extends therethrough along the central axis CA. In use, the coupling assembly  120  includes an anchor assembly  104  for structural stake elements  114 , as described in further detail below. 
         [0046]    In practicing the present coupling assembly  120 , a post  200  is positioned and secured on the support element  102  while the attached ball joint element  106  is placed between the upper clamp element  124  and the lower clamp element  126 . The clamp elements  124 ,  126  are held together using two or more fastening element, to securely and rotatably engage the ball joint element  106  therebetween. The post  200  then may be rotated into the desired vertical position. 
         [0047]    The present post support assembly  100  further includes an anchor assembly  104 . In the illustrated embodiment of  FIG. 9 , the anchor assembly  104  is made from a single sheet of rigid material, which forms the upper clamp element  124 , as described in detail above, and at least three elongate tab elements  140 . Each tab element  140  extends along an associated tab axis TA from the nominal periphery P. Each tab element  140  thus extends from a proximal portion  142  at a proximal tab end PTE to a distal tab end DTE, wherein a principal plane of the proximal portion  142  extends along and is parallel to the principal plane PP. 
         [0048]    The tab axes TA are co-planar to, transverse to, and extend radially outward from the central axis CA. Each tab element  140  includes at its distal tab end DTE a capture bend region  144 , defined by the tab axis of a distal portion  148  of the tab element extends from an intermediate point, away from the principal plan in a first direction, and then extends toward and across the principal plane in a second direction to the distal tab end DTE. This forms an essentially S-shaped distal tab end DTE. In addition, each tab element includes a primary bend region  146  between its proximal portion  142  and the intermediate point IP on the tab, whereby the proximal portion is twisted to a degree between 0° and 90° relative to the tab axis. The twist effectively results in the distal portion  148  extending from the intermediate point IP to the distal tab end DTE such that it extends transverse to the tab axis in a direction perpendicular to the principal plane, between a first lateral edge on one side of the principal plane and a second lateral edge on the other side of the principal plane. 
         [0049]    The distal portion  148  of each tab element  140  further includes a slot  150  having a predetermined width W extending from the first lateral edge into the distal portion along an associated slot axis parallel to and a distance S from the central axis CA. 
         [0050]    As shown in  FIG. 8 , when the upper clamp tab elements  164  are twisted in accordance with the above on the upper clamp element  124 , and the corresponding lower clamp tab elements  166  on a lower clamp element  126  are twisted in the corresponding dimensions, then the slots  150  of the each tab element align and interlock to form a secure anchor element assembly  104 . 
         [0051]    Rigid structural stake elements  114  are inserted, or otherwise secured in the space created between the capture bend regions  146  of each pair of complimentary tab elements  140 , as shown in  FIG. 10 . The stakes  114  are set at a predetermined angle, which may be in the range of 0° to 45° from vertical, which is determined by the angle at which the capture bend region is bent. By thus being angled, the stakes  114  transfer the load from the post  200  to the ground, making the entire system  100  secure. 
         [0052]    As shown in  FIG. 11 , once the upper clamp tab element  164  and lower clamp tab element  166  are secured around the structural stake elements  114 , a secondary clamp coupler  152  may be applied to further secure the two tab elements together. 
         [0053]    The anchor assembly  104  preferably is manufactured from a rigid metal, such as steel, and is adapted, as described below, to receive stakes  114  manufactured from rigid steel, aluminum, or other materials commonly used. In a preferred embodiment, the stakes  114  are standard “T” bar fence posts, readily commercially available and relatively inexpensive. 
         [0054]    When using the present post securing system  100 , and as shown in  FIG. 12 , the structural stake elements  114  are driven into the ground using conventional installation methods known in the art, and may further be secured by embedding the stakes in cement or other secure curing material. The structural stakes  114  are preferably arranged in a pattern where the load is spread over a large volume of the ground. In the illustrated embodiment, four stakes  114  are shown in a radial array around the center point CP. For low stress applications, the array include only two or three structural stakes  114 . For extremely high stress applications, five or more structural stakes  114  may be deployed. A preferred embodiment utilizes a maximum of four structural stakes  114 . The length and cross sectional size of the structural stakes  114  may be increased or reduced to match the requirements of the specific application. The cross-sectional shape of the illustrated structural stakes  114  is shown as a “t”. This particular cross section is commonly used for wire type fencing. It should be noted that other shapes could be deployed as well as hollow tubing type sections. 
         [0055]    Once the system  100  is installed, loosening the clamp couplers  128  releases the tension hold of the ball joint element  106  from between the two clamp elements, allowing a user to adjust the angular orientation of the post  200  secured therewithin without compromising the security of the position of the post in the system  100 . Thus, the angle of the post  200  can be maintained at an accurate angle relative to the ground. This allows the system  100  to be installed against a hill, and the ball joint element  106  can be rotated to maintain the accurate alignment of the post  200  in a vertical position relative to the ground, if desired. The angle of the ball joint element  106  and post  200  can be altered at initial deployment of the system  100  or at a later date to readjust the orientation. Such ability to pivot the post  200  within the system  100  makes the installed post  200  more resilient to accidental impacts that otherwise would lift the installation assembly out of the ground. In such an accident, using the present system  100 , the ball joint element  106  rotates with the impact, and absorbs most of the power of such an impact, leaving the system  100  essentially in the ground. The post  200  then merely needs to be realigned, without having to remove or replace the entire system  100 . 
         [0056]    The system  100  may be assembled, e.g., as shown in  FIG. 5 , for commercial sale, or it may be sold in separate components. 
       EXAMPLE 
       [0057]    As illustrated in  FIG. 13 , in using the present system  100 , the system is placed on the earth in the desired area. The structural stakes  114 , of the desired length, are then driven until flush with the planar region of the upper clamp element. The structural stakes  114  are driven with a sledge hammer or similar implement, including a number of commercially available electric or pneumatic drivers available that are specifically designed to drive stakes. The clamp couplers  128  are then tightened to secure the anchor assembly  104 . The post  200  is then inserted on the post support element  102 . The pole  200  is then leveled to vertical and the clamp couplers  128  are tightened further. 
         [0058]    In some installations of round chain link fencing or sign posts/poles, the post/pole once leveled to vertical may be driven to further secure the installation. In some cases, this may be dictated by local building codes. 
         [0059]    The above disclosure is not intended as limiting. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the restrictions of the appended claims.

Technology Classification (CPC): 4