Abstract:
A construction method and apparatus used to form a surround, container or other structure. Posts have slots into which walls, which may be planks or made up of planks, are inserted and retained. Numerous posts may be used with numerous walls therebetween to form many and varied structures. The finished structure is modular, because the posts and walls are not damaged when the walls mount in the slots. Therefore, if more or fewer posts and/or walls are desired later, one need merely disassemble the structure and add the components desired to the existing structure. The walls may have fittings that attach to the inserted ends that cooperate with structures in the slots formed in the posts so the walls are held from being removed from the slots except along the length of the slots.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/281,938 filed Jan. 22, 2016. The prior application is hereby incorporated by reference. 
     
    
     STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT 
       [0002]    (Not Applicable) 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    (Not Applicable) 
       REFERENCE TO AN APPENDIX 
       [0004]    (Not Applicable) 
       BACKGROUND OF THE INVENTION 
       [0005]    The invention relates to containers and screening structures for outdoor use, and more specifically to structures and methods that permit one to combine components into containers and screening structures. 
         [0006]    Deck boxes, planters, fences, and other outdoor containing and screening products have historically been made of wood, and more recently polymer, planks and posts. Fasteners, such as nails or screws, are used to mount the planks to posts that are either held vertically in the ground, or simply resting upon the ground, such as a deck or patio. The final result is useful for containing toys, tools, outdoor deck supplies, or to screen from view entire yards, pool areas, air conditioning units and trash receptacles, among other items. 
         [0007]    One difficulty with such conventional products is that they are made with fasteners that damage the material when inserted and removed. Screws and nails work by being inserted into the objects to be fastened together, and when they are removed they leave holes and cracks. Furthermore, most outdoor items require some amount of maintenance, such as weather-proofing, in the case of wood and corrodible metals. Still further, even outdoor items that are weather-proof are made for their original purpose and cannot be repaired, expanded, or reduced in size without the repair, expansion or reduction being visible due to the damage caused by the removal and replacement of fasteners. 
         [0008]    Therefore, the need exists for a system of components that permit one to construct such an item, and then later repair or modify that item to suit later needs without wasting the materials of the original item or making the repair or modification apparent. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    Disclosed herein are structures and methods of combining walls and posts to construct useful items. The structures and methods result in furniture and other useful items including, but not limited to, planters, raised beds, tables, storage containers, and screen walls. In general, the disclosed structures and methods include the use of two main components: walls and posts. 
         [0010]    Each wall may be a plank, panel, slat and/or board, but may be any structure that, alone or combined, forms a mechanical or visual wall-like boundary on an item. The wall contains at least one end or side, or a plate or other fitting attached to an end or side, which fits into one slot in two or more cooperating posts. Each of the walls may be made of polymer, metal, wood, fiber-reinforced polymer composite or other rigid or semi-rigid material. The walls may be planks with a thickness of ⅛ inch or greater with a width of ½ inch or greater. Of course, these may be larger or smaller, depending on the circumstances. The walls may be hollow or solid panels that are from a foot or two wide and long to several feet wide and long. Elongated walls may be aligned horizontally or vertically. 
         [0011]    Each post is an elongated member with at least one extruded or milled groove or slot into which the walls&#39; ends and/or sides are inserted. The posts may be made of aluminum or other metal, polymer, fiber-reinforced polymer composite, wood, or any other suitable rigid or semi-rigid material. The posts may be solid or hollow. 
         [0012]    The outer contours of the posts, when viewed in cross-section, may be square, rectangular, oval, circular or any other geometric or other shape. A given post may be used in a corner or along a long side in a series of posts, and therefore each post will typically have at least one longitudinal groove or slot into which a wall may be inserted. Furthermore, some posts may receive two, three, four or more walls, such as a T-shaped post that is used along a long wall, and permits the insertion of a wall that divides. At least one side of each post has a minimum width of about ¾ inch to accommodate each wall, and at least one side contains a receiving channel for the insertion of a wall. 
         [0013]    The combination of two or more “posts” with one or more of the “walls” mounted in the slots therein makes a finished planter, table, storage container or other furniture piece, or a screen around an unsightly machine or item, all of which are highly functional, weather-resistant, require little to no maintenance, and may be modified or repaired later with other similar parts and no damage to the original components. The finished item is thus modular, so it can be expanded, reduced, or repaired by the addition or removal of one or more “walls” and/or “posts”. 
         [0014]    Each of the wall and post components must be able to be lifted and manipulated by a typical human user. This may be a carpenter or other skilled tradesman, or a homeowner with little training or experience in skilled trades. 
         [0015]    There may be stiffeners between the walls, particularly if the walls are made of multiple planks, and the stiffeners may function as decorative and/or strength-enhancing spacers. The stiffeners may be extruded, milled or molded aluminum or other metal, plastic, fiber-reinforced polymer composite or wood. A preferred stiffener thickness is less than the thickness of the planks to which they are attached, and so may be a width of ¼ inch or greater. 
         [0016]    Because of the flexibility of the design, the present invention can be used in varied ways to create containers and screens of various sizes and shapes. The posts form the corners and mid-span supports for walls that are fixed in the posts. Thus, in any circumstances in which a post can be mounted, walls (made of planks and/or sheets) are mounted between the posts to form the large surface area that screens something from view or holds back items. An advantage of the materials described herein is that they are weather-proof. By installing polymer decking boards as walls into extruded aluminum posts, as an example, there are virtually no requirements, such as staining, painting or sealing, to maintain the system to keep it functional. Furthermore, the system can be disassembled at a later time and any parts that have become broken or worn can be replaced. The method disclosed herein requires no removal or damage to the components, as would be the case if nails were used in a wooden or polymer product. Thus, subsequent modification or repair is not apparent. 
         [0017]    The system for containing or screening is highly modular and may be distributed in a kit of pre-cut pieces, or may be distributed by raw materials that are cut to length by the end user. In a preferred embodiment, posts may be extruded aluminum, pultruded composite or other materials that resist bending and form a strong foundation for individual planks or sheets to extend as walls between two or more such posts. The planks or sheets hold back soil if the system is used as a planter box, or form sides that contain items such as toys or tools, or form fences that screen something from view. The system can be used to form a deck box or a planter, or to screen an HVAC unit from view, for example. A foraminous or perforated grid can be mounted to the rear of the system to allow plants growing in soil held by the planks to climb up the grid. This grid may be mounted to the wall or the posts, as described below in detail. 
         [0018]    Because the system is modular, other walls and posts may be added to the constructed item at a later time without damage to the original components. Such walls and posts match the appearance of the originals so that the added components do not have the appearance of a later modification. Because of how the components are attached, there is no damage to the components during original construction or later modification. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0019]      FIG. 1  is a top schematic view illustrating an embodiment of the present invention. 
           [0020]      FIG. 2  is a side view illustrating the embodiment of  FIG. 1 . 
           [0021]      FIG. 3  is a side view in section illustrating the embodiment of  FIG. 2  through the line A-A with an enlarged portion. 
           [0022]      FIG. 4  is a top view illustrating a corner of the embodiment of  FIG. 1 . 
           [0023]      FIG. 5  is a top view illustrating an alternative post. 
           [0024]      FIG. 6  is a top view illustrating an alternative post. 
           [0025]      FIG. 7  is a top view illustrating an alternative post. 
           [0026]      FIG. 8  is a top schematic view illustrating an alternative embodiment of the present invention. 
           [0027]      FIG. 9  is a top view illustrating an alternative post. 
           [0028]      FIG. 10  is a top view illustrating an alternative post. 
           [0029]      FIG. 11  is a top view illustrating an alternative post. 
           [0030]      FIG. 12  is a top view illustrating an alternative post combined with at least one wall. 
           [0031]      FIG. 13  is a top view illustrating an alternative post combined with at least one wall. 
           [0032]      FIG. 14  is a top view illustrating an alternative post combined with at least one wall. 
           [0033]      FIG. 15  is a side view illustrating an alternative embodiment of the present invention. 
           [0034]      FIG. 16  is a side view illustrating an alternative embodiment of the present invention. 
       
    
    
       [0035]    In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or terms similar thereto are often used. They are not limited to direct connection, but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    U.S. provisional application Ser. No. 62/281,938 filed Jan. 22, 2016, which is the above claimed priority application, is incorporated herein by reference. 
         [0037]    One example of the structure described herein is the surround  8  shown in  FIGS. 1-4  with four substantially identical posts  10 ,  12 ,  14  and  16  disposed at four corners. Four sets of three horizontally mounted, vertically-stacked planks  20   a - d,    22   a - d  and  24   a - d  are mounted at their opposing ends to respective pairs of the posts  10 - 16 . The planks form walls and the posts retain the walls in position so the surround  8  can retain or screen items behind the walls. Between the posts  10  and  12  are the planks  20   a,    22   a  and  24   a.  Between the posts  12  and  16  are the planks  20   b,    22   b  and  24   b.  Between the posts  14  and  16  are the planks  20   c,    22   c  and  24   c.  Between the posts  10  and  14  are the planks  20   d,    22   d  and  24   d.  The orientation of some of the planks is shown in  FIGS. 2 and 3 , and the location of the planks  22   b  and  24   b  are the same as the location of planks  22   d  and  24   d,  but between the posts  12  and  16  rather than the posts  10  and  14 . 
         [0038]    The corner posts  10 - 16  may be vertically oriented as shown in  FIGS. 1-4 , such as by extending a lower end (not shown) into soil, concrete or any other substrate. Alternatively, the corner posts  10 - 16  may rest upon a patio  18  or other surface that is at ground level. The corner posts  10 - 16  have longitudinal slots and/or grooves into which the ends of the planks are inserted, as described in more detail below, to retain the planks solidly and until such time as the planks are deliberately removed therefrom. 
         [0039]    The planks may be mounted at their ends to the posts and form walls, in the example shown and described, that may serve to contain items, such as toys or tools, within the surround  8 , and/or may serve to screen from view one or more items within the walls, such as an air-conditioning unit or a pool pump. The posts maintain the vertical orientation of the planks, and the planks screen from view, or restrain, items within. 
         [0040]    As shown in  FIGS. 1 and 3 , the posts  14  and  16  are spaced from the posts  10  and  12 , and the planks  20   c,    22   c  and  24   c,  which are parallel to the planks  20   a - 24   a,  extend between, and are attached to, the posts  14  and  16 . Furthermore, the planks  20   d,    22   d  and  24   d  extend between, and attach to, the posts  10  and  14 , and they are parallel to the planks  20   b,    22   b  and  24   b  that extend between, and attach to, the posts  12  and  16 . The posts  10 - 16  may be positioned at corners of an imaginary rectangle, with predetermined distances between next adjacent posts, and with the planks of similar lengths mounted to and disposed between the posts forming the sides of the surround  8 . In this manner, a containment system is formed that, when viewed from the top, is rectangular. This containment system may form a flower box or any other container. 
         [0041]    A section view through the line A-A of  FIG. 2  is shown in  FIG. 3 , in which the planks  20   c - 24   c  and the planks  20   a - 24   a  held in the posts  10  and  14  are sectioned.  FIG. 3  shows a magnified view of an encircled portion. A stiffener  34  is placed between, and inserted into grooves  40   a  and  42   a  formed in, the edges of the adjacent planks  20   a  and  22   a,  respectively, to stiffen the entire wall made up of the planks  20   a - 24   a.  The stiffener  34  mechanically attaches the planks  20   a  and  22   a  that are adjacent to one another, thereby binding the planks  20   a  and  22   a  together so they reinforce one another. The stiffener  34  also stiffens the wall by having substantial thickness, thereby functioning as an “I-beam” that is added to the planks  20   a  and  22   a.  The stiffener  34  may be made of extruded aluminum, stainless steel, fiber-reinforced polymer composite or other strong material. 
         [0042]    Other similar stiffeners are attached to, and stiffen, all adjacent pairs of planks. Thus, just as the planks  20   a  and  22   a  each receive a tongue  30   a  and  32   a,  respectively, of the stiffener  34  as shown in  FIG. 2 , all plank edges that are adjacent another plank edge may be slotted to receive a similar stiffener. The stiffeners stiffen the walls, and prevent soil and/or other particulate matter contained in the surround  8 , so that particulate matter does not flow past the planks and stiffeners. The stiffeners prevent items hidden by the planks from being visible through cracks between adjacent planks. The stiffener  34  and its identical cousins shown herein are optional. 
         [0043]    As shown in  FIG. 4 , the corner post  10  is shown from a top view with the planks  20   a  and  20   d  mounted at their ends to the post  10 . A post cap may cover the top of the post  10  during normal use so the interior thereof is not visible or exposed to weather. The corner post  10  with attached planks is representative of the posts  12 - 16  and their respective attached planks, and therefore these other posts and planks are not described herein in detail. 
         [0044]    The ends of each of the planks  20   a  and  20   d  may insert into longitudinal slots or channels  50   a  and  50   d  that are formed in adjacent sides, and along the entire length, of the post  10 . The channels may be integrally formed in the post  10 , such as during manufacture, and the post  10  may be made of aluminum extruded through a mold having a void cross section similar to the shape of the post  10  shown in  FIG. 4 . The channels  50   a  and  50   d  are defined by the post material having a cross-sectional shape shown in  FIG. 4 , which channels  50   a  and  50   d  receive the ends of the respective planks  20   a  and  20   d.  In this manner, the ends of the planks  20   a  and  20   d  may simply be retained in the channels  50   a  and  50   d,  respectively, by friction, such as between the opposing channel sidewalls. 
         [0045]    Alternatively, each plank may have a fitting removably or integrally (such as by simultaneous molding during manufacture) mounted to each end thereof, with each fitting cooperating mechanically with structures that define the channels  50   a  and  50   d.  It is contemplated that two or more planks may be mounted to or within a single fitting, and the fitting mounted in a channel in a post. 
         [0046]    In a preferred embodiment, the fittings  60   a  and  60   d  are mounted to the respective ends of the planks  20   a  and  20   d,  and similar fittings are mounted to all other plank ends that are retained within channels in the posts  10 - 16 . The fittings  60   a  and  60   d,  which may be generally U-shaped in cross-section, mount to the ends of the planks  20  and  20   a,  respectively, by inserting the end of the plank into the void formed therein. A respective fastener, such as the screws  62   a  and  62   d,  extend through the fittings  60   a  and  60   d  into a respective end of each of the planks  20   a  and  20   d.  Any fastener is contemplated, but screws, adhesive and rivets are examples. The ridges  52   a,d  and  54   a,d  project inwardly from the respective channels  50   a  and  50   d,  defining pairs of ridges with tips spaced apart substantially equal to, or slightly greater than, the thickness of the planks  20   a  and  20   d,  but less than the width of the fittings  60   a  and  60   d.  The distance between a pair of tips is referred to as the ridge gap. 
         [0047]    The fittings  60   a  and  60   d  are the same width or are narrower than the portions of the channels into which they are inserted in an operable position, but are at least as wide as the ridge gaps, which are the spaces between the tips of the ridges  52   a,d  and  54   a,d.  This relationship causes the fittings  60   a  and  60   d  to be retained in the channels  50   a  and  50   d,  respectively, on the opposite side of the ridges from the remainder of the planks. In the embodiment illustrated, the end of the plank may be considered a leg with the fitting considered a foot that forms an enlarged portion that prevents the wall from coming out of the channel along the plane of the wall, other than along the length of the channel. This configuration permits the fittings and their respective planks to be slid along the length of the channels  50   a  and  50   d  into place in the post  10  during installation and removal. Typically, this is a tight fitment that allows sliding along the length of the channels  50   a  and  50   d  under the force of average human strength, but prevents substantial movement of the planks relative to the posts in any direction except along the lengths of the channels. Once the planks are in position, they remain there due to the requirement for deliberate sliding along the channels for removal. Each wall end that is mounted in a post slot may have a fitting that provides a leg portion and a foot portion. 
         [0048]    Thus, a method of constructing the surround  8  may include the positioning of each post  10 - 16 , preferably spaced from one another, and each of the planks being placed with one end in one channel and an opposite end in a facing channel of another post. This process is repeated until the surround is complete. If desired, a fitting may be mounted to the end of each plank, and the insertion step carried out by inserting the leg portion and foot portion at a side of a slot or channel, and then forcing the wall along the slot&#39;s length with the foot portion deeper than the leg portion, until the wall is in the desired longitudinal position in the slot. In a contemplated method, the first, typically lowest, layer of planks is inserted into the channels of opposing posts, and a stiffener is placed on the exposed top edge of each plank, if needed. Then another plank is placed on top of the first (lowest) plank with its slot receiving the stiffener. This process is repeated for the entire second layer of planks. This process of inserting a stiffener is repeated by placing a stiffener in the slot on a top edge of the second layer of planks, and a third layer of planks is installed with slots in their lower edges receiving the top of the second stiffeners. This can continue for each desired layer. Top and bottom planks typically do not have a stiffener on top and bottom sides, respectively, but each plank that is adjacent two other planks may have a stiffener on both of its sides. A floor or cover may be mounted to one or more of the posts or planks, and such cover may be hinged. A clasp or other structure that permits locking of the surround  8  may also be used in a conventional manner. 
         [0049]    It is contemplated that a single fitting may be mounted to two or more planks and one or more stiffeners. Thus, a method of constructing a surround may include the positioning of each post, preferably spaced from one another. Each of the planks is placed with one end in a first fitting and an opposite end in a second fitting. In a contemplated method, the first, typically lowest, plank is inserted into the fittings, and a stiffener, if needed, may be placed in a slot on the exposed top edge of the first plank. Then a second plank is placed on top of the first (lowest) plank with the second plank&#39;s slot receiving the stiffener. This process of inserting a stiffener is repeated by placing a stiffener in the slot on a top edge of the second plank, and a third plank is installed with the slot in its lower edge receiving the top of the second stiffener. Once the fitting is mounted to all the planks (and stiffeners, if desired), the fittings at opposite ends of the wall may be mounted in the post channels by inserting the first and second fittings at sides of slots or channels in the posts. The entire wall is then forced along the slots&#39; lengths with the foot portion deeper than the leg portion, until the wall is in the desired longitudinal position in the slots. 
         [0050]    If the span between corner posts is too long for the strength of the planks, even if stiffeners are used, one or more mid-posts, such as the mid-post  70  shown in  FIG. 5 , may be used. The mid-post  70  is substantially similar to the posts  10 - 16 , except that it has structures on opposite sides that form opposing channels  70   e  and  70   f.  The planks described herein may mount to mid-posts  70 , and all other posts described herein, in the same manner as described herein for the corner post  10 . The ends of the planks are inserted into the channels  70   e  and  70   f  as described above for insertion into the channels of the corner posts  10 - 16 . However, instead of the planks being oriented at about a 90 degree angle to one another, the planks are aligned in a single plane that intersects the mid-post  70 . The mid-post  70  may be inserted into the ground or attached to another structure as with the corner posts  10 - 16 . 
         [0051]    The surround  8  is shown and described above in relation to  FIGS. 1-4 , a surround or container that is useful for any purpose may be readily constructed using four posts  10 - 16  and a plurality of planks  20 - 24   a - d.  In an even more basic embodiment, a fence may be constructed according to the invention, and such a fence may use a structure that resembles one side of the surround  8 , such as that shown in  FIG. 2  with two posts  14  and  16 , and one wall. This fence may be used to screen from view an unsightly mechanical item, such as an air-conditioning unit. In this case, the fence is formed of two end posts and a wall, such as can be made up of three planks inserted in the posts. The corner posts  10 - 16 , and the mid-post  70 , all of which have two channels, would not be as attractive for such a purpose as posts that have only a single channel, such as the member  80  shown in  FIG. 6 . The member  80  has a single channel  80   g  that is substantially the same as the channels  50   a  and  50   d  formed in the post  10 . 
         [0052]    The member  80  may also be used as a top and/or bottom rail that extends horizontally between vertical posts, as shown in the fence  500  of  FIG. 16 . A wall may be made of one or more vertical planks  520  with lower ends that rest in the member  80  with its channel  80   g  upwardly oriented and serving as a bottom rail. Another member  510 , which may be identical to the member  80 , may serve as a top rail and is disposed with its channel downwardly oriented with the top ends of the vertical planks  520  inserted in the channel. Stiffeners  530  may be inserted into slots formed in the adjacent edges of the vertical planks  520  to eliminate any leaks in the wall. The top and bottom rails  510  and  80  are inserted at their ends into channels formed in the vertical posts  512  and  514 , which channels are similar to the channels shown in  FIG. 4 . In the embodiment of  FIG. 16 , the wall is made up of the top and bottom rails  510  and  80 , the planks  520  and the stiffeners  530 , if stiffeners are used. 
         [0053]      FIG. 7  shows a T-shaped post  90  that has structures defining the channels  90   h,i,j  that receive three walls at 90 degree angles to one another. Such a post  90  may be used as a mid-post in a structure in which perpendicular divider walls are desired. The T-shaped post  90  allows one to construct a container or surround with walls that divide the container into multiple sections, as shown in  FIG. 8 . Four posts  110 ,  112 ,  114  and  116  may be mounted at corners of an elongated rectangle, and two T-shaped posts  90  and  100  may be mounted midway along longer, opposing walls  120   a,    120   b,    120   c,    120   d,    120   e  and  120   f  between the corners. Thus, a surround  108  may be constructed having two or more chambers  92  and  94  with a wall  96  separating the chambers. The wall  96  inserts into the channels of the posts  90  and  110  in a manner described herein. 
         [0054]    With regard to the embodiment shown in  FIGS. 1-4 , any number of planks can be oriented vertically along the height of the posts  10 - 16 , and this variability illustrates the modularity of the system. One example of a plank is a 1×6 polymer deck board, with three such boards making the wall with a height of about 18 inches taking into consideration the stiffeners and the fact that a 1×6 board is nominally 5.5 inches wide. Any planks of any common dimension, such as 1×4, 2×6, etc., or any dimension that is not common, may be used with the posts  10 - 16  to construct a container or surround of virtually any size. A single sheet, such as plywood or glass, may be used as an alternative to the planks. Polymer decking planks are contemplated, as are virtually any material known to be suitable to outdoors use. 
         [0055]    Alternative posts are shown in  FIGS. 9-13 . For example, a corner post  200  for use with a wall that has essentially the same thickness as the post  200  is shown in  FIG. 9 . A similar corner post  210  is shown in  FIG. 10  having a larger radius of curvature on the corner facing away from the two channels. The post  220  of  FIG. 11  is similar to the post of  FIG. 9 , but with a larger depth and thickness than the wall that inserts into the channels. The posts mid-post  300 , corner post  310  and end post  320  shown in  FIGS. 12, 13 and 14 , respectively, match the corner posts  10 - 16  of  FIGS. 1-4 , and are shown with walls inserted therein. 
         [0056]    Another alternative embodiment of the present invention is shown in  FIG. 15 . As noted above, the post and wall components can be combined to form a planter  410 , and a foraminous or perforated grid  420  can be mounted to one side of the planter  410 . Such a grid  420  may be screen or “hardware cloth” mounted within a rigid, rectangular frame that is mounted to the planter  410 . The grid  420  allows climbing plants growing in soil held by the planter  410  to climb up the grid  420 . This grid  420  may be mounted to the wall or the posts. In an example, posts that are similar to the post  220  shown in  FIG. 11  are used in the planter  410 , and the grid  420  is mounted by screwing the grid to the protuberance  222  on two of the adjacent posts of the planter  410 . 
         [0057]    This detailed description in connection with the drawings is intended principally as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and that various modifications may be adopted without departing from the invention or scope of the following claims.