HEAVY DUTY SURFACE MOUNT POST SYSTEM

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Nos. 63/677,561 filed on Jul. 31, 2024, 63/686,150 filed on Aug. 22, 2024, and 63/690,785 filed on Sep. 4, 2024, which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

This invention relates generally to fences and their installation and, more particularly, to a heavy-duty surface-mount post system for use in fence installations.

BACKGROUND OF THE INVENTION

Conventional fence installation methods often require digging post holes, setting posts in concrete, and waiting for the concrete to cure. This process is time-consuming, labor-intensive, and may not be feasible in certain environments, such as on concrete slabs or structures where penetration is undesirable or impossible. An alternative installation method is to use a post base that is mounted to a foundation, such as concrete, and then mounting the post to the post base.

Conventional fence installations require the fence post base and the fence post to be made from the same material. If the fence post base is steel for strength, the post must also be made of steel to prevent galvanic corrosion. Using both the post and base made of steel increases the fence's weight, raises shipping costs, and makes installation more difficult. If the fence post is made of aluminum to reduce weight, then the fence post base must also be aluminum to prevent galvanic corrosion. However, this can lead to a less sturdy fence due to the aluminum base.

Conventional fence installations also require close tolerances between the post and the base when the post is installed over the base. This increases costs and makes installation more difficult, since the post must be forced over the base. If the tolerances are not tight, the post can wobble on the base, which is not desirable.

There is a need for a surface-mounted fence post system that is strong, durable, easy to install, and adaptable to various post and base configurations. The disclosed invention meets these needs with a heavy-duty mountable post base and shimming system that enables fence posts to be made from a different material than the post base. As described, the post base is made of steel for strength and durability, while the post is made of aluminum for reduced weight and easier handling. The shim also makes manufacturing and installation easier since the tolerances between the post and base don't have to be as tight as in traditional fence systems.

SUMMARY OF THE INVENTION

In general terms, this invention provides an efficient, economical, and sturdy fence post system for use in installing a fence.

The heavy-duty surface mount post system of the present invention includes a post base plate and a vertically extending mounting member secured to the base plate. In the disclosed embodiment, the base plate and the vertically extending mounting member are made of steel.

An aluminum post is mounted to the mounting member. At least one shim is configured to fit between the mounting member and the post. In this way, the aluminum post is separated from the mounting member to inhibit galvanic corrosion and to provide a tight fit between the steel mounting member and the aluminum post, restricting movement between them.

The shim is made from a pliable material and is self-forming when compressed between the post and the mounting member. In the disclosed embodiment, the shim includes an elongated body and an inwardly angled finger for engaging the top of the mounting member. It is made from materials such as aluminum, plastic, steel, or stainless steel, for example.

In another embodiment, the shim includes surface ridges to increase friction and maintain spacing between the post and the mounting member.

In still another embodiment, the base plate includes a U-shaped bracket adapted to fit the top surface of a concrete barrier.

These and other features and advantages of this invention will become more apparent to those skilled in the art from the detailed description of a preferred embodiment. The drawings that accompany the detailed description are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the heavy-duty surface mount post system of the present invention.

FIG. 2 is a partial perspective view of a fence assembly using the heavy-duty surface mount post system of the present invention.

FIG. 3 is a perspective view of the post base and shims of the present invention.

FIG. 4 is a partial perspective view of the post base and post assembled.

FIG. 5 is a perspective view of a second embodiment of the present invention.

FIG. 6 is a rear perspective view of a third embodiment of the present invention.

FIG. 7 is a front perspective view of FIG. 6.

FIG. 8 is a perspective view of a post wedge lower piece.

FIG. 9 is a further perspective view of FIG. 8.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The heavy-duty surface-mount post system of the present invention is shown generally at 10 in the figures. The post system 10 is used, for example, in mounting a fence 12, shown generally in FIG. 2. The fence 12 is shown with a post base plate 14, which can be mounted to a support surface, a post 3, and a fence panel assembly 15, which is mounted to the post 3. As illustrated, the fence panel assembly 15 is pre-assembled and mounted to the post 3 as a single unit. Four screws 17 are used to attach the panel assembly 15 between opposed posts 3, one of which is shown.

The post system 10 includes a post base 1. The post base 1 as illustrated includes base plate 14 to which a mounting member 16 is attached, for example, by welding. The base plate 14 has holes 18 for receipt of mounting bolts, which extend into a foundation, such as a concrete slab, to which the post base 1 is attached (not shown). The mounting member 16 is illustrated as a square tube, but as will be understood by those of ordinary skill in the art, could be other shapes, such as, for example, rectangular, triangular, round, oblong, pentagonal, hexagonal, etc. In the disclosed embodiment, the mounting member 16 is made of heavy gauge steel, 3½ inch square tube with ⅛-inch wall thickness. The base plate 14 is made of ¼ inch steel plate. The post base 1 is powder coated with a prime layer and a finish layer in the disclosed embodiment. In the disclosed embodiment, the post base is sandblasted, and then a primer coat is applied; the primer used is Primer Akzo Nobel Medium grey primer EL015QF. The finish coat is then applied and is Black texture Akzo Nobel AC Black JN507QF.

Shims 2 are positioned on the open top of the tube 16. In the disclosed embodiment, the shims are aluminum, but could be made from other material, such as for example, steel, stainless steel, plastic, etc. The shims 2 have an elongated body 20 and a finger 22 that is angled with respect to the body 20. The shims 2 are hooked over the open top of the tube 16, by placing the finger 22 on the inside of the tube 16 and draping the body 20 along the side of tube 16. The shims 2 hang from the top of the tube 16. This can be seen in FIG. 3. As illustrated, there are 4 shims, one per side of tube 16; however, those of ordinary skill in the art will understand that less or more shims could be used if desired.

Post 3 is configured to tightly fit over the tube 16 with the shims 2 creating a tight fit. In the disclosed embodiment, the post 3 is made of aluminum with a 4 inch outside diameter and 3¾ inside diameter. The shims 2 reduce or eliminate transverse movement of the post 3 with respect to the tube 16, restrict vertical movement and reduce or eliminate galvanic corrosion between the aluminum post 3 and the post base 1.

The shims 2 are self-forming when the post 3 is forced over the tube 16. The aluminum material allows for this self-forming deformation. The shims 2 allow for less specific tolerance requirements between the post 3 and the tube 16. The shims also reduce the contact area between the aluminum post and the tube 16 reducing or eliminating galvanic corrosion.

A universal post skirt 5 conceals the base plate 14 and fasteners 4 to give a decorative, finished appearance. As will be appreciated the skirt 5 is optional.

In FIGS. 6 and 7, an alternative design for the mounting system is illustrated. The shims 21, as shown, are made of plastic, but they could be made from other materials, such as steel, stainless steel, aluminum, etc. As previously described with respect to the shims 2, the shims 21 have an elongated body 20 and a finger 22. In this embodiment, ridges 23 are added to the body 20 and the fingers 22. The ridges 23 provide an additional separation of the post base 1 and post 3. The ridges 23 also provide a deformation surface for a tight fit. The shims 21 are hooked over the open top of tube 16 by placing finger 22 on the inside of tube 16 and draping body 20 along the side of tube 16. The shims 21 hang from the top of the tube 16.

With reference to FIGS. 8 and 9, the post wedge lower piece 25 is illustrated. The wedge 25 has a bottom 27, a body portion 29 and an opening 31 for receipt of the post base 1. The opening 31 can include ridges 33 if desired. The ridges 33 engage the base plate 14. The bottom 27 covers and hides the welds at the base plate 14. Additional ridges 35 are provided on the exterior of the body portion 29. The additional ridges 35 provide an additional separation between the post base 1 and post 3. The ridges 35 also provide a deformation surface for a tight fit. The wedge 25 is mounted over the post base 1. As with the shims 2 and 21, the body portion 29 and additional ridges 35 separate the post 3 from the post base 1 and provides a tight fit. The post 3 is positioned over the body portion 29 of wedge 25. The wedge 25, as shown, is made of plastic, but could be made from other materials, such as steel, stainless steel, aluminum, etc.

Fasteners 4 are used to further secure the post 3 to the tube 16. In this way, the post 3 is secured to the tube 16 and restricted from movement in any direction. The use of the shims 2 reduce the cost of manufacturing more precise tubes 16 and posts 3 and make assembly and installation easier.

In use several post bases 1 are mounted with bolts secured to a support structure such as a concrete slab or concrete base. The shims 2 are hung from the tubes 16 and the post 3 is slid down over the tubes 16. The tubes 16 are tightly received by the post 3, and the shims 2 automatically conform and adjust as the posts 3 are slid down over them. Once the posts 3 are fully slid down the tubes 16, fasteners 4 are screwed into the posts 3 and the tubes 16 to further secure them to one another. The optional post skirt 5 can then be positioned over and conceal the base plate 14 and fasteners 4 to give a decorative and finished appearance. The fence panel assemblies 15 can then be attached to the posts 3 to complete the fence.

In a further embodiment, the wedge 25 can be slid over the post base 1 to provided additional separation and fit. If the wedge 25 is used, the post skirt 5 would not be needed.

FIG. 5 shows an additional embodiment of the invention. In this embodiment, the application is for use on a barrier 50. The base plate 14 has been specially engineered to fit the top 52 of the barrier base 54. The base plate 14 has a u-shaped bracket 56 which receives mounting bolts 58.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.