U.S. patent application number 10/284961 was filed with the patent office on 2003-07-24 for post system.
Invention is credited to Gregori, Karl H W.
Application Number | 20030136077 10/284961 |
Document ID | / |
Family ID | 26962915 |
Filed Date | 2003-07-24 |
United States Patent
Application |
20030136077 |
Kind Code |
A1 |
Gregori, Karl H W |
July 24, 2003 |
Post system
Abstract
A post system comprises at least one building member and at
least one post. The post is made from a composite material and has
at lest nine longitudinally extending channels defined by channel
walls. The channels are linked to one another through the channel
walls. At least one channel has a portion of an outer channel wall
providing an opening sized to receive a portion of the building
member such that the building member can be received through said
opening into a slot formed in the post Also another post has at
least one channel for receiving a reinforcing element such as
tubular steel.
Inventors: |
Gregori, Karl H W;
(Hawkestone, CA) |
Correspondence
Address: |
Woodard, Emhardt, Naughton,
Moriarty & McNett LLP
Suite 3700
Bank one Center/Tower, 111 Monument Circle
Indianapolis
IN
46204-5137
US
|
Family ID: |
26962915 |
Appl. No.: |
10/284961 |
Filed: |
October 31, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60335196 |
Oct 31, 2001 |
|
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Current U.S.
Class: |
52/848 |
Current CPC
Class: |
E04H 17/1447 20210101;
E04C 3/29 20130101; E04H 17/1456 20210101; E04H 17/1465 20210101;
E04H 17/1439 20130101; E04C 3/36 20130101; E04H 17/146 20210101;
E04H 17/1413 20130101 |
Class at
Publication: |
52/736.1 ;
52/726.4 |
International
Class: |
E04C 003/30 |
Claims
1. A post for use with a fence or railing systems, said post made
from a composite material and said post comprising at least nine
longitudinally extending channels defined by channel walls, each of
said nine channels having walls inter-connected with at least one
other channel and said channels being arranged in a three by three
configuration, at least one channel having a portion of an outer
channel wall that is removable to provide an opening sized to
receive a portion of a building member, whereby a building member
can be received through said opening into a slot formed in said
post.
2. A post as claimed in claim 1 wherein said slot is defined by
channel wall portions in said post.
3. A post as claimed in claim 2 wherein said post is integrally
formed from a composite wood material.
4. A post as claimed in claim 1 wherein said nine channels includes
four corner channels and four intermediate channels, each of said
intermediate channels disposed between two corner channels, and
further comprising a middle channel disposed between each of said
four intermediate channels, and at least one of said intermediate
channels has a removable outer wall portion that can provide an
opening.
5. A post as claimed in claim 4 wherein at least two of said
intermediate channels and said middle channel have removable outer
wall portions that can provide at least two openings.
6. A post as claimed in claim 5 wherein said two openings are
interconnected through said middle channel to provide a continuous
slot through said post.
7. A post as claimed in claim 6 wherein said openings are at an end
portion of said post and said passageway is open at said end,
whereby one or more building members can be received into said
passage at said end and said one or more building members will
protrude from said post through said openings.
8. A post as claimed in claim 7 wherein one of said intermediate
channels has a first removable wall portion for providing a first
opening at an end of said post and a second removable wall portion
for providing a second opening between said first opening and said
second end,
9. A post as claimed in claim 1 wherein said channels are
configured to provide a transverse cross section that has a
perimeter that is substantially square in shape.
10. A system comprising at least one building member and at least
one post, said at least one post made from a composite material and
said at least one post comprising at least nine longitudinally
extending channels defined by channel walls, said channels being
linked to one another through said channel walls, at least one
channel having a portion of an outer channel wall providing an
opening sized to receive a portion of said building member such
that said building member can be received through said opening into
a slot formed in said post.
11. A system as claimed in claim 10 wherein said composite material
is a composite wood material.
12. A system as claimed in claim 1 wherein said opening receives a
post-supporting member.
13. A system as claimed in claim 13 wherein said channel walls have
a second opening.
14. A system as claimed in claim 13 wherein said second opening is
configured for receiving an additional building member.
15. A system as claimed in claim 14 wherein said first and second
openings in said channel walls, provide a continuous passageway
through said post.
16. A system as claimed in claim 13 wherein said first opening is
oriented at ninety degrees to said second opening.
17. A system as claimed in claim 13 wherein said first opening is
oriented at one hundred and eighty degrees to said second
opening.
18. A system as claimed in claim 13 wherein said first and second
openings are linked to provide an L-shaped passageway through said
post.
19. A system as claimed in claim 18 wherein said L-shaped
passageway is at an open end of said post and provides for
receiving an L-shaped portion of another building member therein
from said end of said post.
20. A system as claimed in claim 18 wherein said first and second
openings are at an end of said post.
21. A system as claimed in claim 13 further comprising third and
fourth openings through said channel walls.
22. A system as claimed in claim 21 wherein said third and fourth
openings are closer to a second end of said post than said first
end of said post.
23. A system as claimed in claim 11 wherein said post has first,
second and third openings in said channel walls, said first and
second openings at each end of said post, and said third opening at
a position intermediate said ends, said first, second and third
openings each receiving a building member, for connecting said
three building members to said post.
24. A system as claimed in claim 11 wherein said at least nine
channels include four corner channels and four intermediate
channels, each of said intermediate channels disposed between two
corner channels, at least one of said intermediate channels having
an outer channel wall with an opening for receiving a building
member, and wherein said corner channels are not as wide as said
intermediate channels.
25. A method of securing a post to a construction member, said post
made from a composite material and said post comprising at least
nine longitudinally extending channels defined by channel walls,
each of said channels being inter-connected and arranged in a three
channel by three channel configuration, said method comprising the
steps of: a) removing a part of an outer channel wall of a channel
to create an opening in said post; b) inserting a portion of said
construction member through said opening into a slot formed within
said post by said opening; c) securing said portion of said
construction member in said opening to attach said post to said
construction member with one or more fasteners.
26. A method as claimed in claim 25 in which said opening has a
width of approximately 1.5 inches and can accommodate the width of
a standard 2 inch wide piece of lumber.
27. A method as claimed in claim 25 wherein said composite material
is composite wood.
28. A method as claimed in claim 25 wherein said removal of said
part of said outer channel wall is by a cutting device.
29. A method as claimed in claim 25 further comprising the steps of
a) removing a part of a second outer wall of a second channel to
create a second opening in said post; b) inserting a portion of a
second construction member through said opening into a second slot
in said post formed by said second opening; c) securing said
portion of said second construction member in said second opening
to attach said post to said second construction member with one or
more fasteners.
30. A method as claimed in claim 29 wherein said post comprises at
least nine channels configured in a three by three channel
arrangement.
31. A post made from a composite wood material, said post
comprising at least nine longitudinally extending channels defined
by channel walls, arranged in a three channel by three channel
configuration, said plurality of channels adapted such that at
least one of said channel walls can be cut to provide an opening
forming a slot having slot walls formed from one or more of said
channel walls, said slot adapted to receive a building member
through said opening and into said slot, such that said post can be
attached to said building member and be stabilized by said slot
wall.
32. A post made from a composite wood material and comprising at
least one longitudinally extending channels defined by channel
walls, said channel having a strengthening element received herein
along at least part of its length.
33. A post as claimed in claim 32, wherein said post comprises at
least nine channels defined by walls and being arranged in a three
by three configuration.
34. A post as claimed in claim 33 wherein a strengthening element
is received in at least one corner channel of said three by three
channel arrangement.
35. A post as claimed in claim 33, wherein at least one channel has
a portion of an outer channel wall that is removable to provide an
opening sized to receive a portion of a building member, whereby a
building member can be received through said opening into a slot
formed in said post.
36. A post as claimed in claim 32 wherein said strengthening
element is made from a metal.
37. A post as claimed in claim 36 wherein said metal is steel.
38. A method of reinforcing a post made from a composite wood
material and said post comprising at least one longitudinally
extending channel defined by channel walls, said method comprising
the step inserting a strengthening element inside said channel
along at least part of its length.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. provisional
application No. 60/335,196 filed Oct. 31, 2001.
TECHNICAL FIELD
[0002] The present invention relates to posts, and post systems,
particularly composite wood posts and post systems.
BACKGROUND OF THE INVENTION
[0003] Fence and railing systems that employ posts are well known.
For example, such systems are often used as perimeter demarcations
for property and for protection of persons on decks, balconies and
the like, to prevent them from falling off.
[0004] Wood products have been one of the primary sources and
choices of materials for such systems. It is a relatively easy
material to work with when constructing a structure such as a fence
or railing system. Wood can be readily notched, grooved or cut
using conventional tools such as saws or drills. It is also
relatively easy to attach one piece of wood to another using such
fasteners as nails or screws.
[0005] Wood is one of the materials of choice when building a fence
or railing system, as standard size and shape posts can be easily
shaped and attached to supporting members and to other building
members such as rail or fence members.
[0006] However, wood is becoming scarce and expensive. Also,
untreated wood has a susceptibility to rot, particularly when used
in wet environments It is also susceptible to damage by pest
infestation. The treatment of wood with preservatives, however, has
drawbacks, including possible environmental concerns.
[0007] Alternate construction materials are known which can be used
in certain building applications. For example, vinyl siding is now
well known. Also, composite materials are becoming more popular,
including composite wood materials made from the combination of a
suitable resin and wood particles, flakes, fibers or the like. For
example, it is known to use composite wood material in producing
decking. However, in some applications these materials are not as
easy to work with as wood. In particular, using a composite
material in the construction of a fencing or railing system is
relatively difficult because of the need to have posts, which can
be readily adapted to one of several applications. For example,
when building a railing system for a deck, it is typically
necessary to firmly secure a series of posts to an underlying
supporting substructure, such as joists, at several locations and
in several orientations. Posts are usually needed at the corners of
the deck as well as at intermediate positions along the deck To
accomplish this, the posts may need to be configured in one of
several different shapes. A standard piece of wood (eg. 2.times.4
or 4.times.4 piece of lumber) can readily be modified with standard
workplace tools to form a connection portion of suitable
configuration. This is in part because such standard pieces of wood
are solid in cross section and thus select pieces of wood can
readily be removed to form a connecting portion or connecting
slot.
[0008] With posts made from composite materials, particularly
composite wood materials, shaping a piece of material for a
particular application is more difficult and time consuming. In
part, this is because cutting through composite materials such as
composite wood is much more difficult than cutting through wood.
More importantly, composite members are not created with solid
cross sections, one reason being because of the difficulty of
forming such members with conventional techniques. Without a solid
piece of material to work with, creating a connecting portion to
connect a composite member to another member is relatively
difficult.
[0009] Accordingly there is a need for a composite post that is not
a solid piece of material, but which is of such a configuration
that it can be easily adapted for use in a variety of different
construction situations.
SUMMARY OF THE INVENTION
[0010] One aspect of the present invention provides a post for use
with a fence or railing system, the post made from a composite
material and the post comprising at least nine longitudinally
extending channels defined by channel walls, each of the nine
channels having walls inter-connected with at least one other
channel and the channels being arranged in a three by three
configuration, at least one channel having a portion of an outer
channel wall that is removable to provide an opening sized to
receive a portion of a building member, whereby a building member
can be received through the opening into a slot formed in said
post.
[0011] In another aspect of the present invention a system
comprising at least one building member and at least one post, at
least one post made from a composite material and at least one post
comprising at least nine longitudinally extending channels defined
by channel walls, the channels being linked to one another through
the channel walls, at least one channel having a portion of an
outer channel wall providing an opening sized to receive a portion
of the building member such that the building member can be
received through the opening into a slot formed in said post.
[0012] In still another aspect of the present invention a method of
securing a post to a construction member, the post made from a
composite material and the post comprising at least nine
longitudinally extending channels defined by channel walls, each of
the channels being inter-connected and arranged in a three channel
by three channel configuration, said method comprising the steps
of:
[0013] a) removing a part of an outer channel wall of a channel to
create an opening in the post;
[0014] b) inserting a portion of the construction member through
the opening into a slot formed wills the post by the opening;
[0015] c) securing the portion of the construction member in said
opening to attach the post to the construction member with one or
more fasteners.
[0016] In still another aspect of the present invention, a post
made from a composite wood material, the post comprising at least
nine longitudinally extending channels defined by channel walls,
arranged in a three channel by three channel configuration, the
plurality of channels adapted such that at least one of the channel
walls can be cut to provide an opening forming a slot having slot
walls formed from one or more of the channel walls, the slot
adapted to receive a building member through the opening and into
the slot, such that the post can be attached to the building member
and be stabilized by the slot wall.
[0017] In still another aspect of the present invention a post made
from a composite wood material and comprising at least one
longitudinally extending channels defined by channel walls, the
channel having a strengthening element received therein along at
least part of its length.
[0018] In still yet another aspect of the present invention a
method of reinforcing a post made from a composite wood material
and the post comprising at least one longitudinally extending
channel defined by channel walls, the method comprising the step
inserting a strengthening element inside the channel along at least
part of its length.
[0019] Other aspects and features of the present invention will
become apparent to those ordinarily skilled in the art upon review
of the following description of specific embodiments of the
invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In drawings that illustrate by way of example only,
preferred embodiments of the present invention:
[0021] FIG. 1 is a perspective view of a composite post;
[0022] FIG. 1a is a perspective view of the post of FIG. 1, cut
away;
[0023] FIG. 1b is a top view of the post of FIG. 1;
[0024] FIG. 1c is a front view of the post of FIG. 1, the rear view
being the same;
[0025] FIG. 1d is a right side view of the post of FIG. 1, the left
side view being the same;
[0026] FIG. 1e is a bottom view of the post of FIG. 1;
[0027] FIG. 2a is a perspective view of the post of FIG. 1 adapted
to a first configuration;
[0028] FIG. 2b is a perspective view of the post of FIG. 2a, cut
away;
[0029] FIG. 2c is a top view of the post of FIG. 2a;
[0030] FIG. 2d is front view of the post of FIG. 2a, the rear view
being the same;
[0031] FIG. 2e is a right side view of the post of FIG. 2a, the
left side view being the same;
[0032] FIG. 2f is a bottom view of the post of FIG. 2a;
[0033] FIG. 2g is a perspective view of the post of FIG. 2a in use
in an environment;
[0034] FIG. 3a is a perspective view of the post of FIG. 1 adapted
to a first configuration;
[0035] FIG. 3b is a perspective view of me post of FIG. 3a, cut
away;
[0036] FIG. 3c is a top view of the post of FIG. 3a;
[0037] FIG. 3d is front view of the post of FIG. 3a, the rear view
being the same;
[0038] FIG. 3e is a right side view of the post of FIG. 3a, the
left side view being the same as FIG. 2e;
[0039] FIG. 3f is a bottom view of the post of FIG. 3a;
[0040] FIG. 3g is a perspective view of the post of FIG. 1 adapted
to a second configuration in an environment;
[0041] FIG. 4a is a front perspective view of tile post of FIG.
2;
[0042] FIG. 4b is a front perspective view of the post of FIG. 2,
cut away;
[0043] FIG. 4c is a top view of the post of FIG. 2;
[0044] FIG. 4d is a front view of the post of FIG. 2, the rear view
being the same as FIG. 1c;
[0045] FIG. 4e is a right side view of the post of FIG. 2;
[0046] FIG. 4g is a perspective view of the post of FIG. 1 adapted
to a third configuration in an environment;
[0047] FIG. 4f is a bottom view of the post of FIG. 2;
[0048] FIG. 5 is a perspective view of the post of FIG. 1 adapted
to a fourth configuration
[0049] FIG. 5a is a top view of the post of FIG. 5;
[0050] FIG. 5b is a perspective view of the post of FIG. 1 adapted
to a fifth configuration;
[0051] FIG. 5c is a top view of the post of FIG. 5b;
[0052] FIG. 5d is a perspective view of the post of FIG. 1 adapted
to a sixth configuration;
[0053] FIG. 5e is a top view of the post of FIG. 5b;
[0054] FIG. 5f is a perspective view of the post of FIG. 1 adapted
to a seventh configuration;
[0055] FIG. 5g is a top view of the post of FIG. 5f;
[0056] FIG. 5h is a perspective view of the post of FIG. 1 adapted
to a seventh configuration;
[0057] FIG 5i is a top view of the post of FIG. 5h;
[0058] FIG. 5j is a perspective view of the post of FIG. 1 adapted
to a eighth configuration;
[0059] FIG. 5k is a top view of the post of FIG. 5j;
[0060] FIG. 5l is a perspective view of three posts of FIG. 1
adapted to configuration permitting them to be employed in a
railing system;
[0061] FIG. 6 is a top view of two posts of FIG. 1 adapted for use
with a beam member;
[0062] FIG. 7 is a front elevation view of the combination of FIG.
6;
[0063] FIG. 8 is an isolated perspective view of a post one of the
posts illustrated in FIGS. 6 and 7, the other post being the
same;
[0064] FIG. 9 is an isolated perspective view of the post of FIG. 8
connected to a beam;
[0065] FIG. 10 is a perspective view of the composite post of FIG.
1 employed with several strengthening elements;
[0066] FIG. 11 is a perspective view of tee post of FIG. 10, with
one of walls cut away;
[0067] FIG. 12 is a perspective view of three posts of FIG. 10
adapted to a configuration that permits them to be employed in a
railing system;
[0068] FIG. 13 is a cross section view at 13-13 in FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0069] With reference to FIGS. 1 and 1a to 1e, a post 10 of width
W, depth D and length L, has a top end 10a and a bottom end 10b.
Post 10 is formed with elongated channels comprising corner
channels 12, intermediate channels 14 and a middle channel 16. Each
channel is defined by a series longitudinally extending channel
walls or web members. The channel walls are all integrally formed
with each channel 12, 14 and 16 sharing more than one channel wall
with another channel Thus, all the channels 12, 14 and 16 are
positioned adjacent to at least two channels through common wall
members. In a preferred configuration, each of the corner channels
12, have walls that provide for a channel that has an outer
perimeter that is substantially square in its transverse cross
section shape. Intermediate channels 14 preferably have wall
members that provide a channel that is greater in width than in
depth, thus providing a rectangular shaped channel in cross
section. This results in a middle channel 16, which is generally
square in shape but larger than corner channels 12 (FIGS. 1b and
1e). As will appreciated from the disclosure herein, variations are
possible from this preferred configuration of the nine channels
arranged in a three by three channel configuration.
[0070] Post 10 could possibly be made from composites of plastics,
and fibers including wood, elastomers, ceramics and glass.
Such-composite materials are quite suitable as these materials can
be extruded or pultruded to a desired configuration for post 10
using generally known extrusion or pultrusion techniques.
[0071] One of the most advantageous composites for post 10 is to
make it from a composite wood material. Such a product can be made,
for example, by combining wood fragments such as wood flakes,
strands, particles, chips and fibers with a resin, particularly a
thermoplastic resin, and then extruding the mixture through an
extruding die, and allowing the extruded product to fully set.
Examples of suitable resins include polyethylene and polypropylene.
Some examples of a composite wood materials and equipment and
methods that could be adapted to make a post 10 are disclosed in
U.S. Pat. No. 6,153,293to Dahl et al., U.S. Pat. No. 5,516,472 to
Laver and U.S. Pat. No. 5,088,910 to Gosforth et al. the contents
of each, being hereby incorporated herein by reference.
[0072] Although post 10 could be used without any adaptations being
made to it, it is contemplated that in most cases, the shape of
post 10 will have a modified shape when put to use. The initial
configuration of post 10 has been designed so that it is versatile
and can be easily modified on site in numerous different ways to
meet a particular construction situation. The modification to post
10 takes place by selectively removing part of one or more channel
walls to provide an opening and slot. The slot and opening can then
receive part of another building member, and the post can then be
firmly connected to the other building member with conventional
fasteners, such as nails, screws or the like. Selected portions of
the channel walls can be removed by conventional construction
tools, such as for example, reciprocating or circular saws.
[0073] By way of example, in FIGS. 2a-2f, a post 110 is shown in
which a post 10 has been adapted to a first configuration. Post 110
has an opening 120 made in it transversely through the outer and
inner walls of one set of opposed intermediate channels 114a and
114b, and walls of middle channel 116. This provides a slot 121
with inner side channel walls, and slot 121 passes through post
110. The opening 120 is made from the bottom end 110b of post 110
toward top end 110a. As is evident in FIG. 2g, post 110 can, for
example, be fitted to a supporting joist 140, which is received
into slot 121. Post 110 can then be secured to supporting joist 140
with conventional fastening devices providing a secure connection
between post 110 and joist 140. As many pieces of conventional
lumber (such as 2 .times.4, 2.times.6 and 2.times.8 members) are
approximately 1.5 inches wide, the width w1 (FIG. 2a) of slot 121
is preferably sized to snugly accommodate the width of such a piece
of lumber.
[0074] In FIGS. 3a-3f, a post 210 is shown which is a post 10
adapted to a second configuration. Like post 119, post 210 has a
first opening 220a made in it transversely through outer and inner
walls of one set of opposed intermediate channels 214a and walls of
middle channel 216a. This provides a slot 221a with side channel
walls (one of which has an opening or break in it). Slot 221a
passes straight through post 210. The opening 220a for slots 221a
is made from bottom end 110b part way towards top end 110a. A
second opening 220b is made in post 210 to provide a second slot
221b at right angles to slot 220a through walls of one intermediate
channel 214b. The combination of slots 221a and 221b provide a
combined slot that is T-shaped. As is evident from FIG. 3g, post
210 can be fitted at the intersection of supporting joist 240 and
supporting joist 242 from the end of post 210. This T-joint of
supporting joists 240, 242 is received into slots 221a, 222b. Post
210 can then be secured to supporting joists 240, 242 with
conventional fastening devices and/or the like, providing a secure
connection between post 210 and joists 240, 242. Again, it is
preferable that width W2 of the slots 221a, 221b throughout be just
wide enough to snugly receive the width of a standard 2.times.4,
2.times.6 or 2.times.8 piece of lumber which has a width of about
1.5 inches.
[0075] In FIGS. 4a-4f, a post 310 is shown which is a post 10
adapted to a third configuration. Post 310 has had a first slot or
opening 320a made in it transversely through the outer and inner
walls of one channel 314a, the inner wall of which is a shared wall
of the middle channel 316a, from bottom end 310b part way to top
end 310a. A second opening 320b is made at right angles to slot
320a through outer and inner walls of one channel 314b. This
provides a continuous L-shaped slot 321a, 321b as illustrated in
FIGS. 4f and 4g. Post 310 can thus be fitted to an end of post 310
to the L-shaped intersection of supporting joist 340 and supporting
joist 342. This L-joint of supporting joists 340, 342 is received
into L-shaped slot 321a, 321b. Post 310 can then be secured to
supporting joists 240, 242 with conventional fastening devices
and/or the like providing a secure connection between post 310 and
joists 340, 342.
[0076] Alternatively, or in addition to modifying post 10 to be
secured to supporting members as depicted in FIGS. 2g, 3g and 4g,
post 10 can be modified in other ways to be secured to other
building members For example, FIGS. 5 to 5k illustrate other
possible configurations that can be readily formed from post 10
shown in FIG. 1a, and thus are suitable for use in other building
situations.
[0077] It should be noted That in each case when the opening is
made in some of the walls of one or more channels to form a slot,
by removal of a portion of a channel wall, the slot or slots are
defined by inner channel walls that provide side walls for the
slots. These slot sidewalls help to stabilize any building member
That is received into the slot.
[0078] In FIGS. 5 and 5a, a post 410 is shown having a first slot
420 formed at one end of post 410 by removal of one outer wall of
channel 414a (FIG. 5a) a part way from end 410a. A second slot 420b
is formed by removal of an additional part of the same outer wall
of channel 414a at a location between slot 420a and the second end
410b of post 410. Thus, slots 420a and 420b can both accommodate
building members such as ends of railing members.
[0079] Post 510 in FIGS. 5b and 5c bas the same configuration as
post 410 except that slots 420a and 420b are bot extended within
post into and through the second opposite inner wall of channel
514a into channel 516. This permits building members to be received
further into post 510.
[0080] Post 610 in FIGS. 5d and 5e is the same as post 510 except
that slots 620a and 620b extend completely through post 610--in
particular through outer and inner walls of channel 614a, 616 and
614c. Parts of building members can be received in slots 620a,
620b, passing completely through post 610. Thus a portion of a
building member that is not an end can be securely attached to post
610 through slots 620a and 620b. Alternatively, each of the slots
can receive an end portion of a building member at each or the two
slot openings.
[0081] Post 710 shown in FIGS. 5f and 5g has two end slots 720a and
720b oriented at right angles to each other and two intermediate
slots 720c and 720d also oriented at right angles to each other.
Slots 720a and 720c are formed by removing the outer wall of
channel 714a along parts of its length. Slots 720b and 720d are
formed by removing the outer wall of channel 714b along parts of
its length and each are suitable for receiving for example an end
portion of a building member
[0082] Post 810 shown in FIGS. 5h and 5i has two sets of slots;
each set comprising four slots. The first set of slots 820a-820d is
located at an end 810a. The second set of slots 820e-820h is
located between the first set of slots 820a-820d and end 810b. Each
of the slots is formed by removing a part of one of the outer walls
of channels 814a-814d. Each of the slots is configured to receive
for example, an end portion of a building member.
[0083] Post 910 illustrated in FIGS. 5j and 5k is substantially a
combination of post 410 and post 610. Slots 920a and 920c are the
same as slots 620a and 620b, and form a passageway completely
through post 910 Slots 920b and 920d on the other hand are formed
only by the lack of part of outer channel wall in channel 914c.
[0084] In FIG. 51, a series of posts 630, 730 and 830 (each made
from a post 10) are shown in an arrangement whereby they can be
connected to a supporting joist structure generally designated 840,
a series of medial rail members 740 and a series of upper rail
members 640.
[0085] With reference to FIG. 8, a further configuration to which a
post 10 can be adapted is shown. In this configuration, post 1010
has a pair of ledges 1020 and 1021 on each side of a medial portion
1019. As shown in FIG. 9, post 1010 can be employed to support
joist or beam members 1040 which themselves are interconnected to a
middle joist or beam member 1042. Post 1010 can be appropriately
sized so members 1040 could be, for example, standard 2.times.8 or
2.times.10 lumber.
[0086] As shown in FIGS. 6 and 7, two posts 1010a and 1010b are
shown supporting members 1040 and 1042.
[0087] In use, a post 10 is provided which may be any one of
several standard lengths. As the post is constructed from several
channels, each channel formed with channel walls that for a
composite wood material are preferably in the range of about 5 to 7
millimeters in thickness. However, the wall thickness can be
altered for specific applications. A post constructed in such a
manner can relatively easily by cut using standard construction
tools such as reciprocating saws, circular saws or the like.
[0088] The foregoing demonstrates the versatility of the composite
post described herein. With one standard cross sectional
configuration (e.g. post 10) being supplied to a construction site,
a worker can take the standard post and easily modify it to suit a
particular construction situation. It will however be appreciated
by persons skilled in the art the limits of load bearing capacity
of such posts is dependent upon the composite material selected
among other factors.
[0089] The load bearing capacity of post 10 can, however, be
increased, by the use of reinforcing elements, as illustrated in
FIGS. 10 to 12. It has been recognized that the compressive
strength of composite wood material is relatively high compared to
its tensile strength. To increase the overall strength of a post
1210 (FIGS. 10 and 11) one or more of channels 1214, 1214, and 1216
can have a strengthening element 1233 inserted therein. It is
preferred in most applications that the elements 1233 are received
in corner channels 1212 or center channel 1216. Strengthening
elements can be selected from a wide variety or materials having
good tensile strength properties such as steel, aluminum, fiber
glass. concrete and even solid wood. Metals are a preferred type of
material and in many applications tubular steel tubing is preferred
to provide the required reinforcement.
[0090] The dimensions of post 1210, including the size of channels
1212 and 1216, including the respective wall thickness can be
chosen such standard 1 inch by 1 inch tubing can be received in
channels 1212 and/or standard 1.5 by 1.5 inch tubing can be
received in channels 1216.
[0091] In most applications it is not necessary to affix the
elements 1233 inside the channels of a composite wood post 1210.
However, there is likely to be some indirect connection between the
post 1210 and at least some of the elements 1233 by virtue of the
connections that are made between the post and other structural
members (see for example FIGS. 12 and 13).
[0092] In addition to providing overall increased strength
performance of the post 1210, strengthening elements also can be
particularly useful in providing a strong connection location for
post 1210 to be secured to other structural members. In the absence
of a strengthening element 1233, securing connectors such as bolts
through the channel walls of a post, can cause channel walls to be
loaded beyond their load bearing capacity at the connection
locations The channel walls might be crushed or otherwise damaged,
if for example bolts must be highly tightened in making a
connection to an underlying supporting substructure. As illustrated
in FIGS. 12 and 13, bolts 1244 pass through a pair of opposite
channels 1211, their respective strengthening elements 1233 and a
joist 1240. It will be appreciated That nuts 1255 can be tightened
much further without risking the collapse of the channel walls or
channels 1212.
[0093] It should be noted that although in the arrangement of FIG.
12, elements 1233 are employed in both corner channels 1212 and
center channel 1216, the element in channel 1216 will run only to
the top of joist 1240.
[0094] Posts 1210 could be provided for use with elements 1233
already placed into one or more of the channels. However, it is
preferred that one or more posts and one of more strengthening
elements be provided separately (in one embodiment as a kit), such
that de elements can be used as needed in each post in each
particular application.
[0095] Further variations are contemplated within the scope of the
invention, which is defined by the claims following hereafter. By
way of example, it is not necessary that the post be configured
with just nine channels arranged in a free by three channel
configuration. For example, the post could have additional
channels, such as twelve channels, with the channels arranged in a
four by three channel configuration.
* * * * *