Post-to-base attachment

Abstract

A post-and-base apparatus, including a substantially rigid base formed with a mounting surface and an opposing surface thereon, and an aperture formed into the mounting surface, the aperture having a non-round interior sidewall surface extending at least partially through the body toward the opposing surface. A substantially rigid post is formed with a non-round locking structure adjacent to a first end thereof, the non-round locking structure forming an external sidewall surface that is structured to fit into the non-round aperture in a rotational locking relationship relative thereto. A body of substantially rigid load-bearing material is formed an aperture, and a fastener is coupled between the locking structure and the opposing surface of the base with the body of load-bearing material interposed there between.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a means for attaching a post to a base, and in particular to a means for permanently attaching a post perpendicular to a base and rotationally fixing the post relative to the base.

BACKGROUND OF THE INVENTION

[0002] Many methods and devices are known for attaching posts to bases. Those methods that permanently attach the post and fix it rotationally relative to the base include, for example, soldering, welding, gluing, and bolting or screwing the post to the base. The first three, soldering, welding, and gluing, all involve a chemical bond. Known forms of the latter, bolting or screwing the post to the base, require multiple fasteners to additionally fix the post rotationally relative to the base. These methods thus require the materials, i.e., multiple bolts or screws, and both time and labor to install the multiple fasteners. Additionally, the post must present a large enough footprint on the base to receive the multiple fasteners.

SUMMARY OF THE INVENTION

[0003] The present invention overcomes the manufacturing and post size limitations of the prior art by providing a faster, more efficient method for permanently attaching a post perpendicular to a base while simultaneously fixing the post rotationally relative to the base.

[0004] Large size posts and bases are difficult to mold integrally in a single mold. Furthermore, when large sized, the integrally molded post and base combination are difficult to fit into secondary machines for secondary operations, such as over-molding and vulcanizing a nitrile rubber or other resiliently pressure deformable coupler onto an end of the post opposite from the base. Therefore, although the invention is practicable using any size post with any size base plate, according to the present invention, a combination post and base plate is formed of a base plate having a body of substantially rigid material, the body being formed with a mounting surface on one side and an opposing surface on an opposite side from the mounting surface. A polygonal or other non-round aperture is formed into the mounting surface and has a plurality of interior sidewall surfaces that extend at least partially through the body toward the opposing surface. A post having a body of substantially rigid material is formed with a polygonal or other non-round locking structure projected from a first end thereof, the polygonal locking structure has a plurality of external sidewall surfaces and is structured to fit into the aperture in the body of the base plate and to nest therewith. A fastener is coupled into the locking structure for securing the post relative to the mounting surface of the base plate. A body of substantially rigid load-bearing material is interposed between the opposing surface of the body and a clamping portion of the fastener, the body of load-bearing material is formed with a bearing surface thereon for engaging the clamping portion of the fastener and a clearance aperture that is formed through the body of material and the bearing surface and is sized to pass the fastener there through.

[0005] According to different aspects of the invention, plurality of interior sidewall surfaces of the polygonal or other non-round aperture extend either entirely through the body to the opposing surface, or only partially through the body to an intervening surface part way through the body, whereby the plurality of interior sidewall surfaces of the polygonal or other non-round aperture form a cavity that extends into the body of the base plate from the mounting surface. When the plurality of interior sidewall surfaces of the polygonal or other non-round aperture extend either entirely through the body to the opposing surface, the body of load-bearing material interposed between the opposing surface of the body and a clamping portion of the fastener is, for example, a metal washer. In the second case where the plurality of interior sidewall surfaces of the polygonal or other non-round aperture form a cavity that extends into the body of the base plate, the body of load-bearing material interposed between the opposing surface of the body and a clamping portion of the fastener is a portion of the base plate material having an aperture sized to pass the fastener there through.

[0006] According to different aspects of the invention, plurality of interior sidewall surfaces of the polygonal or other non-round aperture are either substantially perpendicular to the mounting surface of the base plate, or are inclined relative thereto. In either case, the polygonal or other non-round locking structure projected from a first end of the post is similarly structured to mate with aperture in the base plate and to nest therewith.

[0007] According to different aspects of the invention, the fastener is a male threaded member, such as a bolt or screw, and the clamping portion of the fastener is provided by a head portion formed on one end thereof A female threaded bore is provided in an end surface of the locking structure of the post to receive the male threaded member. Alternatively, the fastener is a male threaded stud coupled to the end surface of the locking structure of the post and receives a mating female threaded member or nut that provides the clamping portion of the fastener.

[0008] According to one aspect of the invention, a nitrile rubber or other resiliently pressure deformable coupler is vulcanized onto an end of the post opposite from the base.

[0009] Other aspects of the invention are detailed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0011] FIG. 1 is a bottom perspective view of the post-to-base attachment of the invention;

[0012] FIG. 2 is a bottom perspective view of an alternative embodiment of the post-to-base attachment of the invention;

[0013] FIG. 3 is a bottom perspective exploded view of the post-to-base attachment of the invention;

[0014] FIG. 4 is a top perspective exploded view that illustrates another embodiment of the post-to-base attachment of the invention;

[0015] FIG. 5 is a downward partial perspective exploded view that illustrates another alternative embodiment of the post-to-base attachment of the invention; and

[0016] FIG. 6 is a downward perspective exploded view that illustrates yet another alternative embodiment of the post-to-base attachment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0017] In the Figures, like numerals indicate like elements.

[0018] FIG. 1 illustrates the present invention by example and without limitation embodied as an assembly 10 of a post 12 attached to a base plate 14. The post 12 and base plate 14 are shown, by example and without limitation, as round or cylindrical, and flat and rectangular, respectively. However, the practitioner will easily recognize by the follow description of the present invention, that the method of the invention is applicable to any shape of both post and base plate. Therefore, any shape of both post and base plate is considered to be equivalent to the shapes illustrated, and Other conventionally and unconventionally shaped post 12 and base plate 14 are also contemplated and may be substituted without deviating from the scope and intent of the present invention. According to one embodiment of the present invention, the post 12 and base plate 14 are both formed of a rigid material, such as but not limited to metal or plastic.

[0019] FIG. 1 illustrates the post 12 as a short and round or cylindrical rod having a substantially part-spherical coupler 16 formed on one end 18 opposite from the base plate 14. By example and without limitation, the part-spherical coupler 16 is formed of a resiliently pressure-deformable material, such as a nitrile rubber, although another resiliently pressure-deformable material may be substituted without deviating from the scope and intent of the present invention. The coupler 16 is bonded to the end 18 of the post 12, by example and without limitation, by over-molding and vulcanization, although another bonding process, such as adhesive bonding, may be substituted without deviating from the scope and intent of the present invention. Thus, the coupler 16 is, by example and without limitation, a coupler of the type disclosed by Carnevali, the inventor of the present invention, in U.S. Pat. No. 5,845,885, "Universally Positionable Mounting Device," issued Dec. 8, 1998, the complete disclosure of which is incorporated herein by reference. A mechanical fastener 20, such as but not limited to a Philips flat head machine screw, a socket head screw, a flat head screw, a fillister head screw, a round head screw, an oval head screw, a hexagon "hex" head screw, or another screw-type threaded fastener, is used to couple the post 12 to the base plate 14. Another non-threaded fastener, such as a rivet, is optionally substituted for the screw fastener illustrated without deviating from the scope and intent of the present invention. Although one fastener 20 is illustrated, multiple fasteners 20 are optionally provided, without deviating from the scope and intent of the present invention. An substantially rigid intermediate washer 22, such as but not limited to a conventional metal finish washer, a flat washer, a lock washer, or a fender washer, is optionally provided between the fastener head 24 and a non-mounting or bottom surface 26 of the base plate 14 opposite from the post 12. The washer 22 operates as a body of substantially rigid load-bearing material against which the fastener head 24 operates as a clamping portion of the fastener 20 that acts to secure the post 12 to the base plate 14. According to one embodiment of the present invention, the fastener 20 is a Philips flat head machine screw used in combination with a finish washer 22.

[0020] The washer 22 is optionally omitted from the assembly 10, without deviating from the scope and intent of the present invention.

[0021] Optionally, one or more fastener apertures 28 are provided through the base plate 14 for fastening to an external surface. Alternatively, the apertures 28 are deleted, and the base plate 14 is secured to an external surface using a method, such as soldering, brazing, welding, or gluing, that does not require the apertures 28.

[0022] FIG. 2 illustrates an alternative embodiment of the assembly 100 of the present invention, where in one or more stand-off spacers 30 are provided on the bottom surface 26 for offsetting the bottom surface 26 from an external surface a sufficient distance to adequate provide clearance for the head 24 of the fastener 20. The base plate 14 is optionally formed by molding or forging, whereby the spacers 30 are optionally integral with the base plate 14. The spacers 30 optionally include apertures 32 there through as clearance for the fasteners 20. Accordingly, the apertures 32 are substantially aligned with the apertures 28 through the base plate 14.

[0023] FIG. 3 is a bottom perspective exploded view that illustrates the practice of the post-to-base attachment of the present invention. The base plate 14 is formed according to the following steps which are optionally performed in any convenient order and are explained in the present sequence, by example and without limitation, to demonstrate the invention. Alternate sequences are also contemplated and may be substituted without deviating from the scope and intent of the present invention. According to one embodiment of the present invention, the base plate is formed by molding, cutting, stamping, machining, forging, casting or another conventional forming process appropriate for use with the material selected for practicing the invention. If formed in a single operation, such as molding, the base plate 14 is simultaneously formed with a body 34 and a non-round or non-cylindrical aperture 36 that optionally extends entirely through the body 34 between the bottom surface 26 and a mounting or top surface 38 upon which the post 12 is mounted. The fastener apertures 28, if present, and the stand-off spacers 30, also if present, are formed simultaneously formed with the body 34 and non-round aperture 36. Else, the body 34, non-round aperture 36, fastener apertures 28, if present, and the stand-off spacers 30, also if present, are formed in any order or combination that is convenient for the practitioner and appropriate for the material selected for practicing the invention.

[0024] The size, shape, material and other physical properties of the body 34 are not relevant to practicing the invention. However, according to one embodiment of the present invention, the body 34 is substantially rigid and is formed of injection molded plastic. The non-round aperture 36 is formed through a portion of the body 34 at any desired location. The non-round aperture 36 is formed in any selected shape, including triangular, rectangular, square, diamond, parallelogram, pentagonal, hexagonal, heptagonal, octagonal, or having any larger number of straight and substantially flat or planar interior sidewall surfaces 40 that are optionally formed substantially perpendicular to the mounting surface 38, with adjacent sidewall surfaces 40 forming substantially linear intersections 42. Optionally, the non-round aperture 36 is curved, including elliptical, kidney, heart, wave, or free-form shapes. The only limitation on the non-round aperture 36 is that it is not round. Optionally, the non-round aperture 36 is a combination of straight and curved portions, for example, straight sides having curved intersections, or curved sides having straight line intersections, or combinations of straight and curved sides, such as half-circle or round-topped square or long straight sides joined at their ends by half-circle sidewalls. However, for ease of manufacturing, the non-round aperture 36 is formed with the multiple straight and intersecting interior sidewalls 40.

[0025] The post 12 is formed having a body 43 formed of a substantially rigid material according to the following steps which are optionally performed in any convenient order and are explained in the present sequence, by example and without limitation, to demonstrate the invention. Alternate sequences are also contemplated and may be substituted without deviating from the scope and intent of the present invention. According to one embodiment of the present invention, the post 12 is formed by molding, cutting, machining, forging, casting or another conventional forming process appropriate for use with the substantially rigid material selected for practicing the invention. A base end 44 of the post 12 is formed with a substantially flat or planar end surface 46 that is sized at least larger than the minimum width of the aperture 36, that is to say larger than a distance between interior flat sidewalls 40 on opposite sides of the aperture 36 through the base plate body 34, whereby the base end 44 of the post 12 cannot enter into the smaller aperture 36. The top surface 38 of the base plate 14 thus operates as a stop for the post base end 44 against which the post base end 44 rests. Optionally, the flat end surface 46 is sized larger the maximum width of the aperture 36, that is to say larger than the larger distance between intersections 42 between adjacent flat sidewalls 40 on opposite sides of the aperture 36 through the base plate body 34, whereby the base end 44 of the post 12 completely covers the aperture 36.

[0026] The flat end surface 46 of the post 12 is embossed with a raised non-round locking structure 48 that is optionally substantially flat or planar on its end surface 50. The raised non-round locking structure 48 is formed with substantially flat or planar outside or exterior sidewall surfaces 52 that are optionally formed substantially perpendicular to the planar end surface 46 of the post 12, with adjacent sidewall surfaces 52 forming substantially linear intersections 54. The raised non-round locking structure 48 complements and cooperates with the non-round aperture 36, that is to say the raised non-round locking structure 48 is slightly smaller overall than the non-round aperture 36, and its exterior sidewall surfaces 52 are shaped and angularly oriented substantially identically with the interior flat sidewall surfaces 40 of the non-round aperture 36. Accordingly, the raised non-round locking structure 48 fits into the aperture 36 with its exterior sidewall surfaces 52 oriented substantially parallel with the interior sidewall surfaces 40 of the aperture 36 and intersections 54 of its exterior sidewall surfaces 52 nesting with the intersections 42 between adjacent flat sidewalls 40 of the non-round aperture 36. Thus, when the post 12 is mounted on the top surface of the base plate 14 having the raised locking structure 48 engaged with the non-round aperture 36, as illustrated in FIGS. 1 and 2, the raised non-round locking structure 48 is thus substantially unable to rotate within the non-round aperture 36 and the post 12 is substantially rotationally fixed or locked relative to the base plate 14.

[0027] The raised locking structure 48 is sized the same length or shorter than the thickness "T" of the base plate 14, at least in the area surrounding the aperture 36 if the base plate 14 includes variations in thickness. Therefore, when engaged with the aperture 36 and having the end surface 46 flush against the top surface 38 of the base plate 14, the raised locking structure 48 does not penetrate all the way through the aperture 36 and does not protrude from the base plate bottom surface 26.

[0028] Additionally, the end surface 50 of the raised locking structure 48 is pierced with one or more female threaded bore 56 (one shown) that is or are smaller than the locking structure end surface 50 so that the female threaded bore 56 lies entirely within the smallest width of the end surface, that is to say is completely encompassed by the locking structure exterior sidewall surfaces 52. According to one embodiment of the present invention, the post 12 is formed of injection molded plastic. When the post 12 is formed of injection molded plastic or another soft material, such as aluminum, the threaded bore 56 is optionally structured oversize relative to the mating fastener 20, and a threaded insert of type well-known in the art is installed in the bore to provide more robust threads. The female threaded bore 56 is formed with any thread type and diameter-pitch combination desired, including but not limited to Unified and American Standard in coarse, fine, extra-fine, 8 thread, 12 thread, 16 thread, and in any of the eight recognized thread classes, including Classes 1A, 2A, 3A, 1B, 2B, 3B, class 2 and class 3. The threads are optionally right-hand or left-hand. Optionally, the female threaded bore 56 is formed with threads according to any of the international standards, including but not limited to Whitworth, British Association, French metric and International metric thread standards. Optionally, the female threaded bore 56 is formed with threads according to any of the power-transmission standards, including but not limited to Acme, 29 degree general purpose, 29 degree stub, 60 degree stub and 10 degree modified square thread standards. Optionally, the female threaded bore 56 is formed with threads according to any of the pipe thread standards, including but not limited to American Standard taper, American Standard straight, and American Standard Dryseal pipe thread standards.

[0029] The fastener 20 is a screw or bolt or other fastener having a male thread type and diameter-pitch combination along at least a portion of its shaft 58 that is structured to mate with the threads of the female threaded bore 56 in the end surface 50 of the raised locking structure 48.

[0030] The intermediate washer 22 is formed there through with an interior aperture 60 that is sized to fit over the male threaded shaft 58 of the fastener 20, and an outer diameter 62 that is sized at least larger than the minimum width of the aperture 36, that is to say the washer outer diameters 62 is sized larger than a distance between interior flat sidewalls 40 on opposite sides of the aperture 36 through the base plate body 34, whereby the washer 22 overlaps a portion of the base plate bottom surface 26 adjacent to the aperture 36 and cannot enter into the aperture 36. The bottom surface 26 of the base plate 14 thus operates as a bearing surface for the washer 22 against which a far-side flat surface 64 of the washer 22 rests. Optionally, the flat washer outer diameter 62 is sized larger the maximum width of the aperture 36, that is to say larger the washer flat surface 64 is sized than the larger distance between intersections 42 between adjacent flat sidewalls 40 on opposite sides of the aperture 36 through the base plate body 34, whereby the washer far-side flat surface 64 completely covers the aperture 36.

[0031] The shaft 58 of the fastener 20 is sized long enough to reach between a near-side surface 66 of the washer 22 and into the female threaded bore 56 in the end surface 50 of the raised locking structure 48 of the post 12 to an extent that at least a first two male threads of the shaft 58 engage a first two female threads of the threaded bore 56. Optionally, additional male threads of the shaft 58 engage additional female threads of the threaded bore 56. The relative lengths of the fastener shaft 58 and threaded bore 56 are coordinated to the extent that, when the raised locking structure 48 of the post 12 is engaged with the base plate aperture 36 and the post end surface 46 is seated flush against the top surface 38 of the base plate 14, the threaded fastener 20 is engaged with the threaded bore 56 such that the head 24 of the fastener 20 is tightly seated against the near-side surface 66 of the washer with the far-side washer surface 64 flush and tightly seated against the bottom surface 26 of the base plate 14 opposite from the post 12. Thus, the washer 22 operates as a bearing surface for the fastener head 24 to bear against the bottom surface 26 of the base plate 14.

[0032] Alternatively, the washer 22 is omitted. For example, according to one embodiment of the invention, the fastener head 24 is sufficiently large relative to the base plate aperture 36 as to overlap a portion of the base plate bottom surface 26 adjacent to the aperture 36 and cannot enter into the aperture 36. The bottom surface 26 of the base plate 14 thus operates as a bearing surface for the fastener head 24 against which to rest. In such case, the relative lengths of the fastener shaft 58 and threaded bore 56 are coordinated to the extent that, when the raised locking structure 48 of the post 12 is engaged with the base plate aperture 36 and the post end surface 46 is seated flush against the top surface 38 of the base plate 14, the threaded fastener 20 is engaged with the threaded bore 56 such that the head 24 of the fastener 20 is flush and tightly seated directly against the bottom surface 26 of the base plate 14 opposite from the post 12.

[0033] A thread locking compound, of which several are well-known, is optionally provided between the threaded fastener 20 and the threaded bore 56 such that the fastener 20 is rotationally fixed or locked relative to the bore 56.

[0034] Upon engagement of the raised locking structure 48 of the post 12 with the base plate aperture 36 and having the post end surface 46 seated flush against the top surface 38 of the base plate 14, and the threaded fastener 20 is engaged with the threaded bore 56, with or without the optional washer 22 in between, the assembly 10 is complete with the post 12 secure against the top surface 38 of the base plate 14 and simultaneously rotationally fixed or locked relative to the base plate 14.

[0035] FIG. 4 is a downward perspective exploded view that illustrates an alternative embodiment of the assembly 10 of the post 12 attached to the base plate 14. Accordingly, the non-round aperture 36 formed in the body 34 of the base plate 14 is optionally formed as a closed-end cavity that extends only part way through the body 34 between the top surface 38 upon which the post 12 is mounted through to an intervening surface 68 part way through the body 34. The non-round aperture 36 is formed in any selected shape, including by example and without limitation in a rectangular or square shape having four straight and substantially flat or planar interior sidewall surfaces 40, with adjacent sidewall surfaces 40 forming the substantially linear intersections 42. For example, the non-round aperture 36 is formed with the intervening surface 68 during a molding or casting operation during which the base plate 14 is formed. Alternatively, the non-round aperture 36 and intervening surface 68 are formed in a metal base plate 14 by a secondary operation, such as stamping, forging, or machining.

[0036] An aperture 70 is formed through a remaining thickness of the body 34 between the intervening surface 68 and the bottom surface 26. The aperture 70 is structured as a clearance hole for the fastener 20 to pass through. Floor material 72 of the body 34 remaining between the intervening surface 68 and the bottom surface 26 operates in the same capacity as the washer 22 in the embodiments of FIGS. 1-3. In other words, the remaining floor material 72 operates as a body of substantially rigid load-bearing material having a bearing surface against which the fastener 20 acts to secure the post 12 to the base plate 14. The floor material 72 and the fastener clearance-hole aperture 70 there through permit the washer 22 to be omitted as an option.

[0037] Optionally, when the floor material 72 is thicker than is convenient for a desired fastener 20, a counter surface 74, formed by example and without limitation as a counterbore aperture, is formed in the bottom surface 26 substantially aligned with the fastener clearance-hole aperture 70. The counterbore aperture 74, if present, is sized to at least receive the fastener head 24, and optionally is sized to further receive the intermediate washer 22, if present. According to one embodiment of the invention, the counterbore aperture 74 is deep enough that the fastener head 24 is completely below the bottom surface 26 when installed in the fastener clearance-hole aperture 70. The depth of the counterbore aperture 74 is determined, in combination with the depth of the non-round aperture 36 to the intervening surface 68 and the thickness T of the base plate body 34, to ensure that at least a minimum thickness "t" of the floor material 72 remains between the intervening surface 68 and a floor 76 of the counterbore aperture 74 to operate as the bearing surface for the fastener head 24, or washer 22 if present, to bear against the base plate 14 opposite from the top surface 26. When the fastener 20 is formed with a conical head 24, such as a Philips flat head machine screw or a flat head screw, rather than the planar head 24 of the socket head screw illustrated here, the counter surface 74 is instead formed as a countersink aperture at an angle selected to cooperate with the head 24 of the selected fastener 20. The depth of the countersink aperture 74 is also determined, in combination with the depth of the non-round aperture 36 to the intervening surface 68 and the thickness T of the base plate body 34, to ensure that at least the minimum thickness t of the floor material 72 remains between the intervening surface 68 and the floor 76 of the countersink aperture 74 to operate as the bearing surface for the fastener head 24, or washer 22 if present, to bear against the base plate 14 opposite from the top surface 26.

[0038] The base end 44 of the post 12 is formed with the substantially flat or planar end surface 46 that is sized at least larger than the minimum width of the non-round aperture 36, that is to say larger than a distance between interior flat sidewalls 40 on opposite sides of the aperture 36 part way through the base plate body 34, whereby the base end 44 of the post 12 cannot enter into the smaller aperture 36. The top surface 38 of the base plate 14 thus operates as a stop for the post base end 44 against which the post base end 44 rests. Optionally, the base end 44 of the post 12 completely covers the aperture 36.

[0039] The flat end surface 46 of the post 12 is embossed with the raised non-round locking structure 48 that is optionally substantially flat or planar on its end surface 50. The raised locking structure 48 is formed with the substantially flat or planar exterior sidewall surfaces 52 that form substantially linear intersections 54. The raised non-round locking structure 48 complements and cooperates with the non-round aperture 36, that is to say the raised locking structure 48 is slightly smaller overall than the aperture 36, and its exterior sidewall surfaces 52 are shaped and angularly oriented substantially identically with the interior flat sidewall surfaces 40 of the aperture 36. Accordingly, the raised non-round locking structure 48 fits into the non-round aperture 36 with its exterior sidewall surfaces 52 oriented substantially parallel with the interior sidewall surfaces 40 of the non-round aperture 36 and intersections 54 of its exterior sidewall surfaces 52 nesting with the intersections 42 between adjacent flat sidewalls 40 of the non-round aperture 36. Thus, when the post 12 is mounted on the top surface of the base plate 14 having the raised non-round locking structure 48 engaged with the non-round aperture 36, as illustrated in FIGS. 1 and 2, the raised non-round locking structure 48 is thus substantially unable to rotate within the non-round aperture 36 and the post 12 is substantially rotationally fixed or locked relative to the base plate 14.

[0040] The raised non-round locking structure 48 is sized the same length or shorter than a depth "d" of the closed-end non-round aperture 36. Therefore, when engaged with the non-round aperture 36 and having the end surface 46 flush against the top surface 38 of the base plate 14, the raised non-round locking structure 48 does not penetrate all the way into the non-round aperture 36 and does not engage the intervening surface 68.

[0041] Additionally, the end surface 50 of the raised locking structure 48 is pierced with the one or more female threaded bore 56 (one shown) that is or are smaller than the locking structure end surface 50. According to one embodiment of the present invention, the post 12 is formed of injection molded plastic. When the post 12 is formed of injection molded plastic or another soft material, such as brass or aluminum, the threaded bore 56 is optionally structured oversize relative to the mating fastener 20, and a threaded insert of type well-known in the art is installed in the bore to provide more robust female threads.

[0042] According to one embodiment of the present invention, a planar contact surface is provided on the end surface 46 of the post 12 by three or more feet 78 that protrude from the end surface 46. The feet 78 form a plane such that the post 12 sits flush against the top surface 38 of the base plate 14 without rocking when the top surface 38 is non-planar. Alternatively, the feet 78 protrude from the top surface 38 for the end surface 46 of the post 12 to rest against. It is well-known in the art that providing a planar surface is easier to accomplish on three small points than on a larger unbroken surface, such as the area of the top surface 38 where the end surface 46 of the post 12 rests.

[0043] FIG. 5 is a downward partial perspective exploded view that illustrates another alternative embodiment of the assembly 10 of the post 12 attached to the base plate 14. Accordingly, the non-round aperture 36 formed in the body 34 of the base plate 14 is formed as a closed-end cavity that extends only part way through the body 34 between the top surface 38 upon which the post 12 is mounted through to the intervening surface 68 part way through the body 34. The straight and substantially flat or planar interior sidewall surfaces 40 of the closed-end non-round aperture 36 form the substantially linear intersections 42. However, rather than being formed substantially perpendicular to the mounting surface 38, the interior sidewall surfaces 40 are optionally formed at an angular incline to the mounting surface 38. When the closed-end non-round aperture 36 is formed as a square, the interior sidewall surfaces 40 form a truncated inverse pyramid shape.

[0044] Similarly, the non-round locking structure 48 of the post 12 is formed with the exterior sidewall surfaces 52 and form the substantially linear intersections 54. However, rather than being formed substantially perpendicular to the end surface 46 of the post 12, the exterior sidewall surfaces 52 are optionally formed at an angular incline to the end surface 46. When the non-round locking structure 48 is formed as a square, the exterior sidewall surfaces 52 form a truncated pyramid shape. Accordingly, the non-round locking structure 48 fits into and mates in the rotational locking arrangement with the non-round aperture 36. According to one embodiment of the present invention, the pyramidal locking structure 48 is wider at its base than the opening into the inverse pyramidal cavity or aperture 36. The inclined exterior sidewall surfaces 52 of the pyramidal locking structure 48 engage the intervening inclined interior sidewall surfaces 40 of the inverse pyramidal aperture 36 and are drawn flush and tight against the inclined interior sidewall surfaces 40.

[0045] Alternatively, the base of the raised non-round locking structure 48 is sized the same length or less than the opening into the inverse pyramidal cavity or aperture 36. Therefore, when engaged with the non-round aperture 36 and having the end surface 46 flush against the top surface 38 of the base plate 14, the inclined exterior sidewall surfaces 52 of the raised pyramidal locking structure 48 do not engage the inclined interior sidewall surfaces 40 of inverse pyramidal aperture 36.

[0046] FIG. 5 also illustrates the fastener 20 being configured as a threaded male stud 80 coupled to the end surface 50 of the raised locking structure 48 of the post 12. A female threaded member or nut 82, such as hexagonal "hex" nut, lock nut, wing nut or other female threaded member, replaces the fastener head 24 as a clamping portion of the stud fastener 80. The stud fastener 80 and nut 82 act together to secure the post 12 to the base plate 14 by the stud fastener 80 being inserted through the clearance-hole aperture 70 in the base plate 14, and the nut 82 being threaded onto the stud fastener 80 with the washer 22 between the nut 82 and the bottom surface 26, or omitted. The stud fastener 80 and nut 82 are optionally substituted for the fastener 20 in any of the different embodiments of the invention disclosed herein without departing from the spirit and scope of the invention.

[0047] FIG. 6 is a downward perspective exploded view that illustrates another alternative embodiment of the assembly 10 of the post 12 attached to the base plate 14. Accordingly, the non-round aperture 36 formed in the body 34 of the base plate 14 is formed as a closed-end cavity that extends only part way through the body 34 between the top surface 38 upon which the post 12 is mounted through to the intervening surface 68 part way through the body 34.

[0048] The base end 44 of the post 12 is formed as the non-round locking structure 48 that is substantially flat or planar on its end surface 50. The non-round locking structure 48 fits into and mates in the rotational locking arrangement with the non-round aperture 36. The end surface 50 of the non-round locking structure 48 engages the intervening surface 68 that provides the floor of the non-round aperture 36. The end surface 50 of the non-round locking structure 48 is drawn flush and tight against the intervening surface 68 by the fastener 20 through the clearance-hole aperture 70, with the washer 22 between the fastener head 24 and the counter surface 74, or omitted.

[0049] Alternatively, the raised non-round locking structure 48 is sized the same length or less than the depth "d" of the closed-end non-round aperture 36. Therefore, when engaged with the non-round aperture 36 and having the end surface 46 flush against the top surface 38 of the base plate 14, the raised non-round locking structure 48 does not penetrate all the way into the non-round aperture 36 and does not engage the intervening surface 68.

[0050] The counter surface 74 is optionally conical, as shown, and the fastener head 24 is a mating conical shape, such as a Philips flat head machine screw. The post 12 is not drawn through the non-round aperture 36 in the base plate 14 because the floor material 72 acts as a stop against which the base end 44 of the post 12 is stopped.

[0051] Either the intervening surface 68 in the floor of the non-round aperture 36, or the end surface 50 of the non-round locking structure 48, is optionally formed with the multiple feet 78 to provide a planar mounting surface for the post 12 relative to the base plate 14.

[0052] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, materials may be substituted for the different components of the flexible support apparatus of the invention without departing from the spirit and scope of the invention. Therefore, the inventor makes the following claims.

Claims

1. A post-and-base apparatus, comprising: a substantially rigid base having a body of substantially rigid material formed with a mounting surface thereon and an opposing surface opposite from the mounting surface, and an aperture formed into the mounting surface and having a non-round interior sidewall surface extending at least partially through the body toward the opposing surface; a substantially rigid post having a body of substantially rigid material formed with a non-round locking structure adjacent to a first end thereof, the non-round locking structure forming an external sidewall surface that is structured to fit into the non-round aperture in a rotational locking relationship relative thereto; a body of substantially rigid load-bearing material formed with a bearing surface thereon and an aperture formed through the body of material and the bearing surface; and a fastener coupled between the locking structure and the opposing surface of the base with the body of load-bearing material interposed there between, the fastener securing the locking structure of the post within the aperture of the base with the post being rotationally fixed relative to the base.

2. The apparatus of claim 1 wherein the post further comprises a substantially planar end surface adjacent to the first end thereof, the substantially planar end surface having the non-round locking structure being raised relative thereto, the substantially planar end surface being sized relatively larger than the aperture formed into the mounting surface of the base.

3. The apparatus of claim 2 wherein the non-round aperture extends fully through the base between the mounting surface and the opposing surface thereof

4. The apparatus of claim 3 wherein the body of substantially rigid load-bearing material further comprises a substantially rigid washer positioned between a clamping portion of the fastener and the opposing surface of the base.

5. The apparatus of claim 2 wherein the non-round aperture further comprises a plurality of substantially straight and planar sidewall surfaces, the sidewall surfaces being relatively angularly oriented with adjacent sidewall surfaces forming substantially linear intersections therebetween; and the non-round locking structure further comprises a like plurality of substantially straight and planar sidewall surfaces, the sidewall surfaces being relatively angularly oriented with adjacent sidewall surfaces forming substantially linear intersections therebetween.

6. The apparatus of claim 5 wherein the non-round locking structure further comprises a threaded bore formed in the first end thereof substantially perpendicular to the mounting surface of the base.

7. The apparatus of claim 6 wherein the fastener further comprises one of a bolt, a screw and a threaded stud.

8. The apparatus of claim 6 wherein the post further comprises a substantially part-spherical coupler formed adjacent a second end thereof opposite from the first end, the part-spherical coupler being formed of a resiliently pressure-deformable material.

9. The apparatus of claim 1 wherein the non-round aperture extends through the base only between the mounting surface and an intervening surface part way between the mounting surface and the opposing surface thereof, the intervening surface being formed with a clearance aperture structured to receive the fastener there through; and wherein the body of substantially rigid load-bearing material further comprises a portion of the substantially rigid material of the body of the base between the intervening surface and the opposing surface.

10. The apparatus of claim 1 wherein the non-round aperture further comprises a plurality of substantially straight and planar sidewall surfaces, the sidewall surfaces being angularly inclined relative to the mounting surface of the base plate and being angularly oriented relative to adjacent sidewall surfaces and forming substantially linear intersections therebetween; and the non-round locking structure further comprises a like plurality of substantially straight and planar sidewall surfaces, the sidewall surfaces being similarly angularly inclined relative to the first end of the post and being similarly angularly oriented relative to adjacent sidewall surfaces and forming substantially linear intersections therebetween.

11. A post-and-base assembly, comprising: a substantially rigid base plate having a body of substantially rigid material formed with a mounting surface thereon and an opposing surface opposite from the mounting surface, and a polygonal aperture formed into the mounting surface and having a plurality of interior sidewall surfaces extending at least partially through the body toward the opposing surface; a substantially rigid post having a body of substantially rigid material formed with a polygonal locking structure projected from a first end thereof, the polygonal locking structure having a plurality of external sidewall surfaces and being structured to fit into the polygonal aperture and nest therewith; a fastener coupled into the locking structure for securing the post relative to the mounting surface of the base plate; and a body of substantially rigid load-bearing material formed with a bearing surface thereon and a clearance aperture formed through the body of material and the bearing surface and sized to pass the fastener there through.

12. The assembly of claim 11 wherein the interior sidewall surfaces of the polygonal aperture further comprise surfaces that are substantially perpendicular to the mounting surface.

13. The assembly of claim 11 wherein the interior sidewall surfaces of the polygonal aperture further extend entirely through the body between the mounting surface and the opposing surface; and body of substantially rigid load-bearing material further comprises a conventional metal washer interposed between the opposing surface of the base plate and a clamping portion of the fastener.

14. The assembly of claim 11 wherein the interior sidewall surfaces of the polygonal aperture further extend to an intervening surface of the body between the mounting surface and the opposing surface; and body of substantially rigid load-bearing material further comprises a portion of the body interposed between the intervening surface and the opposing surface of the base plate.

15. A method of forming a post-and-base apparatus, the method comprising: of substantially rigid material forming a base having a body with a mounting surface formed thereon and an opposing surface formed opposite from the mounting surface; forming a non-round cavity into the body of the base having a non-round opening in the mounting surface and having a non-round interior sidewall surface extending at least partially through the body toward the opposing surface; of substantially rigid material forming a substantially rigid post having a body with a non-round locking structure adjacent to a first end thereof, the non-round locking structure being formed of an external sidewall surface that is structured to fit into the non-round cavity; inserting the non-round locking structure of the post through the non-round opening in the mounting surface of the base into the non-round cavity in the body of the base in a substantially fixed rotational relationship therewith; and drawing the first end of the post into a secure relationship with the mounting surface of the base.

16. The method of claim 15 wherein forming a non-round cavity into the body of the base further comprises forming a polygonal opening in the mounting surface and forming a plurality of relatively angularly oriented and intersecting substantially planar interior sidewall surfaces.

17. The method of claim 16 wherein forming a non-round cavity into the body of the base further comprises forming a floor of the cavity as an intervening surface part way between the mounting surface and the opposing surface; and further comprising forming a clearance aperture through the floor of the cavity extending between the intervening surface and the opposing surface.

18. The method of claim 16 wherein forming a plurality of relatively angularly oriented and intersecting substantially planar interior sidewall surfaces further comprises forming the plurality of relatively angularly oriented and intersecting substantially planar interior sidewall surfaces entirely through a portion of the body of the base between the mounting surface and the opposing surface.

19. The method of claim 18 wherein forming a substantially rigid post having a body with a non-round locking structure adjacent to a first end thereof further comprises forming a substantially planar surface adjacent to the first end of the body of the post and forming the non-round locking structure as a raised structure relative to the substantially planar surface; and wherein inserting the non-round locking structure of the post through the non-round opening in the mounting surface of the base into the non-round cavity in the body of the base further comprises installing the substantially planar surface adjacent to the first end of the body of the post substantially flush against a portion of the mounting surface of the base surrounding the non-round opening therein.

20. The method of claim 15 wherein drawing the first end of the post into a secure relationship with the mounting surface of the base further comprises threading a threaded fastener between the non-round locking structure of the post and a body of substantially rigid load-bearing material formed with a bearing surface thereon and formed with a clearance aperture through the body of material and the bearing surface and sized to pass the fastener there through.