U.S. patent application number 11/620623 was filed with the patent office on 2007-07-05 for sports board apparatus and method.
This patent application is currently assigned to 1,035,032 ONTARIO INC. O/A AIMCON RECREATION. Invention is credited to Waldemar H. GREINER, Thomas H. McCONNELL, Phillip G. OUELLETTE.
Application Number | 20070155518 11/620623 |
Document ID | / |
Family ID | 38229476 |
Filed Date | 2007-07-05 |
United States Patent
Application |
20070155518 |
Kind Code |
A1 |
GREINER; Waldemar H. ; et
al. |
July 5, 2007 |
SPORTS BOARD APPARATUS AND METHOD
Abstract
A sports board apparatus, for use with a sports surface and
boards, includes posts, a web, and an upper support, each
constructed from a roll-formed metal material. Each post has lower
and upper ends, and includes two post channels securely nested with
one another. Each channel has back and side walls defining a
C-shaped channel profile. The web securely engages two posts, and
has back and side walls defining a C-shaped web profile. The upper
support securely engages two posts adjacent to the upper ends
thereof. The upper support, the web, and the posts are secured
relative to the boards. The posts are secured relative to the
sports surface, with the lower ends adjacent thereto. A method of
forming the sports board apparatus includes a post channel
roll-forming step, a web roll-forming step, and an upper support
roll-forming step.
Inventors: |
GREINER; Waldemar H.;
(Waterdown, ON) ; McCONNELL; Thomas H.; (Kettleby,
ON) ; OUELLETTE; Phillip G.; (Barrie, ON) |
Correspondence
Address: |
LANG MICHENER LLP
BCE PLACE
SUITE 2500, 181 BAY STREET
TORONTO
ON
M5J 2T7
CA
|
Assignee: |
1,035,032 ONTARIO INC. O/A AIMCON
RECREATION
61 Forest Plain Road, RR 1
Orillia
CA
L3V 6H1
|
Family ID: |
38229476 |
Appl. No.: |
11/620623 |
Filed: |
January 5, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60756231 |
Jan 5, 2006 |
|
|
|
Current U.S.
Class: |
472/92 |
Current CPC
Class: |
E04B 2/7422 20130101;
A63C 19/08 20130101; E04B 2/767 20130101; E04B 2002/7418
20130101 |
Class at
Publication: |
472/092 |
International
Class: |
A63J 3/00 20060101
A63J003/00 |
Claims
1. A sports board apparatus for use with a sports surface and one
or more substantially planar boards, said apparatus comprising: a)
a plurality of posts, each having a lower end portion and an upper
end portion, with each of said posts comprising two elongate post
channel members in securely nested relation with one another, with
each of said post channel members extending longitudinally upward
from said lower end portion to said upper end portion, and with
each of said post channel members having a post back wall and two
post side walls extending from said post back wall, with said post
back wall and said two post side walls being together shaped to
define a substantially C-shaped post channel profile; b) at least
one web member extending substantially between and securely
engaging at least two of said posts, with said web member having a
web back wall and two web side walls extending from said web back
wall, with said web back wall and said two web side walls being
together shaped to define a substantially C-shaped web profile; and
c) at least one upper support member securely engaging said at
least two of said posts substantially adjacent to each said upper
end portion of said at least two of said posts; with each said
upper support member, each said web member, and each of said post
channel members being constructed from a roll-formed metal
material; wherein each said upper support member and each said web
member is operatively securable relative to the boards; and wherein
each of said posts is operatively securable relative to the boards
and to the sports surface, with said lower end portion of each of
said posts operatively positioned substantially adjacent to the
sports surface.
2. An apparatus according to claim 1, wherein said metal material
is a light gauge steel material.
3. An apparatus according to claim 2, wherein each of said post
channel members has a retention member extending inwardly from one
of said post side walls, and wherein said post back wall of each of
said post channel members is shaped so as to define a retention
depression, such that in said securely nested relation, said
retention depression of a first one of said two elongate post
channel members receives therewithin a substantial extent of said
retention member of a respective other one of said two elongate
post channel members.
4. An apparatus according to claim 3, wherein a first member and a
second member are selected from a group consisting of each said
upper support member, each said web member, and each of said post
channel members, with each of said first member and said second
member comprising one or more dimpled portions, with each of said
dimpled portions of said first member being in said securely nested
relation with a respective one of said dimpled portions of said
second member, so as to form one or more nested pairs of said
dimpled portions.
5. An apparatus according to claim 4, further comprising a
plurality of mechanical fasteners securely attaching said first
member to said second member, with each of said mechanical
fasteners extending substantially through a respective one of said
nested pairs of said dimpled portions.
6. An apparatus according to claim 5, wherein each of said
mechanical fasteners comprises a head portion and a threaded
portion, with each said threaded portion threadingly engaging a
respective one of said nested pairs of said dimpled portions, and
with a substantial extent of each said head portion being fully
received within said respective one of said nested pairs of said
dimpled portions.
7. An apparatus according to claim 3, wherein each of said posts
and said post channel members extends in a substantially upright
direction.
8. An apparatus according to claim 7, wherein each one of said web
member and said upper support member extends substantially
horizontally.
9. An apparatus according to claim 3, wherein said web member has
opposing web end portions and flanged web portions, with each of
said flanged web portions extending from substantially adjacent to
a respective one of said opposing web end portions, and securely
engaging a respective one of said two of said posts.
10. An apparatus according to claim 9, further comprising a
plurality of mechanical fasteners securely attaching each of said
flanged web portions to said respective one of said two of said
posts.
11. An apparatus according to claim 3, further comprising at least
one web cover extending substantially between said two of said
posts, with said web cover securely engaging said web member and
being constructed from said roll-formed metal material.
12. An apparatus according to claim 11, wherein said web cover has
a cover back wall and two cover side walls extending from said
cover back wall, with said cover back wall and said two cover side
walls being together shaped to define a substantially C-shaped
cover profile, and with each of said cover side walls having a web
retention portion securely engaging said web member over a
respective one of said web side walls.
13. An apparatus according to claim 3, wherein said two of said
posts comprise a first male end post and a first female end post,
with said plurality of posts further comprising a second male end
post matingly engaging said first female end post, and with said
plurality of posts still further comprising a second female end
post matingly engaging said first male end post.
14. An apparatus according to claim 13, wherein one of said post
channel members of each said male end post comprises a post mating
protuberance, and wherein one of said post channel members of each
said female end post comprises a post mating depression, with each
said post mating protuberance matingly engaging a respective one
said post mating depression in substantially aligned and
close-fitting relation.
15. An apparatus according to claim 14, further comprising post
securing means for securely attaching said first male end post to
said second female end post and for securely attaching said first
female end post to said second male end post.
16. An apparatus according to claim 3, wherein said web back wall
has a notched web portion defining a web aperture therethrough, and
wherein said web member securely engages at least three of said
posts, with said three of said posts comprising two end posts and a
middle post, with said web member extending substantially between
said two end posts, and with said middle post being positioned
between said two end posts and being securely received within said
web aperture.
17. An apparatus according to claim 16, wherein said upper support
member has a notched beam portion defining a beam aperture, and
wherein said upper support member securely engages said two end
posts and said middle post, with said upper support member being
mechanically fastened to said upper end portion of each of said two
end posts, and with said middle post being securely received within
said beam aperture.
18. An apparatus according to claim 3, wherein said upper support
member comprises a support channel member having a support back
wall and two support side walls extending from said support back
wall, with said support back wall and said two support side walls
being together shaped to define a substantially C-shaped support
channel profile, with said upper support member further comprising
a first beam and a second beam in substantially parallel and spaced
relation with said first beam, such that said first beam and said
second beam define a beam opening therebetween, with each of said
first beam and said second beam being positioned substantially
between said two support side walls of said support channel
member.
19. An apparatus according to claim 18, wherein each of said first
beam and said second beam has a beam back wall and two beam side
walls extending from said beam back wall, with said beam back wall
and said two beam side walls being together shaped to define a
substantially C-shaped beam channel profile, with said beam back
wall of said first beam substantially engaging a first one of said
support side walls, and with said beam back wall of said second
beam substantially engaging a second one of said support side
walls.
20. An apparatus according to claim 18, wherein said support back
wall has a notched support portion defining a support aperture
therethrough, wherein each of said first beam and said second beam
has a beam back wall and two beam side walls extending from said
beam back wall, wherein each of said beam side walls of each of
said first beam and said second beam has a notched beam portion
defining a beam aperture, and wherein said upper support member
engages at least three of said posts, with said three of said posts
comprising two end posts and a middle post positioned between said
two end posts, with each of said first beam and said second beam
being mechanically fastened to said upper end portion of each of
said two end posts, with said support channel member extending
substantially between said two end posts, and with said middle post
being securely received within said support aperture and within
each said beam aperture.
21. An apparatus according to claim 20, wherein each one of said
first beam and said second beam has two flanged beam portions, with
each of said flanged beam portions extending from a first wall that
is selected from the group consisting of said beam back wall and
said beam side walls, and with each of said flanged beam portions
being mechanically fastened to said upper end portion of a
respective one of said two end posts.
22. An apparatus according to claim 18, wherein said support back
wall is shaped so as to define two or more pole openings
therethrough, with said apparatus further comprising two or more
poles and a substantially transparent and substantially planar
sheet supported between said poles, with said each of said poles
extending through the beam opening and through a respective one of
said pole openings, and wherein each of said poles has a pole base
that is securely attached relative to said web member.
23. An apparatus according to claim 22, further comprising at least
one web cover extending substantially between said two of said
posts, with said web cover securely engaging said web member and
being constructed from said roll-formed metal material, with said
pole base securely attached to said web cover.
24. An apparatus according to claim 22, further comprising at least
one substantially planar top cover securely engaging said upper
support member in substantially overlying relation substantially
adjacent to each said upper end portion of said at least two of
said posts, with said poles extending through apertures shaped in
said top cover.
25. An apparatus according to claim 3, further comprising at least
one bottom channel member extending substantially between and
securely engaging each said lower end portion of said at least two
of said posts, with said bottom channel member having a bottom
channel back wall and two bottom channel side walls extending from
said bottom channel back wall, with said bottom channel back wall
and said two bottom channel side walls being together shaped to
define a substantially C-shaped bottom channel profile, with said
bottom channel member being constructed from said roll-formed metal
material, and with said bottom channel member being operatively
positioned substantially adjacent to the sports surface and being
operatively securable relative to the boards and to the sports
surface.
26. An apparatus according to claim 25, wherein said bottom channel
member extends substantially horizontally.
27. An apparatus according to claim 25, wherein said bottom channel
member and at least one of said post channel members of each of
said at least two of said posts each comprises one or more dimpled
portions, with each of said dimpled portions of said bottom channel
member being in securely nested relation with a respective one of
said dimpled portions of said at least one of said post channel
members of each of said at least two of said posts, so as to form
at least two nested pairs of said dimpled portions.
28. An apparatus according to claim 25, further comprising at least
one bottom cover having a bottom cover back wall and two bottom
cover side walls extending from said bottom cover back wall, with
said bottom cover back wall and said two bottom cover side walls
being together shaped to define a substantially C-shaped bottom
cover profile, and with each of said bottom cover side walls having
a bottom channel retention portion securely engaging said bottom
channel member over a respective one of said bottom channel side
walls, wherein said bottom cover back wall has a notched bottom
cover portion defining a bottom cover aperture therethrough,
wherein said bottom cover extends substantially between said lower
end portion of said two of said posts and is constructed from said
roll-formed metal material, and wherein said plurality of posts
further comprises a middle post positioned between said two of said
posts, with said middle post being securely received within said
bottom cover aperture.
29. A method of forming a sports board apparatus for use with a
sports surface and one or more substantially planar boards, said
method comprising the steps of: a post channel forming step of
roll-forming at least four post channel members by passing first
elongate sheets of light gauge steel material through a series of
roll-forming post channel tool sets, with passage of said first
elongate sheets through each successive one of the post channel
tool sets progressively forming said post channel members, such
that each of said post channel members has a post back wall and two
post side walls extending from said post back wall, with said post
back wall and said two post side walls being together shaped to
define a substantially C-shaped post channel profile; a web forming
step of roll-forming one or more web members by passing second
elongate sheets of light gauge steel material through a series of
roll-forming web tool sets, with passage of said second elongate
sheets through each successive one of the web tool sets
progressively forming said web members, such that each of said web
members has a web back wall and two web side walls extending from
said web back wall, with said web back wall and said two web side
walls being together shaped to define a substantially C-shaped web
profile; an upper support forming step of rbll-forming a plurality
of beams by passing a plurality of third elongate sheets of light
gauge steel material through a series of roll-forming beam tool
sets, with passage of said third elongate sheets through each
successive one of the beam tool sets progressively forming said
beams; wherein each of said post channel members is adapted to be
in operative securely nested relation with another one of said post
channel members to form at least two posts, with each of said posts
having a lower end portion and an upper end portion, and with each
of said post channel members extending longitudinally upward from
said lower end portion to said upper end portion; wherein each of
said web members and each of said beams is adapted to operatively
extend substantially between and securely engage said two posts,
with each of said beams engaging said two posts substantially
adjacent to each said upper end portion of said two posts; and
wherein each of said beams and each of said web members is
operatively securable relative to the boards; and wherein each of
said posts is operatively securable relative to the boards and to
the sports surface, with said lower end portion of each of said
posts operatively positioned substantially adjacent to the sports
surface.
30. A method according to claim 29, wherein in said post channel
forming step, a retention member and a retention depression are
roll-formed on each of said post channel members, with passage of
said first elongate sheets through each successive one of said post
channel tool sets progressively forming said retention member and
said retention depression, such that said retention member extends
inwardly from one of said post side walls, and said retention
depression is formed in said post back wall, such that in said
operative securely nested relation, said retention depression of
said each of said post channel members receives therewithin a
substantial extent of said retention member of said another one of
said post channel members.
31. A method according to claim 30, further comprising a mechanical
fastening step of securely attaching a first member to a second
member using a mechanical fastener extending substantially
therethrough, with each of said first member and said second member
being selected from a group consisting of said post channel
members, said web members, and said beams.
32. A method according to claim 31, further comprising: a dimpling
step, before said mechanical fastening step, of forming one or more
dimpled portions in each of said first member and said second
member; and a nesting step, after said dimpling step and before
said mechanical fastening step, of securely nesting each of said
dimpled portions of said first member in said operative securely
nested relation with a respective one of said dimpled portions of
said second member, so as to form one or more nested pairs of said
dimpled portions; wherein in said mechanical fastening step, each
of said mechanical fasteners extending substantially through a
respective one of said nested pairs of said dimpled portions, such
that a substantial extent of said each of said mechanical fasteners
is fully received within said respective one of said nested pairs
of said dimpled portions.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
sports board apparatus and methods, and more specifically to sports
board apparatus and methods for forming sports boards using
roll-formed metal materials.
BACKGROUND OF THE INVENTION
[0002] It is often necessary, be it for the purposes of the playing
of various sports, for safety, or otherwise, to surround the
perimeter of a sports surface (e.g., an ice surface, a sports
field, a ring, and a court) with a sports board apparatus. For
example, the sport of hockey requires boards, often with acrylic
plastic sheets or another substantially transparent and durable
material positioned thereabove. These boards and transparent sheets
may preferably serve both to define the area on which the game is
played, and to prevent any projectiles from leaving the surface and
thus disrupting the game or injuring onlookers.
[0003] Of course, hockey and other sports and entertainment may
involve body contact among the competitors and/or movement of
players and sports equipment (e.g., pucks, balls, other
projectiles, sticks, other sporting implements and means of
conveyance) at considerable speeds--whether these sports are played
wearing, for example, bare feet, shoes, ice skates, or inline
skates. As such, in order to be effective for its intended purpose,
a sports board apparatus must be capable of withstanding the impact
of any sports equipment and competitors that may have occasion to
collide heavily therewith. Such impacts may occur, for example, as
the result of calculated body checking, equipment malfunction,
and/or misfortune or a lack of skill in traversing the sports
surface.
[0004] It is also very common for multi-purpose use to be made of
sports surfaces. For example, the same sports surface that is used
for hockey may periodically have the ice surface removed therefrom,
so as to be capable of use for basketball, concerts, equestrian
events, and/or various other events. Sometimes, multi-purpose uses
of the sports surface may call for the disassembly of the sports
board apparatus. For these and other reasons, it may be desirable
to provide a sports board apparatus that is capable of being
quickly and easily assembled and disassembled on a regular or as
needed basis, without employing highly skilled workers, and/or
without sacrificing the structural integrity of the sports board
apparatus. In this regard, prior art sports board assemblies may
have been woefully inadequate, and/or may possibly have resulted in
serious injury to such workers, to the sporting competitors, and/or
to the entertainment onlookers, amongst others.
[0005] In order to provide the necessary strength, many prior art
sports board assemblies may have been constructed, at least in
part, from very heavy metal materials. While such materials may be
structurally sound, they may also be inappropriately unwieldy
and/or cumbersome. Some conventional sports board assemblies may
have included components constructed from extruded aluminum (which
has the benefit of a high resistance to corrosion) and/or hot
rolled structural steel. The use of these materials may have been
prohibitively costly, whether due to (i) the inherent cost of such
materials, (ii) the high amount of labor involved in (the possibly
quite mechanical and/or manual) manufacturing processes which may
heretofore have been used to construct the individual components of
these prior art sports board assemblies from such materials, and/or
(iii) other factors.
[0006] Notwithstanding that light gauge steel (alternately referred
to herein as "LGS") may have similar corrosion resistant properties
to those exhibited by aluminum, LGS--which may include coiled
stainless steel and the like--may not have been used previously as
a main structural component of prior art sports board assemblies.
This prior failure to successfully employ LGS, as a main structural
component in a sports board apparatus, may have been due in part to
the shortcomings of LGS when used in conventional component
geometries, insofar as it may heretofore have been structurally too
weak, in comparison to some of the thicker and heavier materials
mentioned above.
[0007] In addition to its anti-corrosive properties, LGS has the
further advantage of being highly formable, enabling construction
of components having relatively complex shapes from LGS, through
the use of a series of continuous roller dies. As such, the use of
LGS in a sports board apparatus--though not previously
successful--may afford a relatively high efficiency of manufacture
(e.g., in terms of time and money) in comparison with components
formed from prior art sports board materials, without requiring the
use of exceedingly heavy and/or otherwise cumbersome components.
Preferably, such use of LGS in a novel and inventive sports board
apparatus (e.g., according to the present invention) would also
avoid seriously sacrificing the structural integrity of the sports
board apparatus.
[0008] It is thus an object of the present invention to provide a
sports board apparatus comprising posts formed from C-shaped post
channel members nested in clusters for strength.
[0009] It is another object of the present invention to provide
posts which are joined together in a nested fashion.
[0010] It is yet another object of the present invention to provide
first and second beams in spaced relation from one another so as to
define an elongate beam opening therebetween, which might allow
passage therethrough of poles for holding substantially transparent
sheets of material (e.g., acrylic plastic sheets).
[0011] It is still another object of the present invention to
provide components of a sports board apparatus in a configuration
that substantially conceals and/or reduces the prominence of all
sharp edges thereof, so as to prevent and/or reduce risk of
injury.
[0012] It is also an object of this invention to obviate or
mitigate at least one of the above mentioned disadvantages of the
prior art.
SUMMARY OF THE INVENTION
[0013] In accordance with the present invention there is disclosed
a sports board apparatus for use with a sports surface and one or
more substantially planar boards. According to the invention, the
apparatus includes a plurality of posts, at least one web member,
and at least one upper support member. Each upper support member,
each web member, and each of the post channel members is
constructed from a roll-formed metal material. Each of the posts
has a lower end portion and an upper end portion. Each of the posts
includes two elongate post channel members in securely nested
relation with one another. Each of the post channel members extends
longitudinally upward from the lower end portion to the upper end
portion. Each of the post channel members has a post back wall and
two post side walls extending from the post back wall. The post
back wall and the two post side walls are together shaped to define
a substantially C-shaped post channel profile. Each web member
extends substantially between and securely engages at least two of
the posts. Each web member has a web back wall and two web side
walls extending from the web back wall. The web back wall and the
two web side walls are together shaped to define a substantially
C-shaped web profile. Each upper support member securely engages
the at least two of the posts substantially adjacent to each upper
end portion of the at least two of the posts. Each upper support
member and each web member is operatively securable relative to the
boards. Each of the posts is operatively securable relative to the
boards and to the sports surface, with the lower end portion of
each of the posts operatively positioned substantially adjacent to
the sports surface.
[0014] According to an aspect of a preferred embodiment of the
invention, the metal material may preferably, but need not
necessarily, be a light gauge steel material.
[0015] According to an aspect of a preferred embodiment of the
invention, each of the post channel members may preferably, but
need not necessarily, have a retention member extending inwardly
from one of the post side walls. Each post back wall of each of the
post channel members may preferably, but need not necessarily, be
shaped so as to define a retention depression. According to this
aspect of the invention, in the securely nested relation, the
retention depression of a first one of the two elongate post
channel members may preferably, but need not necessarily, receive
therewithin a substantial extent of the retention member of a
respective other one of the two elongate post channel members.
[0016] According to an aspect of a preferred embodiment of the
invention, a first member and a second member are selected from a
group that may, but need not necessarily, consist of each upper
support member, each web member, and each of the post channel
members. Each of the first member and the second member may
preferably, but need not necessarily, include one or more dimpled
portions. Each of the dimpled portions of the first member may
preferably, but need not necessarily, be in the aforesaid securely
nested relation with a respective one of the dimpled portions of
the second member, so as to form one or more nested pairs of the
dimpled portions.
[0017] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include a plurality of mechanical fasteners securely
attaching the first member to the second member. Each of the
mechanical fasteners may preferably, but need not necessarily,
extend substantially through a respective one of the nested pairs
of the dimpled portions.
[0018] According to an aspect of a preferred embodiment of the
invention, each of the mechanical fasteners may preferably, but
need not necessarily, include a head portion and a threaded
portion. Each threaded portion may preferably, but need not
necessarily, threadingly engage a respective one of the nested
pairs of the dimpled portions. A substantial extent of each head
portion may preferably, but need not necessarily, be fully received
within the respective one of the nested pairs of the dimpled
portions.
[0019] According to an aspect of a preferred embodiment of the
invention, each of the posts and the post channel members may
preferably, but need not necessarily, extend in a substantially
upright direction.
[0020] According to an aspect of a preferred embodiment of the
invention, each one of the web member and the upper support member
may preferably, but need not necessarily, extend substantially
horizontally.
[0021] According to an aspect of a preferred embodiment of the
invention, the web member may preferably, but need not necessarily,
have opposing web end portions and flanged web portions. Each of
the flanged web portions may preferably, but need not necessarily,
extend from substantially adjacent to a respective one of the
opposing web end portions, and may preferably, but need not
necessarily, securely engage a respective one of the two of the
posts.
[0022] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include a plurality of mechanical fasteners securely
attaching each of the flanged web portions to the respective one of
the two of the posts.
[0023] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one web cover extending substantially
between the two of the posts. The web cover may preferably but need
not necessarily, securely engage the web member, and may
preferably, but need not necessarily, be constructed from the
roll-formed metal material.
[0024] According to an aspect of a preferred embodiment of the
invention, the web cover may preferably, but need not necessarily,
have a cover back wall and two cover side walls extending from the
cover back wall. The cover back wall and the two cover side walls
may preferably, but need not necessarily, be together shaped to
define a substantially C-shaped cover profile. Each of the cover
side walls may preferably, but need not necessarily, have a web
retention portion securely engaging the web member over a
respective one of the web side walls.
[0025] According to an aspect of a preferred embodiment of the
invention, the two of the posts may preferably, but need not
necessarily, include a first male end post and a first female end
post. The plurality of posts may preferably, but need not
necessarily, further include a second male end post matingly
engaging the first female end post. The plurality of posts may
preferably, but need not necessarily, still further include a
second female end post matingly engaging the first male end
post.
[0026] According to an aspect of a preferred embodiment of the
invention, one of the post channel members of each male end post
may preferably, but need not necessarily, include a post mating
protuberance. One of the post channel members of each female end
post may preferably, but need not necessarily, include a post
mating depression. Each post mating protuberance may preferably,
but need not necessarily, matingly engage a respective one post
mating depression in substantially aligned and close-fitting
relation.
[0027] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include post securing means for securely attaching the
first male end post to the second female end post and for securely
attaching the first female end post to the second male end
post.
[0028] According to an aspect of a preferred embodiment of the
invention, the web back wall may preferably, but need not
necessarily, have a notched web portion defining a web aperture
therethrough. The web member may preferably, but need not
necessarily, securely engage at least three of the posts. The three
of the posts may preferably, but need not necessarily, include two
end posts and a middle post. The web member may preferably, but
need not necessarily, extend substantially between the two end
posts. The middle post may preferably, but need not necessarily, be
positioned between the two end posts and may preferably, but need
not necessarily, be securely received within the web aperture.
[0029] According to an aspect of a preferred embodiment of the
invention, the upper support member may preferably, but need not
necessarily, have a notched beam portion defining a beam aperture.
The upper support member may preferably, but need not necessarily,
securely engage the two end posts and the middle post. The upper
support member may preferably, but need not necessarily, be
mechanically fastened to the upper end portion of each of the two
end posts. The middle post may preferably, but need not
necessarily, be securely received within the beam aperture.
[0030] According to an aspect of a preferred embodiment of the
invention, the upper support member comprises a support channel
member, and may preferably, but need not necessarily, have a
support back wall and two support side walls extending from the
support back wall. The support back wall and the two support side
walls may preferably, but need not necessarily, be together shaped
to define a substantially C-shaped support channel profile. The
upper support member may preferably, but need not necessarily,
further include a first beam and a second beam in substantially
parallel and spaced relation with the first beam. The first beam
and the second beam may preferably, but need not necessarily,
define a beam opening therebetween. Each of the first beam and the
second beam may preferably, but need not necessarily, be positioned
substantially between the two support side walls of the support
channel member.
[0031] According to an aspect of a preferred embodiment of the
invention, each of the first beam and the second beam may
preferably, but need not necessarily, have a beam back wall and two
beam side walls extending from the beam back wall. The beam back
wall and the two beam side walls may preferably, but need not
necessarily, be together shaped to define a substantially C-shaped
beam channel profile. The beam back wall of the first beam may
preferably, but need not necessarily, substantially engage a first
one of the support side walls. The beam back wall of the second
beam may preferably, but need not necessarily, substantially engage
a second one of the support side walls.
[0032] According to an aspect of a preferred embodiment of the
invention, the support back wall may preferably, but need not
necessarily, have a notched support portion defining a support
aperture therethrough. Each of the first beam and the second beam
may preferably, but need not necessarily, have a beam back wall and
two beam side walls extending from the beam back wall. Each of the
beam side walls of each of the first beam and the second beam may
preferably, but need not necessarily, have a notched beam portion
defining a beam aperture. The upper support member may preferably,
but need not necessarily, engage at least three of the posts. The
three of the posts may preferably, but need not necessarily,
include two end posts and a middle post positioned between the two
end posts. Each of the first beam and the second beam may
preferably, but need not necessarily, be mechanically fastened to
the upper end portion of each of the two end posts. The support
channel member may preferably, but need not necessarily, extend
substantially between the two end posts. The middle post may
preferably, but need not necessarily, be securely received within
the support aperture and within each the beam aperture.
[0033] According to an aspect of a preferred embodiment of the
invention, each one of the first beam and the second beam may
preferably, but need not necessarily, have two flanged beam
portions. Each of the flanged beam portions may preferably, but
need not necessarily, extend from a first wall that is selected
from the group consisting of the beam back wall and the beam side
walls. Each of the flanged beam portions may preferably, but need
not necessarily, be mechanically fastened to the upper end portion
of a respective one of the two end posts.
[0034] According to an aspect of a preferred embodiment of the
invention, the support back wall may preferably, but need not
necessarily, be shaped so as to define two or more pole openings
therethrough. The apparatus may preferably, but need not
necessarily, further include two or more poles and a substantially
transparent and substantially planar sheet supported between the
poles. Each of the poles may preferably, but need not necessarily,
extend through the beam opening and through a respective one of the
pole openings. Each of the poles has a pole base that may
preferably, but need not necessarily, be securely attached relative
to the web member.
[0035] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one web cover extending substantially
between the two of the posts. The web cover may preferably, but
need not necessarily, securely engage the web member, and may
preferably, but need not necessarily, be constructed from the
roll-formed metal material. The pole base may preferably, but need
not necessarily, be securely attached to the web cover.
[0036] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one substantially planar top cover
securely engaging the upper support member in substantially
overlying relation, preferably, but not necessarily, substantially
adjacent to each upper end portion of the at least two of the
posts. The poles may preferably, but need not necessarily, extend
through apertures shaped in the top cover.
[0037] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one bottom channel member extending
substantially between and securely engaging each lower end portion
of the at least two of the posts. The bottom channel member may
preferably, but need not necessarily, have a bottom channel back
wall and two bottom channel side walls extending from the bottom
channel back wall. The bottom channel back wall and the two bottom
channel side walls may preferably, but need not necessarily, be
together shaped to define a substantially C-shaped bottom channel
profile. The bottom channel member may preferably, but need not
necessarily, be constructed from the roll-formed metal material.
The bottom channel member may preferably, but need not necessarily,
be operatively positioned substantially adjacent to the sports
surface, and may preferably, but need not necessarily, be
operatively securable relative to the boards and to the sports
surface.
[0038] According to an aspect of a preferred embodiment of the
invention, the bottom channel member may preferably, but need not
necessarily, extend substantially horizontally.
[0039] According to an aspect of a preferred embodiment of the
invention, the bottom channel member and at least one of the post
channel members of each of the at least two of the posts may
preferably, but need not necessarily, each include one or more
dimpled portions. Each of the dimpled portions of the bottom
channel member may preferably, but need not necessarily, be in
securely nested relation with a respective one of the dimpled
portions of the at least one of the post channel members of each of
the at least two of the posts, so as to preferably, but not
necessarily, form at least two nested pairs of the dimpled
portions.
[0040] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one bottom cover having a bottom cover
back wall and two bottom cover side walls extending from the bottom
cover back wall. The bottom cover back wall and the two bottom
cover side walls may preferably, but need not necessarily, be
together shaped to define a substantially C-shaped bottom cover
profile. Each of the bottom cover side walls may preferably, but
need not necessarily, have a bottom channel retention portion
securely engaging the bottom channel member over a respective one
of the bottom channel side walls. The bottom cover back wall may
preferably, but need not necessarily, have a notched bottom cover
portion defining a bottom cover aperture therethrough. The bottom
cover may preferably, but need not necessarily, extend
substantially between the lower end portion of the two of the
posts, and may preferably, but need not necessarily, be constructed
from the roll-formed metal material. The plurality of posts may
preferably, but need not necessarily, further include a middle post
positioned between the two of the posts. The middle post may
preferably, but need not necessarily, be securely received within
the bottom cover aperture.
[0041] In accordance with the present invention there is also
disclosed a method of forming a sports board apparatus for use with
a sports surface and one or more substantially planar boards. The
method includes a post channel forming step, a web forming step,
and an upper support forming step. In the post channel forming
step, at least four post channel members are roll-formed by passing
first elongate sheets of light gauge steel material through a
series of roll-forming post channel tool sets. Passage of the first
elongate sheets through each successive one of the post channel
tool sets progressively forms the post channel members, such that
each of the post channel members has a post back wall and two post
side walls extending from the post back wall, with the post back
wall and the two post side walls being together shaped to define a
substantially C-shaped post channel profile. In the web forming
step, one or more web members are roll-formed by passing second
elongate sheets of light gauge steel material through a series of
roll-forming web tool sets. Passage of the second elongate sheets
through each successive one of the web tool sets progressively
forms the web members, such that each of the web members has a web
back wall and two web side walls extending from the web back wall,
with the web back wall and the two web side walls being together
shaped to define a substantially C-shaped web profile. In the upper
support forming step, a plurality of beams are roll-formed by
passing a plurality of third elongate sheets of light gauge steel
material through a series of roll-forming beam tool sets. Passage
of the third elongate sheets through each successive one of the
beam tool sets progressively forms the beams. Each of the post
channel members is adapted to be in operative securely nested
relation with another one of the post channel members to form at
least two posts, such that each of the posts has a lower end
portion and an upper end portion, with each of the post channel
members extending longitudinally upward from the lower end portion
to the upper end portion. Each of the web members and each of the
beams is adapted to operatively extend substantially between and
securely engage the two posts, with each of the beams engaging the
two posts substantially adjacent to each the upper end portion of
the two posts. Each of the beams and each of the web members is
operatively securable relative to the boards. Each of the posts is
operatively securable relative to the boards and to the sports
surface, such that the lower end portion of each of the posts is
operatively positioned substantially adjacent to the sports
surface.
[0042] According to an aspect of a preferred embodiment of the
invention, in the post channel forming step, a retention member and
a retention depression may preferably, but need not necessarily, be
roll-formed on each of the post channel members. Passage of the
first elongate sheets through each successive one of the post
channel tool sets may preferably, but need not necessarily,
progressively form the retention member and the retention
depression, with the retention member preferably, but not
necessarily, extending substantially inwardly from one of the post
side walls, and with the retention depression preferably, but not
necessarily, formed in the post back wall, such that in the
operative securely nested relation, the retention depression of the
aforesaid each of the post channel members may preferably, but need
not necessarily, have received therewithin a substantial extent of
the retention member of the another one of the post channel
members.
[0043] According to an aspect of a preferred embodiment of the
invention, the method may preferably, but need not necessarily,
further include a mechanical fastening step of securely attaching a
first member to a second member using a mechanical fastener
extending substantially therethrough. Each of the first member and
the second member may preferably, but need not necessarily, be
selected from a group consisting of the post channel members, the
web members, and the beams.
[0044] According to an aspect of a preferred embodiment of the
invention, the method may preferably, but need not necessarily,
further include a dimpling step before the mechanical fastening
step, and a nesting step after the dimpling step and before the
mechanical fastening step. In the dimpling step, one or more
dimpled portions may preferably, but need not necessarily, be
formed in each of the first member and the second member. In the
nesting step, each of the dimpled portions of the first member may
preferably, but need not necessarily, be securely nested in the
operative securely nested relation with a respective one of the
dimpled portions of the second member, so as to form one or more
nested pairs of the dimpled portions. According to this aspect of
the invention, in the mechanical fastening step, each of the
mechanical fasteners may preferably, but need not necessarily,
extend substantially through a respective one of the nested pairs
of the dimpled portions, such that a substantial extent of the
aforesaid each of the mechanical fasteners is fully received within
the aforesaid respective one of the nested pairs of the dimpled
portions.
[0045] Accordingly, this invention obviates or mitigates at least
one of the above mentioned disadvantages of the prior art.
[0046] Other advantages, features and characteristics of the
present invention, as well as methods of operation and functions of
the related elements of the structure, and the combination of parts
and economies of manufacture, will become more apparent upon
consideration of the following detailed description and the
appended claims with reference to the accompanying drawings, the
latter of which is briefly described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The novel features which are believed to be characteristic
of the according to the present invention, as to its structure,
organization, use and method of operation, together with further
objectives and advantages thereof, will be better understood from
the following drawings in which a presently preferred embodiment of
the invention will now be illustrated by way of example. It is
expressly understood, however, that the drawings are for the
purpose of illustration and description only, and are not intended
as a definition of the limits of the invention. In the accompanying
drawings:
[0048] FIG. 1 is a partially exploded top rear left perspective
view of the sports board apparatus of the present invention, shown
with a board and a sports surface;
[0049] FIG. 2 is a top plan view of a first post channel member of
the apparatus shown in FIG. 1;
[0050] FIG. 3 is a top plan view of a second post channel member of
the apparatus shown in FIG. 1;
[0051] FIG. 4 is a top plan view of a third post channel member of
the apparatus shown in FIG. 1;
[0052] FIG. 5 is a top plan view of the middle post shown in FIG.
1;
[0053] FIG. 6 is a top plan view of a male end post in mating
engagement with a female end post, each according to the
invention;
[0054] FIG. 7 is a top plan view of an alternate female end post
according to the invention;
[0055] FIG. 8 is a top plan view of the post shown in FIG. 7 in
mating engagement with an alternate post according to the
invention;
[0056] FIG. 9 is a top rear side perspective view of the member
shown in FIG. 2;
[0057] FIG. 10 is a top rear side perspective view of the posts
shown in FIG. 6;
[0058] FIG. 11 is an exploded view of the posts shown in FIG.
10;
[0059] FIG. 12 is a bottom perspective view of a dimpled portion
shown in FIG. 1;
[0060] FIG. 13 is a side elevational view of a mechanical fastener
engaging a nested pair of dimpled portions, which are shown in
section, according to the invention;
[0061] FIG. 14 is a top sectional view of a cage nut assembly
securing two post back walls to one another according to the
invention;
[0062] FIG. 15 is a left side perspective view of the web member,
and an exploded view of the end post, shown in FIG. 1;
[0063] FIG. 16 is a top left perspective view of the web cover
shown in FIG. 1;
[0064] FIG. 17 is an enlarged view of the encircled portion 17 of
FIG. 16;
[0065] FIG. 18 is a top left perspective view of the support
channel member shown in FIG. 1;
[0066] FIG. 19 is an enlarged view of the encircled portion 19 of
FIG. 18;
[0067] FIG. 20 is an exploded left side perspective view of middle
post and the first and second beams shown in FIG. 1;
[0068] FIG. 21 is top left perspective view of the apparatus in
FIG. 1, showing the fully assembled panel;
[0069] FIG. 22 is a top left perspective view of the panel of FIG.
21, showing an adjacent panel; and
[0070] FIG. 23 is a view, similar to FIG. 22, showing three
alternate panels according to the invention, each adjacent to each
other.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0071] Referring now to FIG. 1 of the drawings, there will be seen
a sports board apparatus 40 for use with a sports surface 30 and
one or more substantially planar boards 32. As best seen in FIG. 1,
the apparatus 40 includes a plurality of posts 50a,50b,50c, at
least one web assembly 150, at least one upper support member 180,
and at least one bottom support member 229. The web assembly 150
preferably includes a web member 152 and a web cover 154 (as best
seen FIG. 16) that securely engages the web member 152. The upper
support member 180 preferably includes a support channel member 181
(as best seen in FIG. 18) and first and second beams 210,212 (as
best seen in FIG. 20). As best seen in FIG. 1, the bottom support
member 229 preferably includes a bottom channel member 230 and a
bottom cover 240 that securely engages the bottom channel member
230.
[0072] The posts 50 may preferably include at least three posts,
namely, two end posts 50a,50c and at least one middle post 50b (as
best seen in FIGS. 1 and 22). The two end posts include a male end
post 50a and a female end post 50c. Each middle post 50b is
preferably positioned between the two end posts 50a,50c. Each of
the posts 50a,50b,50c has a lower end 54 portion and an upper end
52 portion.
[0073] Each of the posts 50a,50b,50c includes two elongate post
channel members 60,80,100 in securely nested relation with one
another. The post channel members 60,80,100 include a first post
channel member 60 (as best seen in FIG. 2), a second post channel
member 80 (as best seen in FIG. 3), and a third post channel member
100 (as best seen in FIG. 4).
[0074] The post channel members 60,80,100, the web members 152, the
web covers 154, the support channel members 181, the first beam
210, the second beam 212, the bottom channel member 230, and/or the
bottom cover 240 are constructed from a roll-formed metal material.
The metal material is preferably a light gauge steel material.
[0075] As best seen in FIG. 1, each of the post channel members
60,80,100 extends longitudinally upward from the lower end portion
54 to the upper end portion 52. Each of the posts 50a,50b,50c and
the post channel members 60,80,100 preferably extends in a
substantially upright direction.
[0076] As best seen in FIGS. 2, 3 and 4, each of the post channel
members 60,80,100 has a post back wall 70,90,110 and two post side
walls, 62,64, 82,84, and 102,104, extending from the post back wall
70,90,110. As best seen in FIG. 11, (i) the post back wall 70 of
the first post channel member 60 is shaped to define a bolt
aperture 122 therethrough, (ii) the post back wall 90 of the second
post channel member 80 is shaped to define a cage aperture 120
therethrough, and (iii) the post back wall 110 of the third post
channel member 100 is shaped to define an access port 124
therethrough.
[0077] As best seen in FIGS. 2, 3 and 4, each of the post channel
members 60,80,100 preferably has a retention member 66,86,106
extending inwardly from one of the post side walls 62,82,102.
Similarly, each of the post channel members 60,80,100 preferably
has a nesting member 68,88,108 extending inwardly from another one
of the post side walls 64,84,104.
[0078] Each post back wall 70,90,110 of each of the post channel
members 60,80,100 is preferably shaped so as to define a retention
depression 72,92,112 substantially adjacent to one of the post side
walls 64,84,104.
[0079] The post back wall 70,90,110 and the two post side walls,
62,64, 82,84, and 102,104, of each of the post channel members
60,80,100 are together shaped to define a substantially C-shaped
post channel profile, 62,70,64, 82,90,84, and 102,110,104 (as best
seen in FIGS. 2, 3 and 4).
[0080] The two elongate post channel members 60,80,100 are securely
nested relation with one another. As best seen in FIG. 6, the male
end post 50a includes the second post channel member 80 and the
third post channel member 100 in securely nested relation with one
another. As best seen in FIG. 5, the middle post 50b preferably
includes two third post channel members 100 in securely nested
relation with one another. As best seen in FIG. 6, the female end
post 50c includes the first post channel member 60 and the third
post channel member 100 in securely nested relation with one
another. An alternate embodiment of the female end post 50c is
shown in FIGS. 7 and 8, which includes two first post channel
members 60 in securely nested relation with one another. An
alternate embodiment of a post 50 is shown in FIG. 8, which
possesses both male and female characteristics, and which includes
the first post channel members 60 and the second post channel
member 80 in securely nested relation with one another. Of course,
other nested embodiments are also possible.
[0081] In order to readily accommodate the aforesaid nesting, the
outside length C,C',C'' of one of the side walls 64,84,104 is
preferably less than the inside length D,D',D'' of another one of
the side walls 62,82,102 (as best shown in FIGS. 2-6).
[0082] In the aforesaid securely nested relation, and as best shown
in FIGS. 5 and 6, a substantial extent of the retention member
66,86,106 of one of the post channel members 60,80,100 is
preferably received within the retention depression 72,92,112 of
another one of the two elongate post channel members 60,80,100.
[0083] In order to readily accommodate the aforesaid nesting, the
length A,A',A'' of the retention member 66,86,106 is preferably
less than the length B,B',B'' of the retention depression 72,92,112
(as best shown in FIGS. 2-6). Similarly, the thickness E,E',E'' of
the retention member 66,86,106 is preferably less than the depth
F,F',F'' of the retention depression 72,92,112.
[0084] Each web member 152 extends substantially between at least
two of the posts 50, and preferably extends substantially
horizontally (as best seen in FIG. 1). As best seen in FIG. 15,
each web member 152 has a web back wall 165 and two web side walls
166 extending from the web back wall 165. The web back wall 165
preferably has a notched web portion 156 that defines a web
aperture 158 therethrough (as best seen in FIG. 1).
[0085] Preferably, and as best seen in FIG. 1, each web member 152
securely engages at least three posts 50a,50b,50c--though it is
possible for the web member 152 to engage a few number of posts 50
(e.g., the two end posts 50a,50c). The web member 152 preferably
extends substantially between the two end posts 50a,50c, with the
middle post 50b preferably being securely received within the web
aperture 158.
[0086] As best seen in FIG. 15, the web back wall 165 and the two
web side walls 166,166 are together shaped to define a
substantially C-shaped web profile 166,165,166. The web member 152
preferably has opposing web end portions 162 and flanged web
portions 160. Each of the flanged web portions 160 preferably
extends from substantially adjacent to a respective one of the
opposing web end portions 162. As best seen in FIGS. 1 and 15, each
of the flanged web portions 160 preferably securely engages a
respective one of the two of the posts 50 (through web flange holes
164).
[0087] As best seen in FIG. 1, the web cover 154 preferably extends
substantially between the two end posts 50a,50c. As best seen in
FIG. 16, the web cover 154 preferably has a cover back wall 173 and
two cover side walls 174,174 extending from the cover back wall
173. The cover back wall 173 and the two cover side walls 174,174
are preferably together shaped to define a substantially C-shaped
cover profile 174,173,174.
[0088] The cover back wall 173 preferably has a notched web cover
portion 170 that defines a cover aperture 172 therethrough (as best
seen in FIG. 1). The middle post 50b is preferably securely
received within the cover aperture 172.
[0089] As best seen in FIG. 17, each of the cover side walls
174,174 preferably has a web retention portion 176. As aforesaid,
and as best seen in FIG. 1, the web cover 154 securely engages the
web member 152, with the web retention portions 176 preferably
securely engaging the web member 152, each over a respective one of
the web side walls 166.
[0090] As best seen in FIG. 1, each upper support member 180
preferably extends substantially horizontally. As best seen in
FIGS. 18 and 19, the support channel member 181 preferably has a
support back wall 187 and two support side walls 188,188 extending
from the support back wall 187. The support back wall 187 and the
two support side walls 188,188 are preferably together shaped to
define a substantially C-shaped support channel profile
188,187,188. The support back wall 187 is preferably shaped so as
to define two or more pole openings 186 therethrough.
[0091] As best seen in FIG. 18, the support back wall 187 also
preferably has a notched support portion 182 defining a support
aperture 184 therethrough. The middle post 50b is preferably
securely received within the support aperture 184
[0092] As best seen in FIG. 1, the support channel member 181
preferably extends substantially between the two end posts 50a,50c.
As best seen in FIG. 20, the second beam 212 is preferably in
substantially parallel and spaced relation with the first beam 210,
such that the first beam 210 and the second beam 212 preferably
define a beam opening 214 therebetween. Each of the first beam 210
and the second beam 212 preferably has a beam back wall 215 and two
beam side walls 217,217 extending from the beam back wall 215. The
beam back wall 215 and the two beam side walls 217,217 are
preferably together shaped to define a substantially C-shaped beam
channel profile 217,215,217.
[0093] As best seen in FIG. 1, each of the first beam 210 and the
second beam 212 is preferably positioned substantially between the
two support side walls 188 of the support channel member 181. The
beam back wall 215 of the first beam 210 preferably substantially
engages a first one of the support side walls 188. The beam back
wall 215 of the second beam 212 preferably substantially engages a
second one of the support side walls 188.
[0094] As best seen in FIG. 20, each of the beam side walls 217,217
of each of the first beam 210 and the second beam 212 preferably
has a notched beam portion 216,218 defining a beam aperture 220.
The middle post 50b is preferably securely received within the beam
aperture 220.
[0095] With the middle post 50b received within the beam aperture
220, beam retention portions 189 on each of the support side walls
of the support channel member 181 act to impede separation of the
beams 210,212 from the support channel member 181.
[0096] Each one of the first beam 210 and the second beam 212
preferably has two flanged beam portions 219,219 (as best seen in
FIG. 1). Each of the flanged beam portions 219,219 preferably
extends from the beam back wall 215. Each of the flanged beam
portions 219,219 is preferably mechanically fastened, through beam
flange holes 221, to the upper end 52 portion of a respective one
of the two end posts 50a,50c.
[0097] In this manner, the upper support member 180 preferably
securely engages the two end posts 50a,50c and the middle post 50b
substantially adjacent to each upper end 52 portion thereof.
[0098] As best shown in FIG. 1, the bottom channel member 230
preferably has a bottom channel back wall 235 and two bottom
channel side walls 236,236 extending from the bottom channel back
wall 235. The bottom channel back wall 235 and the two bottom
channel side walls 236,236 are preferably together shaped to define
a substantially C-shaped bottom channel profile.
[0099] As best shown in FIG. 1, the bottom cover 240 has a bottom
cover back wall 241 and two bottom cover side walls 242,242
extending from the bottom cover back wall 241. The bottom cover
back wall 241 and the two bottom cover side walls 242,242 are
preferably together shaped to define a substantially C-shaped
bottom cover profile 242,241,242. The bottom cover back wall 241
preferably has a notched bottom cover portion 232 defining a bottom
cover aperture 234 therethrough.
[0100] As best shown in FIG. 1, each of the bottom cover side walls
242,242 preferably has a bottom channel retention portion 243
securely engaging the bottom channel member 230 over a respective
one of the bottom channel side walls 236,236.
[0101] As best shown in FIG. 1, the bottom channel member 230
extends substantially horizontally and substantially between each
lower end portion 54 of the two end posts 50a,50c. The bottom cover
240 preferably extends substantially between the lower end 54
portion of the two end posts 50a,50c. The bottom channel member 230
securely engages each lower end 54 portion of the two end posts
50a,50c. The middle post 50b is preferably securely received within
the bottom cover aperture 234.
[0102] As shown in FIG. 21, the exploded apparatus 40 may be
assembled into a sports board panel 140. Multiple panels
140,140,140 may be connected end to end, as shown in FIG. 22. FIG.
23 depicts alternate panels 140',140' connected end to end, with
each of said alternate panels 140' including three middle posts
50b.
[0103] In each of the panels 140,140' shown in FIGS. 21 to 23, the
posts 50a,50b,50c include a first male end post 50a and a first
female end post 50c, amongst other things. Similarly, and as best
seen in FIGS. 22 and 23, each of the adjacent panels 140,140'
includes a second male end post 50a' and a second female end post
50c'. As best seen in FIG. 10, the second male end post 50a'
matingly engages the first female end post 50c. As best seen in
FIG. 11, the second female end post 50c' matingly engages the first
male end post 50a.
[0104] One of the post channel members 80 of each male end post
50a,50a' preferably includes a post mating protuberance 96 (best
seen in FIG. 6). Similarly, one of the post channel members 60 of
each female end post 50c,50c' preferably includes a post mating
depression 74. Each post mating protuberance 96 preferably matingly
engages a respective one post mating depression 74 in substantially
aligned and close-fitting relation.
[0105] Preferably, and as best seen in FIG. 14, the apparatus 40
further includes post securing means 200 (alternately referred to
herein as a caged nut assembly 200) for securely attaching the
first male end post 50a to the second female end post 50c' and for
securely attaching the first female end post 50c to the second male
end post 50a'. The caged nut assembly 200 includes a bolt 202, a
nut 204, and a cage 206. The cage 206, with the nut 204 secured
therein, is itself secured adjacent to the cage aperture 120 on the
third post channel member 100. The bolt 202 extends through the
bolt aperture 122 of the second post channel member 80, and is
tightened against the nut 204, such that the third post channel
member 100 and the second post channel member 80 are securely
attached to one another. In this manner, the first male end post
50a may be tightened against the second female end post 50c', and
the first female end post 50c may be tightened against the second
male end post 50a'
[0106] The apparatus 40 preferably further includes two or more
poles 226 and a substantially transparent and substantially planar
sheet 224 supported between the poles 226. Each of the poles 226
preferably extends through the beam opening 214 and through a
respective one of the pole openings 186. Each of the poles 226 has
a pole base 228 that is preferably securely attached to the web
cover 154 and securely attached relative to the web member 152.
[0107] According to one aspect of the invention, a first member and
a second member are selected from a group that preferably consists
of the posts 50, the upper and lower end portions 52,54 of the two
end posts 50a,50a',50c,50c', the post channel members 60,80,100,
the web member 152, the flanged web portions 160, the upper support
member 180, the first beam 210, the second beam 212, the flanged
beam portions 219,219, and the bottom channel member 230.
[0108] The apparatus 40 preferably further includes a plurality of
mechanical fasteners 190 (as best seen in FIG. 13) securely
attaching the first member to the second member. Each of the
mechanical fasteners 190 preferably includes a head portion 192, a
threaded portion 196, an underside ridge portion 194, and a
self-drilling portion 198.
[0109] As best shown in FIGS. 12 and 13, each of the first member
and the second member preferably includes one or more dimpled
portions 130. Each of the dimpled portions 130 preferably includes
a downset portion 132, an underside mating portion 134, and a
dimple opening 136.
[0110] As best shown in FIG. 13, each of the dimpled portions 130
of the first member is preferably in securely nested relation with
a respective one of the dimpled portions 130 of the second member,
so as to form one or more nested pairs 138 of the dimpled portions
130. Each of the mechanical fasteners 190 preferably extends
substantially through a respective one of the nested pairs 138 of
the dimpled portions 130. Each threaded portion 196 preferably
threadingly engages a respective one of the nested pairs 138 of the
dimpled portions 130. The underside ridge portion 194 engages the
underside mating portion 134 adjacent the downset portion 132, and
the self-drilling portion 198 may preferably create the dimple
opening 136. A substantial extent of each head portion 192 is
preferably fully received within the respective one of the nested
pairs 138 of the dimpled portions 130.
[0111] Mechanical fastening may also occur without the presence of
dimpled portions 130. For example, mechanical fasteners 190 are
preferably used to securely attach each of the flanged web portions
160 to a respective one of the two end posts 50a,50c (as
aforesaid). In another example, mechanical fasteners 190 are
preferably used to securely attach each of the flanged beam portion
219 to a respective one of the two end posts 50a,50c (as
aforesaid).
[0112] As best seen in FIG. 1, the apparatus 40 preferably further
includes at least one substantially planar top cover 222 securely
engaging the upper support member 180 in substantially overlying
relation, preferably substantially adjacent to each upper end 52
portion of the two end posts 50a,50c. The poles 226 preferably
extend through apertures 223 shaped in the top cover 222.
[0113] As best seen in FIG. 1, each post 50a,50b,50c, each web
member 152, each web cover 154, each upper support member 180,
and/or each bottom support member 229 is operatively securable
relative to the boards 32. The lower end portion 54 of each post
50a,50b,50c, each bottom channel member 230, and each bottom cover
240 is operatively positioned substantially adjacent to the sports
surface 30. Each post 50a,50b,50c, each bottom channel member 230,
and/or each bottom cover 240 is operatively securable relative to
the sports surface 30.
[0114] In accordance with the present invention there is also
disclosed a method of forming a sports board apparatus 40 for use
with a sports surface 30 and one or more substantially planar
boards 32. The method includes a post channel forming step, a web
forming step, an upper support forming step, and a mechanical
fastening step. The method preferably also includes a dimpling step
before the mechanical fastening step, and a nesting step after the
dimpling step and before the mechanical fastening step
[0115] In the post channel forming step, at least four of the post
channel members 60,80,100 are roll-formed by passing first elongate
sheets (not shown) of light gauge steel material through a series
of roll-forming post channel tool sets (not shown). Passage of the
first elongate sheets through each successive one of the post
channel tool sets progressively forms the post channel members
60,80,100.
[0116] In the post channel forming step, the retention member
66,86,106 and the retention depression 72,92,112 are preferably
roll-formed on each of the post channel members 60,80,100. Passage
of the first elongate sheets (not shown) through each successive
one of the post channel tool sets (not shown) preferably
progressively forms the retention member 66,86,106 and the
retention depression 72,92,112.
[0117] In the web forming step, one or more of the web members 152
is roll-formed by passing one or more second elongate sheets (not
shown) of light gauge steel material through a series of
roll-forming web tool sets (not shown). Passage of the second
elongate sheets through each successive one of the web tool sets
progressively forms the web members 152.
[0118] In the upper support forming step, one or more of the beams
210,212 is roll-formed by passing one or more third elongate sheets
(not shown) of light gauge steel material through a series of
roll-forming beam tool sets (not shown). Passage of the third
elongate sheets through each successive one of the beam tool sets
progressively forms the beams 210,212.
[0119] The method may also include other roll-forming steps, e.g.,
a web cover roll-forming step, a support channel roll-forming step,
bottom channel roll-forming step, and/or a bottom cover
roll-forming step. These other roll-forming steps are not further
described herein, but fall generally within the scope of the
invention.
[0120] The method may also include bending steps, e.g., a beam
flange bending step and/or a web flange bending step. These bending
steps are not further described herein, but fall generally within
the scope of the invention.
[0121] In the dimpling step, one or more of the dimpled portions
130 is preferably formed in each of the first member and the second
member.
[0122] The method may also include aperture punching steps, e.g., a
cage aperture punching step, a bolt aperture punching step, and an
access port punching step. These punching steps are further
described herein, but fall generally within the scope of the
invention.
[0123] In the nesting step, each of the post channel members
60,80,100 is positioned in operative securely nested relation with
another one of the post channel members 60,80,100 to form at least
two posts 50a,50b,50c. The aforesaid securely nested relation is
such that each of the post channel members 60,80,100 extends
longitudinally upward from the lower end portion 54 to the upper
end portion 52. The retention depression 72,92,112 of each of the
post channel members 60,80 preferably has received therewithin a
substantial extent of the retention member 66,86,106 of a nesting
one of the post channel members 60,80,100. Each of the dimpled
portions 130 of the first member is also preferably securely nested
in the aforesaid operative securely nested relation with a
respective one of the dimpled portions 130 of the second member. In
this manner, one or more of the nested pairs 138 of the dimpled
portions 130 are assembled.
[0124] In the mechanical fastening step, the first member
(described in greater detail hereinabove) is securely attached to
the second member (described in greater detail hereinabove) using a
mechanical fastener 190 extending substantially therethrough. Each
of the first member and the second member is preferably selected
from the group that includes the post. channel members 60,80,100,
the web members 152, and the beams 210,212, among others.
[0125] In the mechanical fastening step, each of the mechanical
fasteners 190 preferably extends substantially through a respective
one of the nested pairs 138 of the dimpled portions 130. This
mechanical fastening is such that a substantial extent of each of
the mechanical fasteners 190 is fully received within the aforesaid
respective one of the nested pairs 138 of the dimpled portions
130.
[0126] Operatively, each of the web members 152 and each of the
beams 210,212 extends substantially between and securely engages
the at least two posts 50a,50b,50c. Each of the beam members
operatively engages the at least two posts 50a,50b,50c
substantially adjacent to the upper end portion 52 thereof. Each of
the beams 210,212 and each of the web members 152 is operatively
secures relative to the boards 32. Each of the posts 50 is
operatively secured relative to the boards 32 and to the sports
surface 30, such that the lower end portion 54 of each of the posts
50 is operatively positioned substantially adjacent to the sports
surface 30.
[0127] As aforesaid, the sports board apparatus 40 includes posts
50a,50b,50c formed from C-shaped post channel members 60,80,100
which are advantageously nested in clusters, and thus provide
strength. The posts, 50a,50c' and 50a',50c, are joined together in
a nested fashion. The first and second beams 210,212 are provided,
as aforesaid, in spaced relation from one another so as to define
an elongate beam opening 214 therebetween, which allows passage
therethrough of the poles 226 for securely holding the transparent
planar sheet 224 (e.g., an acrylic plastic sheet). The
configuration of the components of the sports board apparatus 40
according to the present invention in such as to substantially
conceal and/or reduce the prominence of sharp edges thereon, so as
to prevent and/or reduce risk of injury.
[0128] It should be additionally appreciated (i.e., from all of the
foregoing, from the claims, and from the drawings) that the use of
LGS in the sports board apparatus 40 according to the invention
provides significant anti-corrosive properties. The use of LGS
according to the present invention provides a highly formable
material and enables construction of components having relatively
complex shapes from LGS, through the use of a series of continuous
roller dies. As such, the components of the sports board apparatus
40 according to the present invention allow for a relatively high
efficiency of manufacture (e.g., in terms of both time and money)
over components formed from prior art sports board materials. The
present invention does not require the use of exceedingly heavy
and/or otherwise cumbersome components, without seriously
sacrificing the structural integrity of the sports board apparatus
40.
[0129] Other modifications and alterations may be used in the
design and manufacture of other embodiments according to the
present invention without departing from the spirit and scope of
the invention, which is limited only by the accompanying
claims.
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