U.S. patent application number 12/727063 was filed with the patent office on 2010-11-04 for post sleeve assembly.
Invention is credited to N. Eric Knudsen.
Application Number | 20100277290 12/727063 |
Document ID | / |
Family ID | 43029960 |
Filed Date | 2010-11-04 |
United States Patent
Application |
20100277290 |
Kind Code |
A1 |
Knudsen; N. Eric |
November 4, 2010 |
POST SLEEVE ASSEMBLY
Abstract
A post sleeve provides a substantially permanent base for
supporting a post for a fence or sign, and from which one post can
be removed and replaced with another post. The sleeve includes a
concrete body that is poured on site, using a sleeve core
prepositioned in the post hole, and around which wet concrete is
poured. After the concrete is cured, the core is removed, leaving a
post sleeve cavity configured to receive a post. The core can be
rigid, or can include a flexible shell and stiffener. A preformed
post sleeve top can be attached to the sleeve core and positioned
therewith in the post hole, to become a permanent part of the post
sleeve, once the concrete cures. A drain is attached to the core,
and remains in the sleeve when the core is removed, and can be a
percolation chamber, or passage extending below the sleeve.
Inventors: |
Knudsen; N. Eric; (Maple
Valley, WA) |
Correspondence
Address: |
SEED INTELLECTUAL PROPERTY LAW GROUP PLLC
701 FIFTH AVE, SUITE 5400
SEATTLE
WA
98104
US
|
Family ID: |
43029960 |
Appl. No.: |
12/727063 |
Filed: |
March 18, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61161327 |
Mar 18, 2009 |
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Current U.S.
Class: |
340/10.52 ;
264/32; 52/169.13; 52/169.14; 52/173.1; 52/835 |
Current CPC
Class: |
E02D 5/26 20130101; E04H
12/2269 20130101; E01F 9/629 20160201; E02D 27/42 20130101; E02D
5/226 20130101; E04H 12/22 20130101; E04C 3/00 20130101; G09F
2007/1804 20130101; E01F 9/623 20160201; B28B 7/306 20130101 |
Class at
Publication: |
340/10.52 ;
52/835; 52/169.13; 52/169.14; 52/173.1; 264/32 |
International
Class: |
H04Q 5/22 20060101
H04Q005/22; E04C 3/30 20060101 E04C003/30; E02D 5/60 20060101
E02D005/60; E02D 19/00 20060101 E02D019/00; G09F 3/18 20060101
G09F003/18; E04B 1/16 20060101 E04B001/16 |
Claims
1. A half sleeve, comprising: a joining face that, when the half
sleeve and a substantially identical half sleeve are mated
together, defines a central longitudinal plane of a resulting post
sleeve; a first alignment element positioned on the joining face; a
second alignment element positioned on the joining face in a
position that corresponds to a position of the first alignment
element, such that, when the half sleeve and the substantially
identical half sleeve are mated together, in which the half sleeve
is placed in face-to-face contact with the substantially identical
half sleeve, with the first alignment element of the half sleeve
received by a second alignment element of the second half sleeve,
and a first alignment element of the second half sleeve received by
the second alignment element of the first half sleeve, the first
and second half sleeves together define a body of a complete post
sleeve; a first adhesive network section formed in the joining
face, including a first inlet port section, a first outlet port
section, and a first adhesive channel section extending between the
first inlet port section and the first outlet port section; and a
second adhesive network section formed in the joining face and
substantially mirroring the first adhesive network section,
positioned so as to be axially symmetrical with the first adhesive
network section such that if the first half sleeve and the
substantially identical second half sleeve are mated together, the
first adhesive network section of the first half sleeve and a
second adhesive network section of the second half sleeve together
define a first inlet port, a first outlet port, and a first
adhesive channel placing the first inlet port in fluid
communication with the first outlet port, and the second adhesive
network section of the first half sleeve and a first adhesive
network section of the second half sleeve together define a second
inlet port, a second outlet port, and a second adhesive channel
placing the second inlet port in fluid communication with the
second outlet port.
2. The half sleeve of claim 1, wherein the first alignment element
is an alignment pin, and the second alignment element is an
alignment aperture.
3. The half sleeve of claim 1, wherein the first alignment element
is a tongue, and the second alignment element is a groove.
4. The half sleeve of claim 1, wherein the first adhesive network
includes a third outlet port section, and the first adhesive
channel section extends also between the first inlet port section
and the third outlet port section, and the second adhesive network
includes a fourth outlet port section, and the second adhesive
channel section extends also between the first inlet port section
and the third outlet port section
5. A post sleeve, comprising: a preformed elongate body of a rigid
material; a cavity extending longitudinally within the body and
configured to receive an end of a post therein; and a chamber
positioned near an upper end of the cavity, sized so that, when a
post is positioned in the post sleeve, an open space is provide
inside the post sleeve and surrounding a portion of the post.
6. The post sleeve of claim 5, comprising a plurality of cavities
formed in an outer surface of the body.
7. The post sleeve of claim 5, comprising a knock-out plug at which
a portion of a side wall of the body is substantially thinner than
other portions of the side wall.
8. The post sleeve of claim 5, comprising a compressible element
positioned in the cavity for freeze protection.
9. The post sleeve of claim 5, comprising: a drainage aperture
extending downward from the cavity to the exterior of the body; and
a drainage chamber form coupled to the body over the drainage
aperture.
10. The post sleeve of claim 9 wherein the drainage chamber form
includes a closure that is of a material that will substantially
disintegrate when exposed to water.
11. The post sleeve of claim 9 wherein the drainage chamber form
includes a compressible element for freeze protection.
12. The post sleeve of claim 9 wherein the drainage chamber form
comprises a non-rigid material.
13. The post sleeve of claim 12 wherein the drainage chamber form
includes a quantity of drainage material.
14. The post sleeve of claim 9 wherein the drainage chamber form
includes a wall that is permeable to water.
15. The post sleeve of claim 9 wherein the drainage chamber form
will substantially disintegrate when exposed to water.
16. The post sleeve of claim 15 wherein the drainage chamber form
has fluted side walls to increase surface area for percolation.
17. A device, comprising: a sleeve core for forming a post sleeve;
elements positioned on the sleeve core for forming features of a
post sleeve cavity, including elements for forming stand-off ribs;
and a fixture coupled to an upper end of the sleeve core by which
the core can be held in a fixed position and orientation while a
post sleeve is formed around the core.
18. The device of claim 17 wherein the sleeve core comprises: an
outer shell made of an elastomeric material, and on which are
positioned the elements for forming features of a post sleeve
cavity; and a stiffener sized to fit snugly into the outer shell,
and configured to support and hold the shell rigidly for formation
of a post sleeve.
19. The device of claim 17 wherein the sleeve core is entirely
rigid.
20. The device of claim 19 wherein the sleeve core has a pattern
draft.
21. The device of claim 17 wherein the sleeve core comprises means
for coupling a sleeve top thereto.
22. The device of claim 17, comprising a plurality of notches
formed in an upper portion of the sleeve core, each configured to
receive a fastener, for coupling a sleeve top to the sleeve
core.
23. The device of claim 17; comprising a preformed sleeve top
configured to be coupled to an upper portion of the sleeve
core.
24. A post sleeve top for use with a sleeve core, comprising: a
body of a rigid material sized and configured to act as an upper
portion of a post sleeve; a post aperture extending axially through
the body, sized to be fully traversed by a post positioned therein;
and a feature coupled to the body near a lower edge thereof,
configured to be engaged by wet concrete when the body is partially
immersed therein, to rigidly lock the body to a concrete base
formed when the wet concrete cures.
25. The post sleeve top of claim 24, comprising a locking aperture
extending transverse to an axis of the body from the exterior
thereof to the post aperture, and configured to receive a locking
mechanism for locking the top to an object positioned in the post
aperture.
26. The post sleeve top of claim 24 wherein an upper portion
includes a decorative shape.
27. The post sleeve top of claim 24, comprising a unique identifier
positioned on the exterior of the body.
28. The post sleeve top of claim 24, comprising a radio frequency
identification tag coupled to the body.
29. The post sleeve top of claim 24, comprising a chamber formed in
the body, sized and positioned so that, when a post is positioned
in a post sleeve that incorporates the post sleeve top, an open
space is provide inside the body and surrounding the post.
30. A method for making a post sleeve, comprising: holding a post
sleeve core in a post hole at a selected position; pouring wet
concrete into the post hole around the post sleeve core; curing the
concrete while the post sleeve core is held in position; and
removing the post sleeve core from the cured concrete.
31. The method of claim 30, further comprising positioning the post
sleeve core in a post aperture of a post sleeve top, and wherein:
positioning the post sleeve core in the post hole comprises
positioning the post sleeve core and the post sleeve top in the
post hole at the selected position; and pouring the wet concrete
into the post hole comprises pouring the wet concrete into the post
hole to a depth sufficient to cover at least a lower portion of the
post sleeve top.
32. The method of claim 30, further comprising coupling a drainage
chamber form to a lower end of the sleeve core and positioning the
chamber form in the post hole with the core before pouring the wet
concrete.
33. The method of claim 32, further comprising placing the drainage
chamber form in contact with a bottom of the post hole.
34. The method of claim 32, further comprising placing a
compressible element inside the drainage chamber form for freeze
protection.
35. The method of claim 32, further comprising placing a drainage
material inside the drainage chamber form to prevent collapse of
the form during the step of pouring wet concrete into the post
hole.
36. The method of claim 30, further comprising applying a release
agent to the post sleeve core.
37. The method of claim 30, further comprising applying, to the
post sleeve core, a layer of wax as a release agent and water
sealant.
38. The method of claim 30, further comprising applying, to the
post sleeve core, as a release agent, a layer of wax of sufficient
thickness to permit removal of the core from the cured concrete,
where the core lacks a pattern draft.
39. The method of claim 30 wherein removing the post sleeve core
from the cured concrete comprises removing a stiffener from the
core, and removing a shell of elastomeric material from a post
sleeve formed in the concrete by the post sleeve core.
40. The method of claim 30, comprising positioning the post sleeve
core inside a preformed post sleeve, and wherein positioning the
post sleeve core comprises positioning the post sleeve core and the
preformed post sleeve in the post hole.
41. The method of claim 30, comprising: assigning a unique
identifier to the post sleeve, by which the post sleeve can be
distinguished from other post sleeves; and recording, as part of
the unique identifier or associated therewith, relevant data, which
include any of: a character string that is unique to the post
sleeve; position, elevation, and orientation of the post sleeve,
relative to an adjacent post sleeve or landmark; date of
installation of the post sleeve; model of the post sleeve core
used; intended purpose for the post sleeve; owner of the post
sleeve; party responsible for maintenance of the post sleeve;
installer of the post sleeve; design, materials, and dimensions of
a fence panel to be attached to a post supported by the post
sleeve; street address of the post sleeve; GPS location of the post
sleeve; street address of a residence or business closest to the
post sleeve.
42. The method of claim 41 wherein recording relevant data
comprises recording the relevant data to a radio frequency
identification tag coupled to the post sleeve.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The embodiments of the present disclosure are related in
general to the field of installation of supports for uprights of
fences, traffic signs, real estate signage, etc., and in particular
to post supports that can be permanently installed, and from which
one post can be removed and another emplaced.
[0003] 2. Description of the Related Art
[0004] A post is a substantially straight, elongated columnar
structure that is anchored at one end so as to stand upright, and
that supports thereon another structure. A post can be made of any
appropriate material, including wood, metal, or plastic. Posts of
various lengths and compositions are used in a wide range of
applications, including supporting fences, traffic control signs,
temporary structures, etc. Where a post is intended to be
substantially permanent, it is often placed in a hole and anchored
in a concrete footing to increase its cross section and hold it
firmly in place. One problem that is commonly encountered in such
situations is that posts, especially wooden posts, are subject to
breakage, warpage, and decomposition. Replacing a post that has
been anchored in concrete is difficult, wasteful, and unfriendly to
the environment for reasons that include excessive use of natural
resources and the generation of landfill material. The concrete
footing must be removed from the ground in order to make room for
the new post. This requires that a much larger hole must be dug
around the concrete footing. In turn, this requires a much larger
volume of concrete or re-compaction of the surrounding soil, to
fill the hole around the new post and create the new footing in
proper contact with undisturbed or adequately compacted soil.
[0005] One of the most common causes of deterioration in wooden
posts is water trapped around the end of the post inside the
concrete. For example, when the post is damp or wet for an extended
period of time, the wood absorbs water and draws it by capillary
action downward into the concrete footing. Water becomes trapped
between the wood and the inside wall of the concrete, so that the
end of the post remains wet even while the upper portion is dry.
This is especially true in cases where the end of the post is
completely encapsulated in concrete, preventing water from escaping
through the bottom of the footing, in which case the majority of
the water escapes only through the wicking action of the end grain
of the post.
[0006] To reduce this problem, installers often pour several inches
of gravel into the bottom of a post hole and place the post
directly on the gravel before they pour concrete around it. This
prevents the concrete from completely sealing up the bottom of the
post by flowing under it, and thus provides a channel for water to
escape into the gravel. However, this is only a partial solution.
Often the drainage gravel is not fully compacted and settles,
causing more need for repair and replacement. Furthermore, with
this common method, it takes substantial time for water, once
having entered the footing, to work its way all the way through the
footing and out the bottom. If the post is subjected to frequent or
extended wet periods, the end of the post inside the footing may
remain constantly wet even though water continues to drain out the
bottom. Additionally, because of the direct contact with the ground
on the end of the post, water can move upward into the footing when
the ground is wet, due to the capillary or wicking effect of the
end grain. This constant dampness encourages the growth of
organisms that digest the wood fiber and eventually destroy the
post, or in the case of steel, rusts the post away. Additionally,
the bottom of the footing is substantially open to insects, which
can enter unobstructed from the gravel below to attack and eat the
post.
[0007] Furthermore, direct contact between concrete and some
species of wood generates a reaction that promotes deterioration of
the wood. This limits the species of wood that can be used for
fence or sign posts where concrete footings will be used in direct
contact with the post.
[0008] Another approach that is used to protect wood posts and
other lumber in direct contact with the ground or with concrete is
commonly referred to as pressure treating. In this process,
protective chemicals are forced into an outer surface of the post
under high pressure. The chemicals provide the post with protection
from common funguses and other organisms that cause deterioration.
Pressure treatment generally extends the useful life of a post by a
factor of five to ten. However, the chemicals used in pressure
treatment are often toxic to humans and non-target organisms, and
can leach into the water supply. In other cases, the chemicals are
highly corrosive, tending to cause corrosion in fasteners and
structures that are attached thereto. An additional problem with
pressure treatment is that the wood cannot generally be recycled
when it is replaced, and should not be composted, because of the
chemicals still present. This means that it must be deposited in a
landfill which in turn is a result of the need to install a post in
direct contact with the ground and or concrete.
[0009] A third approach to this problem is the use of prefabricated
anchors or sleeves, i.e., pockets that are placed in the ground or
anchored in a concrete footing. These anchors permit a post to be
removed and replaced without requiring that the pocket itself be
replaced. Some examples of such anchors are disclosed in the
following U.S. patents, all of which are incorporated herein by
reference in their entireties: U.S. Pat. No. 5,632,464; U.S. Pat.
No. 6,098,353; and U.S. Pat. No. 7,325,790.
BRIEF SUMMARY
[0010] According to an embodiment, a post sleeve includes a
concrete body that is poured on site, using a sleeve core that is
prepositioned in the post hole, and around which wet concrete is
poured. After the concrete is cured, the core is removed, leaving a
post sleeve cavity configured to receive a post. The sleeve core
includes features for forming selected features of the post sleeve.
According to an embodiment, a drainage chamber is attached to the
bottom of the sleeve core, and remains in the concrete when the
core is removed. the chamber can be configured to drain by
percolation, or can be placed in fluid communication with the soil
surrounding the post hole.
[0011] According to one embodiment, the sleeve core comprises a
flexible shell, made of an elastomeric material, for example, and a
stiffener configured to hold the shell to its proper shape while
the concrete cures.
[0012] According to another embodiment, the sleeve core is rigid.
It can be provided with a pattern draft, or a release agent is
applied to a thickness sufficient to permit removal of the core,
without a pattern draft.
[0013] According to an embodiment, a preformed sleeve top is
provided, and configured to be coupled to the sleeve core prior to
placement in the post hole. The wet concrete firmly engages the
sleeve top, which remains as part of the finished post sleeve once
the sleeve core is removed.
[0014] According to an embodiment, half sleeves are provided, which
are configured to be bonded together in a face-to-face position, to
form a complete post sleeve.
THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a post sleeve assembly
according to an embodiment of the invention.
[0016] FIG. 2 shows a partial cutaway view of the post sleeve of
the assembly of FIG. 1, showing a sleeve liner.
[0017] FIG. 3 shows the post sleeve assembly of FIG. 1 positioned
in the ground as a finished footing.
[0018] FIGS. 4 and 5 show respective details of the post sleeve
assembly of FIG. 1 in cutaway view.
[0019] FIG. 6 is a cutaway view of the post sleeve assembly of FIG.
1 and a number of attachments and adapters for use with various
post support configurations.
[0020] FIG. 7 shows a sleeve liner section according to an
embodiment of the invention.
[0021] FIG. 8 shows three post sleeves in respective configurations
according to an embodiment of the invention.
[0022] FIG. 9 shows a chain-link fence according to an
embodiment.
[0023] FIGS. 10 and 11 show post sleeves according to respective
embodiments.
[0024] FIG. 12 shows a transition fitting for a post sleeve,
according to an embodiment.
[0025] FIG. 13 shows a post collar with slots configured receive
replaceable pesticide tablets, according to one embodiment.
[0026] FIG. 14 shows a post sleeve assembly according to an
embodiment.
[0027] FIGS. 15A and 15B show a post assembly for use in
applications where a post is likely to be contacted repeatedly by
vehicles.
[0028] FIG. 16 shows a support plate for use with a round post,
configured to prevent rotation of the post.
[0029] FIG. 17 shows an oversized post support according to an
embodiment.
[0030] FIGS. 18 and 19 show a post sleeve according to an
embodiment.
[0031] FIG. 20 shows an insert configured to engage a commercially
available post sleeve section.
[0032] FIG. 21 shows an insert adaptor that includes a universal
socket, according to an embodiment.
[0033] FIG. 22A shows a concrete half sleeve according to an
embodiment.
[0034] FIG. 22B shows a complete post sleeve formed from two of the
half sleeves of FIG. 22A.
[0035] FIG. 23A shows a concrete half sleeve according to another
embodiment.
[0036] FIG. 23B shows a complete post sleeve formed from two of the
half sleeves of FIG. 23A.
[0037] FIG. 24A shows a half sleeve and a chamber vessel according
to another embodiment.
[0038] FIG. 24B shows a cutaway view of a portion of the chamber
vessel of FIG. 24A.
[0039] FIG. 25 shows a sleeve core according to one embodiment.
[0040] FIG. 26 shows a post sleeve core according to another
embodiment.
[0041] FIG. 27 shows a sleeve top for use with a sleeve core such
as, for example, one of the sleeve cores of FIGS. 25 and 26.
[0042] FIG. 28 shows a sectional view of a post sleeve made with
the sleeve core of FIG. 26 and including the sleeve top of FIG.
27.
[0043] FIG. 29 shows a post sleeve according to another
embodiment.
DETAILED DESCRIPTION
[0044] FIG. 1 shows a post sleeve assembly 100 according to a first
embodiment. The post sleeve assembly 100 includes a post sleeve 102
having a body 116 with a somewhat tapered shape and a wide rim 104
extending outward from the body in each direction. Reinforcing ribs
106 extend from the body 116 to the underside or soffit 144 of the
rim 104. A post 110 is shown positioned in the post sleeve 102. An
upper surface of the rim 104 slopes downward, away from the post on
all sides. An identification plate 108 is inset into an upper
surface of the rim 104. A post collar 112 fits closely around the
post and extends partway into an upper aperture 121 (see FIG. 2) of
the post sleeve 102 providing a means to block insects, debris, and
direct rain from infiltrating while maintaining substantial airflow
to the post sleeve assembly and giving lateral support to the post
from the supporting post sleeve 102.
[0045] The rim 104 is shown as having a smooth regular surface.
According to other embodiments, the rim 104 can have any of a
variety of shapes and configurations. For example, it can be
embossed or debossed with text or symbols, textured to resemble
stone or brick, or provided with architectural detail to coordinate
with other nearby elements. The material of the body can be colored
to add architectural detail, to promote functionality, or provide
decorative appeal. The identification plate 108 is provided with a
unique identifier that may be applied during fabrication, and
serves to separately identify each post sleeve assembly 100.
[0046] Turning now to FIG. 2, the post sleeve 102 is shown with a
portion of the body 116 cut away to show details of the interior. A
sleeve liner 120 is positioned within the body 116 and is
substantially encapsulated therein. The sleeve liner defines a
cavity 111 extending the length of the post sleeve, and configured
to receive a post. The cavity 111 has an upper aperture 121 that is
configured to receive a post, and a lower aperture 115 configured
to provide drainage. Standoff ribs 122 are provided on inner walls
of the cavity 111 with spaces between the standoff ribs 122
defining drain channels 124. The sleeve liner 120 includes a liner
aperture 126, and the body 116 comprises an outer sleeve aperture
128 in a position that corresponds to the liner aperture 126 so as
to be contiguous therewith and provide an aperture extending from
the cavity 111 to the exterior of the post sleeve.
[0047] According to the embodiment pictured, the post sleeve 102 is
sized to receive a 4.times.4 post, of the kind that is widely used
for fences and signs. When a 4.times.4 post is positioned in the
post sleeve 102 (as shown in FIG. 3), it is supported on four sides
by the standoff ribs 122, such that the post sleeve 102 functions
as an extension of the post. While vertically oriented standoff
ribs are shown and described, other standoff elements can be
employed, such as diagonal ribs, short knobs extending within the
cavity 111, etc., all of which fall within the scope of the
invention.
[0048] The sleeve liner 120 is produced by injection molding, blow
molding, or some other appropriate method of manufacture, and can
be assembled from two or more pieces, or can be made as a single
piece. The sleeve liner 120 is placed within a mold, and the body
116 of the post sleeve 102 is cast around the sleeve liner 120. The
body 116 extends above the upper portion of the sleeve liner 120,
which shields the plastic sleeve from long term exposure to UV
rays, which can cause many plastics to deteriorate. The standoff
ribs 122 contact and support the post 110 and prevent contact
between the wood post and the concrete body 116, while the drain
channels 124 allow water to drain away from the post and permit air
ventilation to promote moisture evaporation.
[0049] In one embodiment, the body 116 is cast from a high strength
concrete mix that includes glass fiber reinforcement and is
formulated to have compression strength of 5,000 to 9,000 psi, or
more. It is formed to be highly resistant to most environmental and
incidental wear and tear that such a structure is likely to be
subjected to. Accordingly, it is anticipated that the post sleeve
102 will have a serviceable life span many times that of a typical
wood post footing that is poured on site, and may exceed 50 years,
perhaps reaching 100 years or more.
[0050] According to alternate embodiments, the body 116 and the
sleeve liner 120 can be formed from any suitable material,
including recycled plastic, metal, fiberglass, composite resin etc.
Alternatively, the sleeve liner can be a thin concrete shell into
which the interior features of the sleeve are cast, which is then
encapsulated in a concrete post sleeve or footing, as described
herein
[0051] The identification plate 108 is shown as a metal (e.g.,
brass) plate that is embedded in the body 116 during the
fabrication process. Alternatively, the identification plate 108
can be mounted to the body after fabrication, or the reference
number can be formed in the material of the body 116, either on the
rim 104 or inside the upper aperture 121, during the casting
process. In other embodiments, the post sleeve has no
identification markings.
[0052] FIG. 3 shows the post sleeve assembly 100 anchored in the
ground 134 with a portion of the rim 104 extending above ground
level. The rim 104 is configured to provide added lateral strength
to the post and to reduce or prevent infiltration of water, debris
and ground cover, as well as insects. Furthermore, it serves to
protect the post from gardening tools such as edgers and string
trimmers. The post sleeve 102 is positioned in a hole 138 in the
ground 134. A layer 130 of compacted sand or drainage gravel is
positioned at the bottom of the hole for drainage, and a poured
concrete footing 132 surrounds and encases the post sleeve 102 in
the hole 138. The concrete footing 132 adds cross sectional area
for lateral support, depth for frost line resistance, and fills the
hole between the post sleeve 102 and the undisturbed ground 134. As
shown in FIG. 3, the post sleeve assembly 100 includes a flexible
drain hose 114 coupled at a first end to the post sleeve 102 at the
lower aperture 115, a second end thereof extending into the
drainage gravel 130 at the bottom of the hole 138. The gravel
functions as a dry well in which drainage from the flexible drain
hose 114 accumulates, and from which water infiltrates to the
surrounding soil. A plastic cover 136, such as is commonly used in
vinyl fencing, is shown positioned over the post 110.
[0053] The post collar 112 includes a plurality of spacing ribs 198
distributed around a bottom surface thereof, which are shaped such
that a portion of each of the spacing ribs 198 rests on an upper
slightly outward sloped surface of the rim 104 of the post sleeve
102, with another portion extending into the upper aperture 121 of
the post sleeve 102 between an inner surface of the post sleeve 102
and the post 110. In this way, the spacing ribs 198 serve to
maintain a gap between the upper surface of the rim 104 and the
lower surface of the post collar 112, providing ventilation while
still allowing lateral support to the post by the post collar 112.
The gaps between the spacing ribs 198 permit air to enter the post
sleeve to assist in evaporation of moisture within the sleeve, but
the post collar 112 is shaped to generally prevent water from
entering the sleeve via the gaps between the spacing ribs 198. The
spacing of the spacing ribs 198 is selected to prevent most insects
from entering the post sleeve, including bees, hornets, and larger
termites. An upper surface of the post collar 112 is sloped to
promote run-off of moisture, and the bottom edge of the outer rim
includes a break edge to prevent water from traveling back into the
underside of the collar by capillary action as it drips off the
edge.
[0054] The heating affect of the sun on the exposed concrete rim
104 creates a heat differential within the post sleeve 102 that
generates convection within the cavity 111 to increase the airflow.
Water that does enter the post sleeve 102 readily drains into the
drainage gravel 130 via the flexible drain hose 114. Furthermore,
as noted with reference to FIG. 2, the post 110 is separated from
an inner wall of the post sleeve 102 by the plurality of standoff
ribs 122 that define the internal dimensions of the cavity 111. The
standoff ribs 122 of the embodiment pictured are sized and
positioned to contact and support the outer surface of a common
4.times.4 post. Drain channels 124 extending lengthwise between the
ribs in the post sleeve 102, permit water to flow easily out of the
post sleeve and drain via the lower aperture 115 and the flexible
drain hose 114, thereby preventing water from remaining in contact
with the post 110 for extended periods. Top surfaces 123 of the
standoff ribs 122 are sloped, permitting smooth post insertion
during installation (see also FIG. 4).
[0055] According to an embodiment, the dimensions defined by the
ribs 122 are slightly greater than the dimensions of a standard
4.times.4 post in order to accommodate a swollen or slightly bowed
post. Alternatively or additionally, the material and thickness or
shape of the innermost surfaces of the standoff ribs 122 of the
sleeve liner 120 are selected to permit some resiliency to
accommodate slight variations in size while adequately supporting
the post.
[0056] The post sleeve assembly 100 helps to limit moisture damage
to posts positioned therein in a number of ways. For example, water
that strikes the post 110 runs down until it encounters the post
collar 112, which diverts most of the water away from the post 110
and onto the upper surface of the rim 104 of the post sleeve 102.
The water then flows down the sloped surface of the rim 104 and
away from the post entirely. The limited amount of water that does
enter the post sleeve 102 is generally channeled away from the post
110 by the drain channels 124 of the post sleeve liner 120 and runs
to the bottom of the post sleeve 102, whence it exits via the
flexible drain hose 114. Additionally, air circulation enabled by
the gap under the post collar 112, and enhanced by convection and
the normal flow of air around the post, further reduce the amount
of moisture in the post sleeve 102.
[0057] The soffit 144 extends from an outer surface of the rim 104
to the lower portion of the body 116 of the post sleeve 102 at a
substantial downward angle. When the post sleeve 102 is
encapsulated in the concrete footing 132, as shown in FIG. 3, the
angle of the soffit 144 allows the concrete to flow smoothly around
the post sleeve 102 and fill in the spaces, which reduces the
likelihood that air pockets will be trapped between the freshly
mixed concrete footing 132 and the outer surface of the post sleeve
102. Typical poured-in-place concrete used for anchoring posts,
such as that shown in the embodiment of FIG. 3, is more porous than
concrete handled in a controlled manufacturing environment, such as
the material used to form the post sleeve 102. Accordingly, water
can percolate through the more porous concrete footing 132 and
become trapped in air pockets alongside the body 116 of the post
sleeve 102. If this occurs, there is a danger of cracking of the
post sleeve 102 or the concrete footing 132 in the event the water
freezes. The slanted surface of the soffit 144 reduces this danger.
Additionally, the outer surface of the body 116 may be pre-treated
with a concrete bonding agent to accelerate and perpetuate the bond
of the lower strength concrete footing 132 to the body 116.
[0058] A poured-in-place concrete footing will typically have a psi
rating in the range of 2,500 to 3,500 lbs. In contrast, concrete
that is handled in a controlled manufacturing environment, with
proper temperature control, vibration, mixing, and admixtures, such
as the high strength material used to form the post sleeve 102, can
easily reach a 5,000 to 9,000 psi rating, or more, resulting in a
hardened casing of extreme durability and life expectancy. The life
expectancy of the relatively weaker poured-in-place concrete
footing 132 is significantly increased by the post sleeve 102
because the substantially larger cross-sectional area of the post
sleeve distributes and decreases the point load exerted under
lateral loads by the narrower effective section of the post 110
itself.
[0059] Turning now to FIG. 4, a detail of an upper portion of the
post sleeve 102 and rim 104 is shown in cutaway view. FIG. 4 shows
a fastener 142 extending from the interior of the post sleeve 102
to the exterior via the liner aperture 126 and the outer sleeve
aperture 128. A threaded insert 140 is engaged by threads on the
fastener 142. The fastener 142 extends into the interior of the
post sleeve 102 and includes a pressure pad 143 on the end
positioned within the post sleeve 102. When a post is positioned
within the post sleeve 102, the fastener 142 is then driven in by
rotation to engage a surface of the post collar 112, which
transmits the pressure to the post, locking the post in the post
sleeve 102. When removal of the post is necessary, one merely
releases the fastener 142 and slides the post out of the post
sleeve 102. In one embodiment, the threaded insert 140 is emplaced
in the high strength concrete during the casting process, and is
very securely attached. The material of the fastener is preferably
a corrosion resistant material such as stainless steel and may be
replaced as necessary when the post is removed.
[0060] According to an alternate embodiment, one or more apertures
are provided from the exterior of the post sleeve 102, similar to
the combined apertures 126, 128, and common fasteners, such as, for
example, long deck screws, are driven into the post via the
apertures, thereby securely anchoring the post to the post
sleeve.
[0061] FIG. 5 is a cutaway view of a lower portion of the post
sleeve 102, showing a universal socket section 151 comprising a
plurality of sockets, including sockets configured for a number of
the most common post shapes and dimensions. The sockets preferably
have a slight taper in the sidewalls to allow for small variations
in the dimensions of the post, including variations caused by
surface treatments, swelling due to moisture, and slight
manufacturing defects or tolerances in the actual dimensions of the
posts. The reference characters in FIG. 5 that refer to the sockets
indicate a respective step or ledge, but the socket indicated also
includes sidewalls or other vertical elements to provide lateral
support for a post.
[0062] Uppermost is the 4.times.4 socket 150, configured to receive
a standard 31/2.times.31/2 inch fence post (nominally 4.times.4).
The four sides of the 4.times.4 post are supported laterally by the
standoff ribs 122 to hold the post snugly in place. The bottom end
of the post rests on the ledge, or step, indicated by the reference
number 150. A 31/2 inch round post will also be accommodated in the
4.times.4 socket 150. Next is the 3 inch socket 152, configured to
receive a standard 3 inch square post. The base of the post rests
on the step indicated at reference number 152, and the four sides
are supported by the side walls that extend upward from that step
toward the 4.times.4 socket 150. The 21/2 inch socket 154 is
configured to receive a 21/2 inch square post or a nominal 3 inch
round post. The base of the post rests on the step indicated at
reference number 154, and the four sides are supported by the side
walls that extend upward from the step toward the 3 inch socket
152. Similarly, the (nominal) 21/2 inch round socket 156, (nominal)
2 inch round socket 158, and 15/8 inch round socket 160 are
positioned one beneath the next as shown in FIG. 5, configured to
receive round posts of tubing or pipe commonly used for fence and
sign posts, railing balusters, etc. Additionally, the 21/2 inch
round socket 156 will also accommodate a 2 inch square post by
providing bearing surfaces at the corners.
[0063] The socket sizes shown are merely exemplary, and do not
limit the scope of the invention. For example, according to an
embodiment, the post sleeve is provided with common metric-sized
sockets for use where metric-sized posts are standard. Furthermore,
the post sleeve is not limited to square and round sockets, or even
to the most common sizes. It may be beneficial in some applications
to provide rectangular or polygonal sockets for particular
applications.
[0064] In the embodiment of FIG. 5, most of the standoff ribs 122
terminate above the bearing surface of the 4.times.4 socket 150,
providing a drainage passage 162 for water to run to a corner of
the sleeve liner 120, even when a 4.times.4 post is positioned in
the 4 inch socket. Drain gutters 161 extend down through each of
the bearing surfaces and terminate above the lower aperture 115 to
allow water to drain past the respective sockets and out the drain
hose 114.
[0065] The flexible drain hose 114 shown in FIG. 5 comprises a
plurality of annular ridges that create a flexible yet crush
resistant pipe. Mating ridges 148 formed in the aperture 115 are
sized to engage the ridges of the flexible drain hose 114, which is
snapped into the aperture 115 to attach the flexible drain hose 114
to the sleeve liner 120. According to another embodiment, the lower
aperture 115 is provided with a standard hose thread coupling. In
other embodiments the lower aperture 115 may be a slip fit, press
fit, snap fit, or any other loosely coupled means of providing a
drainage port during the concrete pouring process for the concrete
footing 132. It should be noted that a watertight seal between the
flexible drain hose 114 and the lower aperture 115 is not
necessary. The coupling need merely be sufficiently tight to
prevent concrete from flowing into the lower aperture 115 during
installation. Thus the tube can be any convenient tube, including a
section of recycled garden hose, etc. The portion of the hose that
will be buried in gravel can be provided with perforations to
permit water to drain from the hose at various points to improve
percolation. Alternatively, a length of soaker hose, such as is
commonly used by gardeners to irrigate gardens, may be used in
place of the flexible drain hose 114. It should be further
recognized that the cross sectional area of the lower aperture 115
and accompanying flexible drain hose 114 can be as small or large
as is deemed necessary for different conditions.
[0066] According to an embodiment, the lower aperture 115 sits
directly on the gravel 130. Alternatively, a straight, rigid
fitting is provided that extends directly down into the drainage
gravel 130 below, which is advantageous where the footing is
significantly longer than the post sleeve 102 to extend below a
frost line. According to another embodiment, an elbow fitting 168,
shown in FIG. 6, is provided to direct the flexible drain hose 114
into view from above during installation to simplify burying the
flexible drain hose 114 in the drainage gravel 130. In some
climates where freezing is a concern, post holes may need to be dug
much deeper so that the concrete footing extends below the frost
line to prevent uplift. As the installer can't physically reach to
the bottom of the hole to insert the flexible drain hose 114 into
the drainage gravel 130, the elbow fitting 168 can allow the
installer to direct the hose into an opening provided in the
sidewall of the hole 138 to assure a passage for water into the
soil adjacent to the footing. It should be noted that the elbow 168
can be coupled by any appropriate method, including threaded
coupling, glue, snap fitting, interference fitting, etc., and that
the elbow fitting 168 and the flexible drain hose 114 can be one
piece and of varying dimensions and flexibility.
[0067] It should also be noted that it is not required that the
drain hose be coupled directly to the lower aperture 115. Thus,
according to further embodiments, in place of a drain hose, a large
diameter--e.g., 6 inch or 8 inch--rigid or corrugated plastic or
cardboard tube drain tube can be employed. The lowermost outer
surface of the sleeve can be shaped to be engaged by the drain
tube, and may be round and may have annular ridges to engage
corrugated pipe or smooth-walled tubing. Alternatively, a section
of large diameter pipe can be placed at the bottom of the post
hole, and the post sleeve placed so that its lower end engages the
pipe. It is only necessary that the joint between the post sleeve
and drainage means be sufficiently tight to prevent quantities of
wet concrete from flowing in. According to another embodiment, the
drain hose comprises a thin permeable membrane of plastic or
fabric, for example, which is filled with drainage sand or gravel
to allow drainage, but also to prevent uplift of the drain hose by
displacement as the concrete is poured. The lower end of the
weighted drain hose rests on the soil at the base of the hole to
allow a permanent connection for water to infiltrate out of the
hose. The lower end can be provided with an enlarged
water-permeable or degradable pad placed in contact to the
ground.
[0068] A notch 149 is provided in the sleeve liner 120 above the
lower aperture 115 to receive a replaceable corrosion resistant
mesh screen 146 to prevent debris from accumulating in the flexible
drain hose 114 over the life of the post sleeve 102. While the
spacing ribs 198 of the post collar 112 will prevent most debris
from entering, some will inevitably enter. Additionally, as the
post ages and eventually deteriorates, wood fragments may also drop
to the bottom of the sleeve. The mesh screen 146 prevents most
debris from entering the flexible drain hose 114 and blocking the
drainage of the post sleeve 102. While it is true that such debris
may also block the lower aperture 115 from above the mesh screen
146, it is anticipated that prior to installing a new post, the
installer will vacuum out the bottom of the post sleeve 102 as
necessary, to remove any such blockage. This is a much simpler
operation than cleaning the area below the lower aperture, which
would otherwise be necessary. In the embodiment of FIG. 5, an
additional notch is provided above the mesh screen 146 as an
extension of the surface of the 1 5/8 inch round socket 160. This
additional notch acts as a receiver for a high pressure water
nozzle with vacuum assembly to engage and blow out the area below
the lower aperture 115, if necessary.
[0069] Referring now to FIG. 6, a post sleeve 102 is shown,
together with a variety of elements for adapting the post sleeve to
accommodate various sizes and shapes of posts, and for various
applications. Stop plates 170, 172, 174, 180, 182, and 184, and
support plates 186 and 189 are shown, and will be described in
detail below. Additionally, post collar 112, described above with
reference to FIG. 2, post collars 202 and 204, sleeve cap 206, and
rim cap 190 are shown, all of which will also be described in
detail below.
[0070] Provided the post is adequately supported laterally, it is
not required that the post extend the full depth of the sleeve.
Accordingly, stops are provided at various depths within the post
sleeve 102 to permit the post to be supported at less than the full
depth of the sleeve. Stops are most clearly shown in the embodiment
of FIG. 7. In FIG. 6, the 4.times.4 socket 150 is 19 inches below
the upper surface of the rim 104 of the post sleeve 102. 19 inch
stop plate 170 is provided to rest on the ledge of the 4.times.4
socket 150, and is supported laterally by standoff ribs 122. 19
inch stop plate 170 is provided as support for a 4.times.4 wood
post in heavy post applications such as, for example, extra tall
fences or signs. The 19 inch stop plate 170 is substantially
square, with notched corners, and holes 171 that serve to permit
water to drain past. A raised surface portion in the center of the
stop plate acting as a standoff 173, strengthens the plate and
holds the bottom face of the post slightly away from the plate,
allowing ventilation to the bottom-most surface of the wood post.
As this is the end grain, or "wicking" surface, this is the most
important portion to keep dry in order to prevent rot. The 19 inch
stop plate 170 can be pre-installed to the bottom of the post prior
to insertion by means of a screw through one or two of the drain
holes 171, or it can be dropped into place from the top opening
just prior to setting the post.
[0071] The first stops above the 4.times.4 socket 150 are the 13
inch stops 164, which are 13 inches below the upper surface of the
rim 104. 13 inch stop plate 172 is provided, including a plurality
of tabs 176 extending from the edges of the plate. When the 13 inch
stop plate 172 is positioned in the post sleeve 102, the tabs
extend into the drain channels 124, and engage the 13 inch stops as
shown in FIG. 6. With the exception of the tabs 176, the 13 inch
stop plate 172 is substantially identical to the 19 inch stop plate
170. Thus, the 13 inch stop plate 172 serves to support the bottom
end of a 4.times.4 post 13 inches below the upper surface of the
rim 104. In addition to the 13 inch stop plate 172, other plates,
which will be discussed in detail later, are provided that are
configured to engage the 13 inch stops.
[0072] 9 inch stops 166 are provided 9 inches below the upper
surface of the rim 104. 9 inch stop plate is provided with tabs 176
arranged to engage the 9 inch stops 166, as shown in FIG. 6. As
with the 13 inch stop plate 172, the 9 inch stop plate 174 is also
substantially identical to the 19 inch stop plate 170, excepting
the tabs 176, and serves to support the bottom end of a 4.times.4
post 9 inches below the upper surface of the rim 104.
[0073] FIG. 21 shows an insert adaptor 480 that includes a
universal socket 482 similar to the universal socket section 151
described with reference to FIG. 5, in that it is configured to
receive posts of a number of different sizes and shapes. In the
embodiment shown, the insert adaptor 480 is provided with tabs 176
arranged to engage the 9 inch stops of a post sleeve, as shown in
FIG. 6.
[0074] Referring to FIG. 8, three post sleeve assemblies 100 are
shown in respective configurations: post sleeve assembly 100a
includes an eight-foot post 110a supported by a 19 inch stop plate
170 at 19 inches below the top of the rim 104 of the assembly at
the socket 150; post sleeve assembly 100b includes a seven-foot
post 110b supported by a 13 inch stop plate 172 at 13 inches below
the top of the rim 104 of the assembly; and post sleeve assembly
100c includes a seven-foot post 110c supported by a 9 inch stop
plate 174 at 9 inches below the top of the rim 104 of the
assembly.
[0075] Assuming that a fence of six feet in height is desired,
eight-foot posts would normally be used, and set at a depth of
about 18 to 24 inches, depending on how much of the post is to
extend above the fence. Accordingly, the eight-foot post 110a,
which is supported 19 inches below the rim 104 of the post sleeve
assembly 100a, extends about 79 inches above ground level G, which
is sufficient to accommodate most fence heights by trimming any
excess from the post.
[0076] However, by positioning a post as shown with reference to
post sleeve assembly 100b, using a 13 inch stop plate 172 at the 13
inch stop, the post 110b extends six inches further above ground
level G. Bearing in mind that the post sleeve 102 is to be
installed with the upper surface of the rim 104 at about two inches
above ground level for proper drainage, the top of the seven-foot
post 110b is about 73 inches above ground level G, which will
support a six-foot fence with one inch of clearance below.
Accordingly, where an eight-foot post is normally required for a
six-foot fence, a seven-foot post will serve if installed with a
post sleeve and a 13 inch stop plate 172. Furthermore, by using the
9 inch stop plate 174 at the 9 inch stops 166, as shown with
reference to post sleeve assembly 100c, the seven-foot post 110c
extends an additional four inches above the post 110b. Thus, a
six-foot fence can be built using post sleeves configured as shown
with reference to post sleeve assembly 100b to support most of the
posts, and the corner posts can be supported by post sleeves
configured as shown with reference to post sleeve assembly 100c to
provide additional height for the post cap to be properly placed,
all without cutting any of the posts.
[0077] Furthermore, any portion of the interior of a post sleeve
that lies below the bottom of the post serves as a reservoir to
hold water until it can percolate into the gravel or soil below the
post sleeve assembly. Thus, another desirable benefit of using
plates like stop plates 172 or 174 and the stops 164,166 is that
they create a larger drainage reservoir within the post sleeve 102
below the post and reduce the likelihood that standing water will
contact the wicking end of the post. This is especially beneficial
in climates with seasonal periods of high rain fall.
[0078] According to another embodiment, the drain channels 124 are
tapered or stepped so that they are widest at the top of the post
sleeve 102, and become narrower toward the bottom. Tabs on stop
plates and other fittings have widths selected to engage the drain
channels 124 at different heights. Thus, the position of a post
within the sleeve is infinitely variable, according to the selected
widths of the tabs of the stop plate employed.
[0079] Returning to FIG. 6, and by way of example, 13 inch stop
plate 180, and 9 inch stop plates 182 and 184 are shown, provided
with tabs 176 arranged to engage the 13 inch and 9 inch stops,
respectively. 13 inch stop plate 180 is provided with tabs 176
arranged to engage the 13 inch stops 164, and with a 15/8 inch
socket 178 configured to receive a 15/8 inch steel fence post. 9
inch stop plates 182 and 184 are each provided with tabs 176
arranged to engage the 9 inch stops. 9 inch stop plate 182 is
provided with a 1 7/8 inch round socket 178 configured to receive a
1 7/8 inch steel fence post, while 9 inch stop plate 184 is
provided with a 21/2 inch square socket 185 configured to receive a
21/2 inch square aluminum fence post. Additionally, 9 inch support
plate 186 is shown, having tabs 176 arranged to engage the 9 inch
stops. 9 inch support plate 186 includes an aperture 187 having a
15/8 inch diameter. When a 15/8 inch round post is positioned in
the post sleeve 102, either in the 15/8 inch socket 160 or in a
stop plate such as the 13 inch stop plate 180, the post traverses
the aperture 187 of the 9 inch support plate 186, which provides
lateral support to the post. Finally, the upper support plate 189
is shown, provided with an aperture sized, in the pictured
embodiment, to receive a 15/8 inch round post, and configured to
rest on the upper ends of the standoff ribs 122. The upper support
plate 189 can be used with any length post to provide rigid lateral
support near the top of the post sleeve 102.
[0080] Plates 170, 172, 174, 180, 182, 184, 186, and 189 are
provided as examples only, to show a variety of plates configured
to support fence posts of different sizes and shapes at various
levels within the post sleeve 102, and to properly orient and
support the posts in the x, y, and z axes. It will be recognized
that many different configurations of stop plates and support
plates can be employed for use at the 19, 13, or 9 inch levels, or
any other desired levels, depending on the particular
application.
[0081] The various plates described above can be inexpensively
manufactured in large quantities through a wide variety of
processes, including, for example, stamping or blanking.
Alternatively, where a small number of non-standard plates is
required, and the limited quantity of a given configuration does
not justify the expense of preparing stamping dies, the plates can
be made from an efficiently machineable material such as UHMW
polyethylene. For example, plates with the appropriate apertures,
tabs, sockets, etc., for many applications can be machined from
sheets of UHMW polyethylene. One such plate is described later with
reference to FIG. 12.
[0082] As shown in FIG. 9, the spacing of the 13 inch and 9 inch
stops 164, 166 is particularly advantageous with regard to chain
link fencing. Typically, chain link fences are constructed using a
combination of 15/8 inch "line" posts, which are positioned along
the run of the fence and have a horizontal tube member running
along the tops for support, and 1 7/8 inch "terminal" posts, which
extend four inches above the line posts and typically have a
rounded cap on top as a finish detail. The horizontal tube members
that run along the top of the fence above the line posts tie into
the sides of the terminal posts. Thus, it is necessary to provide
an elevation difference of four inches between the smaller line
posts and the larger terminal posts. The 13 and 9 inch stops
164,166 in the post sleeve 102 are spaced from the top of the post
sleeve 102 in a manner that allows an industry standard 7 foot
steel tube line post or terminal post to be placed in the post
sleeve 102 obtaining the maximum amount of penetration while still
allowing a workable height to construct a 6 foot chain link fence
with no cutting of the tubes and no wasted material, and while
still allowing the bottom of the 6 foot fence to clear the top rim
104 of the post sleeve 102.
[0083] FIG. 9 shows a first post sleeve assembly 100d with a stop
plate 182 and a 17/8 inch socket 178a at the 9-inch stops 166,
supporting a 17/8 inch terminal post 203 with a cap 211. A second
post sleeve assembly 100e has a stop plate 180 and a 15/8 inch
socket 182b at the 13-inch stops 164, and supports a 15/8 inch line
post 205. A horizontal tube 207 extends from the terminal post 203
over the line post 205 and supports a section of chain link fencing
209. Because of the spacing between the stops 64 and 66 of the post
sleeves 102, the tops of the line post 205 and terminal post 203
are properly spaced for the standard fence configuration, without
the need to cut either post.
[0084] Returning again to FIG. 6, various embodiments of post
collars are shown, as examples for use with different cross
sections and sizes of posts. For example, post collar 112 is
configured to accommodate a 4.times.4 square post, post collar 202
is configured to accommodate a 17/8 inch round post, and post
collar 204 is configured to accommodate a 21/2 inch square tube. Of
course, the post collars shown are merely exemplary; post collars
can be provided to accommodate any post that the post sleeve 102
can receive. The material of the post collar is selectable
according to the particular application. Furthermore, a flexible
gasket can be positioned between the post and a post collar to
provide additional protection from water that would otherwise run
between the collar and the post. Where a post is fully supported
laterally within the sleeve by the standoff ribs 122 or by a
support plate, the post collar may serve merely to provide a
finished appearance and shed water. The post collar may also be
configured to provide a degree of resilience or weakness, depending
on the desired functionality. For example, according to an
embodiment, a plastic post collar is provided for use with parking
lot signs, such as "Handicap Only" parking signs, installed with on
a square tubular metal post. The collar is configured to repeatedly
fail on impact by popping out of its aperture, only to be snapped
in again with no damage, to save the post from--likely
frequent--minor bumper impacts. In this way, with minor bumper
impact, the plastic collar will pop out or break before the post
itself bends or breaks, permitting the post to pivot on a 9 inch
stop plate, for example, thereby saving the post and potentially
the post collar.
[0085] Post collars are generally provided with spacing ribs 198
that hold the collars up off the angled top surface of the rim 104
and penetrate into the upper aperture 121 of the post sleeve 102,
providing insect and debris resistant ventilation channels while
also transmitting lateral load from the post to the internal face
of the post sleeve 102. The spacing, thickness, and length of the
spacing ribs 198 can be chosen to provide more or less lateral
resistance to accommodate, for example, a resilient or breakable
model intended to protect a post from damage due to minor impacts.
Alternatively, a hardened post collar can be provided, that
includes a sharp edge to focus lateral force, so that under a
selected lateral force, the post will tend to shear off cleanly at
or below grade, to reduce the likelihood of injury when the post is
struck by a moving vehicle, and to reduce or eliminate the
resulting hazard of a splintered post stub that might otherwise
stand in that location until the post can be replaced. In such
embodiments, it may be beneficial to provide one or two holes
through the post in each direction, in a position that corresponds
to the sharp edge of the sleeve, to further encourage a clean break
at that position. As a further alternative, the sharp edge can be
pre-formed or installed into the sleeve itself, and used in
combination with a resilient collar so that a post is protected
from impacts up to a threshold, but will breakaway under impacts
that exceed the threshold. Where a post sleeve is
[0086] Pressure tabs 199 are positioned so as to be engaged by the
fastener 142 and transmit pressure from the fastener to the post to
lock the post in position. Where the post collar is configured to
support a post that is smaller than the 4.times.4 post size, an
inner pressure tab 195 is provided, with extension ribs 197 or
similar structures extending onto the inner pressure tab 195 to
provide the necessary transition to be engaged by the fastener and
to transmit the pressure to the post.
[0087] According to an alternate embodiment, the fastener is
configured to engage the post directly. Where a smaller post is to
be installed and direct contact with the post is desired, the
standard fastener is removed, and a longer fastener is positioned
in its place. The post is then installed in the post sleeve and the
longer fastener is driven in to engage the post.
[0088] Sleeve cap 206 is configured to be positioned in the upper
aperture 121 of the post sleeve 102 to close the upper aperture 121
during periods of non-use or between the time the post sleeve 102
is installed in the ground and a post is inserted. The sleeve cap
206 serves to prevent the introduction of rocks and debris into the
post sleeve 102, and also to prevent injury to pedestrians or
animals when not in use. Like the post collars, the sleeve cap can
be constructed of any suitable material including, for example,
steel, aluminum, and plastic.
[0089] In the embodiment of FIG. 6, rim cover 190 is constructed of
UV resistant injection molded plastic, and can be any suitable
color. The rim cover is configured to snap into place on the post
collar 112 and rest over the rim 104 to provide a substrate for
identification or information that is temporary, as compared to the
expected life expectancy of the post sleeve 102, or that is added
after the post sleeve 102 is manufactured. For example, in FIG. 6,
a sign plate 194 with a handicap symbol is shown coupled to the rim
cover 190 by fasteners 196, which can be rivets, screws, nuts and
bolts, etc. Additionally, or alternatively, the surface of the rim
cover can be directly marked using vinyl or screen printed images,
or by engraving or embossing, for example.
[0090] It can be seen that the rim cover 190 provides a number of
surfaces that can be used, for example, by the installation
contractor to place a logo or contact information, or to identify
the function of the post, as in the example pictured, or to provide
a backup sign or an indication of the necessary replacement in the
instance where the post becomes snapped off. Other examples of uses
for the rim cover 190 are reflective address markings at the bases
of posts supporting mail boxes for fire and rescue, reflective
"Stop" with red plastic body color for "Stop Signs" and added
visibility, "No Trespassing" warnings for property lines etc.
Spacing ribs 191 provide clearance between the rim 104 and the rim
cover 190 for the fasteners 196. The spacing ribs 198 extend to the
aperture and line up with the spacing ribs 198 in the post collars
to provide continuous air ventilation as described above.
[0091] The rim cover 190 comprises an aperture 192 in a position
that corresponds to the position of the identification plate 108,
such that when the rim cover 190 is coupled to the rim 104 of the
post sleeve 102, the identification plate 108 is visible through
the aperture 192. In those embodiments where the identification
plate 108 is not employed, or where it is not required to be
visible, an additional plate or cover can be snapped into the
aperture 192. The rim cover 190 can also be equipped with motion
sensors, solar cells, luminosity cells, lighting and audible
effects, etc., as described above with reference to the post
collars.
[0092] The stops, stop plates, support plates, post collars, sleeve
caps, and other elements described above with reference to FIG. 6
are shown and described merely as examples. It is within the
abilities of one of ordinary skill in the art to provide such items
with any dimensions or configuration or in any suitable material,
as necessary for a given application.
[0093] The inventor has recognized that a particular problem in the
fencing industry is that fences are often built from scratch on
site, meaning adjoining segments of a fence may not be identical,
and that, even where prefabricated fence panels are employed, many
will be modified or customized to fit specific spans and angles
between posts. When a portion of a fence is damaged or knocked
down, it is generally necessary for a fence contractor to bring to
the site all the materials necessary to re-fabricate the damaged
portions of the fence, and often to reproduce a complex pattern
using materials and equipment on hand, or, alternatively, to come
to the site a first time to take measurements and patterns, then
fabricate replacement panels and return to the site to install
them.
[0094] According to one embodiment, the identification plate 108,
described above with reference to FIGS. 1 and 2, is part of a
system that addresses many of these problems. The identification
plate 108 of each post sleeve is provided with a unique identifier
that is affixed either during fabrication of the post sleeve or
during installation. During installation of a new fence, the
installer records the unique identifiers of each post sleeve,
together with all the pertinent information about the fence,
including the pattern, color, material, dimensions, etc. The
location of each post sleeve is recorded, as well as the
positioning of each sleeve relative to other sleeves, in the x, y,
and z axes and in orientation. The information is deposited in a
central database maintained by the post sleeve manufacturer or an
independent repository. Additional information stored in the
database can include property boundary surveys, CAD drawings of the
actual fence, scale images of each panel, a bill of materials for
the production, finish colors, materials used, etc.
[0095] In the event a repair is required, the property owner makes
note of the identifiers of the post sleeves that are involved and
contacts a contractor--either the original contractor, whose
contact information may be provided on the rim or rim cap of at
least one of the post sleeves, as described above, or another
qualified contractor--and provides the identifiers and a
description of the damage. The contractor then accesses the
database, via a secure website, for example, and obtains the
details and dimensions of the fence design, and, more importantly,
the specific details of the fence panels associated with the
identifiers provided by the property owner. The contractor can then
fabricate the replacement fence sections in a shop to replace the
damaged sections, to the precise dimensions and pattern of the
original, then transport the completed sections and install them at
the site. The property owner may, alternatively, choose to order
the replacement sections and install them herself, without the
assistance of a contractor. Even though the fence dimensions will
vary from one span to the next, the identifying numbers on the post
sleeves will provide the exact location with the exact dimensions.
This saves considerable time and expense, as well as reducing
waste, because material optimization is much easier in a controlled
shop environment than in the field. Because the information is
maintained at a central database, it can be accessed by the
contractor or property owner, even if the original contractor is no
longer in business.
[0096] Similar systems are provided, according to other
embodiments, to track the location and details of commercial signs,
traffic signs, guard rails, etc. If, for example, a traffic sign is
damaged or deteriorated, an inspector need only take note of the
identifying number on the identification plate of the post sleeve
in which the supporting post is mounted, and relay the number to
the appropriate authority.
[0097] The database will provide such details as the text and size
of the sign, the height of the post, the materials of the sign and
post, and even the replacement history of that particular sign. The
replacement sign can be assembled according to the specifications,
and installed.
[0098] According to an embodiment, the identification plate 108
includes a bar code number, which simplifies the capture of the
identifier, and prevents transcription errors. The operator, when
recording the pertinent information, scans the bar code with a
portable scanner, and then enters the associated data.
[0099] According to another embodiment, a radio-frequency
identification (RFID) tag is provided, either as part of the
identification plate 108, embedded in the body 116 of the post
sleeve 102, or otherwise attached thereto. When an interrogation
signal is transmitted from a nearby RFID reader, an antenna of the
RFID tag collects power from the signal and activates a transmitter
circuit that transmits the unique identifier of the respective post
sleeve, which is received by the reader. As is well known in the
RFID art, RFID tags can be extremely simple, providing only basic
identification information, or can be more complex, comprising a
non-volatile memory to store a significant amount of data, either
in a read-only format or in a read-write format. Accordingly, in
some embodiments, additional information that may be relevant to a
particular application can be saved in the RFID tag of a post
sleeve for later retrieval. The RFID tag can also be detected by
properly equipped emergency or delivery vehicles to assist them in
locating a specific location or address.
[0100] The term unique identifier is used broadly to refer to an
identifying element that is unique to a single post sleeve and that
distinguishes one post sleeve from other post sleeves. The unique
identifier can be a string of letters, numbers, symbols, or a
combination of elements. It can, for example, comprise a serial
number applied to a post sleeve during fabrication, or a string of
characters that includes additional information relative to the
make or model of the post sleeve, or its date or place of
manufacture.
[0101] According to an embodiment, a unique identifier associated
with particular post sleeves is maintained in a database, and
includes data necessary to locate each post sleeve, such as, for
example, one or more of: GPS coordinates, street address, and
positioning data with respect to nearby post sleeves or other
reference features. It is therefore not necessary to physically
mark or label each sleeve, because each is identifiable from the
database, on the basis of its unique location.
[0102] Referring now to FIG. 7, a single liner section 118 is
shown, according to an embodiment in which the sleeve liner 120
comprises two substantially identical injection molded liner
sections. The liner section 118 includes a tongue element 165
extending down the left edge, as viewed in the drawing, while a
groove 167 extends down the right edge. When two such sections are
positioned face-to-face, the tongue element 165 of one section
engages the groove 167 of the other section, and vice-versa,
permitting the two sections to be pressed or snapped together to
form the sleeve liner 120. In the illustrated embodiment, the two
sections snap together, although any appropriate fastening means
can be used to couple the sections 118, including solvent or
electronic welds, clips, tape, etc. It is only necessary that the
two sections hold together while the concrete body 116 is cast
around them to form a single integral unit.
[0103] As described above with reference to FIG. 6, the liner
sections 118 include 13 inch stops 164 and 9 inch stops 166
configured to be engaged by the tabs of the respective stop plates
to support a post at those depths below the rim of the post sleeve.
In the embodiment pictured, two sets of stops are shown, but the
invention is not limited to two sets of stops, or to the specific
dimensions described. Liner sections can be provided with more or
fewer sets, and according to some embodiments, there are none.
[0104] Detents 169 are provided to assist in installation of the
post sleeve 102. According to an embodiment, the detents 169 are
engaged by an installation mechanism configured to support the post
sleeve from an overhead structure, so as to permit the sleeve to
hang plumb at the desired height in the hole 138 while an installer
pours the concrete footing. In this way, the post sleeve can, if
required, be provided with a concrete footing that extends some
distance below the sleeve without requiring support from below
while the concrete footing cures, and can be properly oriented and
plumbed.
[0105] While the sleeve liner 120 has been described in combination
with a prefabricated concrete sleeve body, the sleeve liner 120 can
itself serve as a preformed post sleeve, fixed in a concrete
footing in the field, without the prefabricated concrete body. For
example, where the extreme longevity and other advantages afforded
by the high-strength prefabricated body are not primary
considerations, it may be advantageous to omit the concrete body,
and instead to use the sleeve liner 120 as a preformed sleeve and
pour the footing around it. In another example, where a large
surface is to be paved, with a number of sleeves provided to
support posts, e.g., to support a guardrail along a concrete
walkway, the sleeve liners can be set directly in the concrete, as
sleeves, during the pour of the walkway to provide a clean and
unified appearance.
[0106] FIG. 10 shows an embodiment in which a post sleeve 220 is
cast directly from concrete or other suitable material, without a
separate liner. The post sleeve 220 includes ribs 222 and drain
channels 224 that are substantially analogous in function to the
standoff ribs 122 and drain channels 124 described with reference
to FIGS. 2-7. A universal socket section 228 is provided, having
individual sockets configured to receive posts of a variety of
dimensions, much as described with reference to FIG. 5, and stops
230 are shown at various depths below the rim 226, as described
with reference to FIGS. 6 and 7. A coupling configured to engage a
drain hose can be press fitted or cast into the lower aperture 232
of the sleeve liner 220 during the casting process. Alternatively,
the aperture can be left smooth, as shown in FIG. 10, and the drain
hose affixed with a common construction adhesive, or the aperture
232 can be sized to receive the hose in an interference fit.
[0107] Also shown in FIG. 10, horizontal holes 234 are provided
extending through the lower-most part of the post sleeve 220. In
climates where annual freezing and thawing cycles might tend to
lift the post sleeve 220 out of the ground, short pieces of rebar
are positioned in the holes 234 to establish a more secure
engagement between the post sleeve 220 and the concrete footing, to
prevent uplift. In other cases, concrete that flows into the holes
234 during installation of the post sleeve 220 may be adequate to
prevent uplift.
[0108] In many cases, it is not desirable to permit a wood post to
directly contact the concrete of the post sleeve. Accordingly,
where the post sleeve is cast without a separate sleeve liner, such
as the embodiment of FIG. 10, an interior coating can be sprayed
in, to isolate the post from the concrete. If necessary, at
intervals over the life of the post sleeve, the coating can be
re-sprayed at the same time that the post is replaced.
[0109] FIG. 11 shows a post sleeve 240 that, like the embodiment of
FIG. 10, is cast directly from concrete or other suitable material,
without a separate liner. The post sleeve 240 includes ribs 242 and
drain channels 244, a lower aperture 252, a rim 248, and a lower
body portion 250. The post sleeve 242 is configured to receive a
single size of post, and does not include a universal socket
section, nor stops. In certain high volume applications where a
large number of post sleeves are required for a single size of
post, it may be economically or structurally advantageous to
manufacture a custom post sleeve configuration for that size. This
may be true where, for example, because of the dimensions of the
posts, stop plates and support plates would be required for each
post sleeve, or where the anticipated lateral loads on the posts
will possibly render standard stop and support plates
inadequate.
[0110] Also shown in the embodiment of FIG. 11, it can be seen that
the soffit 246 is substantially perpendicular to the vertical sides
of the body 250, and that the sides of the lower body 250 do not
include reinforcing ribs analogous to the ribs 106 of FIG. 1. This
configuration is useful in applications where the soffit is
intended to engage a supporting surface. For example, where a post
is to be installed into a previously paved surface, an opening is
cut in the pavement, with a size that is smaller than the outer
dimensions of the rim 248 but large enough to receive the lower
body 250. According to one embodiment, the lower body of the post
sleeve is cylindrical, such that a circular hole only slightly
larger than the lower body can be bored in the pavement and the
underlying material so that the post sleeve can be dropped into the
hole and will be adequately supported without a concrete footing.
It may be advantageous to apply an adhesive between the soffit and
the pavement to prevent prying up of the post sleeve, and to
prevent water from entering the hole from the surface of the
pavement. In such an embodiment, it may also be advantageous to
have a port through the sidewall of the sleeve to allow the
injection of a foam or grout material or adhesive to fill the void
between the sleeve and the pavement, and under the pavement.
[0111] FIGS. 12-20 show details of post sleeve assemblies according
to various embodiments. According to the embodiment of FIG. 12, a
flange transition fitting 302 is provided, that is sized to fit an
odd sized post, such as, for example, a 11/2 inch square tube, or a
metric tube, or an odd shaped post such as the hexagonal post shown
in FIG. 12. In this way, a non-standard post can be installed in
the closest appropriate socket of the universal socket section 151
of a post sleeve. The embodiment pictured in FIG. 12 is configured
to fit in the 4.times.4 socket 150 of the post sleeve 102, and
comprises a body 304 of UHMW polyethylene with a hexagonal socket
306 machined therein. A steel plate 308 is coupled to the body 304
by fasteners 310 to provide vertical support to a post, while the
body and socket provide lateral support. Other fittings and plates,
such as post collars, support plates, etc., or transition pieces
configured to snap into standard fittings, can be produced in small
volumes by standard machining methods, as previously described.
FIG. 13 shows a post collar 310 with slots 312 configured receive
replaceable pesticide tablets 314 to discourage harmful insects
from entering the post sleeve. Because the tablets are positioned
to place vapor or runoff precisely where it is required, within the
enclosed space around the post and inside the drainage channels 124
and reservoir of the post sleeve 102, the tablet 314 can be
configured to release very minute amounts of chemical over a
prolonged period of time.
[0112] FIG. 14 shows a sleeve assembly 320 that includes a
reservoir 322 positioned beneath a post sleeve 102. The reservoir
322 includes a threaded neck 324 configured to engage threads in
the aperture 115 of the post sleeve 102 or at the lower end of a
drain hose, and has a large opening 326 configured to provide open
contact with the surrounding concrete. A temporary barrier 328,
such as a cardboard panel, is provided in an opening of the
reservoir to prevent entry of concrete during the pour of the
footing. The barrier 328 disintegrates the first time it is
contacted by water, and thereafter does not impede contact of water
with the concrete. The concrete of the footing surrounding the
reservoir 322 is provided with a selected porosity, such as by
controlled entrainment of air, to function as a slow-flow barrier,
to permit very slow passage of water from the reservoir 322 to the
surrounding soil. In some environments, there may be periods during
which the water table rises near the surface, either seasonally, or
in response to heavy rains. Sleeve assemblies that are configured
to allow water to flow quickly out, may also allow water to flow
quickly in when the water table rises above the lower aperture,
which can subject the post to continuous contact with the water
until the table drops again. The slow-flow barrier of concrete is
configured to limit the passage of water so that days or weeks may
be required for water to fill the reservoir 320, with the volume of
the reservoir selected to accommodate water entering from the post
sleeve 102 as well.
[0113] According to a related embodiment, a reservoir is provided
that is covered with gravel or sand before the footing is pouring,
and a slow-flow membrane is provided to regulate the flow of water
into the reservoir from outside the post sleeve 102. The slow-flow
membrane 326 can be formed by providing a plurality of openings of
a selected size in the reservoir, or can be a material with a
selected porosity positioned over an open bottom of the
reservoir.
[0114] FIGS. 15A and 15B show a spring-loaded post assembly 350 for
use in applications where a post is likely to be contacted
repeatedly by vehicles, such as in parking lots, for example. The
post 350 includes a sleeve engagement element 352 configured to be
positioned within a 4.times.4 post sleeve. A stiff spring 354 is
coupled to an upper end of the sleeve engagement element 352, and a
post 356 configured to receive a sign 358 is coupled to an upper
portion of the spring 354. Under normal conditions, the spring 354
holds the post 356 erect, as shown in FIG. 15A, but when subjected
to the an impact, such as by a vehicle bumper, the spring 354
flexes, permitting the post 356 to yield to the impact, as shown in
FIG. 15B, thereby avoiding damage.
[0115] FIG. 16 shows a support plate 360 for use with round posts,
and including a flange 362 that is configured to be engaged by a
pipe clamp 364. When a round post is used to support a sign, for
example, the sign may be prone to rotation around the longitudinal
axis of the post because of wind forces against the sign face. The
pipe clamp 364 firmly grips the post and the flange 362 of the
support plate 360. Because the support plate is square, it cannot
rotate within the post sleeve, and thus prevents rotation of the
post. The support plate 360 includes extended sides 366 that engage
the interior of the post sleeve over a substantial surface area to
distribute the load and permit the inner surface of the post sleeve
to tolerate the rotational forces transmitted by the support plate
360 without damage.
[0116] FIG. 17 shows an oversized post support 380 having a sleeve
engagement element 382 configured to be positioned within a post
sleeve. A post engagement element 384 of the post support 380 is
configured to receive an oversized post having a size that is too
large for the post sleeve. Holes 386 are provided for screws to
permit secure attachment of a post to the post support. The sleeve
engagement element 382 and post engagement element 384 of FIG. 18
are configured, respectively, to be received by a 4.times.4 post
sleeve and to receive a 6.times.6 post, but this is only exemplary,
and can be provided to meet a wide range of size requirements.
[0117] FIGS. 18 and 19 show a post sleeve 400 according to an
embodiment in which the body 402 is formed of two identical
sections 404. FIG. 18 shows a single section 404, while FIG. 19
shows the complete post sleeve 400 comprising two sections 404. The
sections 404 are formed of an expanded plastic material and are
manufactured by an injection molding process. The post sleeve 400
includes a rim 406 and post collar 408 formed integrally with the
body 402 and defining an aperture 410 sized to fit closely around a
post of a selected dimension--4.times.4 in the pictured embodiment.
A cap 417 of a resilient material such as rubber is provided to fit
over smaller sized posts and snap into place over the post collar
408 to prevent entry of water and debris into the post sleeve 400.
In the example shown, the cap 417 has a round aperture 419 to fit
over a 17/8 inch round post. Apertures 409 under the post collar
408 permit ventilation, while the post collar 408 directs water
onto the outwardly sloping rim 406. An aperture 407 is provided to
receive a fastener 411 configured to engage and lock a post
positioned in the sleeve, similar to the fastener described with
reference to FIG. 4.
[0118] Stops 414 are provided at various depths within the post
sleeve 400 for engagement by plates 416. Each plate 416 is provided
with tabs 176 positioned on two opposing edges of the plate so as
to engage opposing stops 414 and bridge across the interior of the
post sleeve 400. In the transverse dimension the plates 416 are
narrower so as to fit through the aperture 410 and between the
standoff ribs 122 at an angle, as shown in FIG. 19, to enable
positioning and removal of the plates 416. A plate 416 can engage
stops 414 at any height by lowering the plate 416 into the post
sleeve 400 at an angle and engaging the stops at a selected depth,
first on one side, then allowing the plate to drop and engage the
stops on the opposite side of the sleeve.
[0119] According to an embodiment, stops 414 on one face of each
section 404 are positioned some distance above the stops on the
adjacent face. When the sections are assembled together, the stops
414 directly opposite each other are at the same depth, while those
on the transverse faces are at a different depth. Thus, the plate
416 can be positioned at any of a number of different depths by
selecting the orientation of the plate as it is introduced into the
sleeve, then selecting the set of stops to engage on a given pair
of opposing faces.
[0120] The sections 404 are joined as described with reference to
the sleeve sections 118 of FIG. 7, and also include apertures 412
configured to receive screws for secure coupling of the sections
404. The post sleeve 400 is configured to be set directly in a
concrete footing without a separate concrete body, and is provided
with thicker sidewalls than those of the liner 120 described in
previous embodiments, which provide sufficient stiffness to resist
the weight of wet concrete and prevent deformation of the body 402
during the pour of the footing. The post sleeve 400 provides, in a
one-piece construction, many of the advantages described above with
reference to other embodiments.
[0121] FIG. 20 shows an insert 420 that is configured to engage a
commercially available post sleeve section 422. There are a number
of post sleeves that are commercially available that provide some
protection to posts set in concrete, such as, for example, the
plastic sleeve 422 shown in FIG. 20. The sleeve 422, manufactured
by PostShield USA.TM., is sized to receive a 4.times.4 post. It is
manufactured using an extrusion process and is therefore very low
in cost, but because of that process, is limited to a single
continuous profile.
[0122] The insert 420 includes an engagement element 424 having
outer dimensions that correspond to the size of a 4.times.4 post,
and therefore fits into the lower end of the sleeve 422. The
engagement element 424 includes a substantially planar top surface
426 with a plurality of notches 428. The insert 420 is provided
with an aperture 115 to permit water to drain via a drain hose,
etc., while preventing direct contact of the post with concrete or
the underlying soil. Additionally, a universal socket section 151
is provided, similar to that described with reference FIG. 4, which
enables a user to convert the commercial post sleeve 422 for use in
other configurations. The insert 420 is formed of an expanded
plastic such as that described with reference to the embodiment of
FIG. 19, and can be manufactured in a single piece or two identical
halves.
[0123] A user positions the insert 420 in the lower end of the post
sleeve section 422 and fixes the combined assembly in the ground
according to the requirements of the particular application.
Typically, the engagement element 424 engages the sleeve section
422 with an interference fit that is sufficient to hold the
assembly together until it is emplaced, especially if it is to be
fixed in a concrete footing. However, if necessary, the insert 420
can be fixed to the sleeve through the use of commercial adhesives,
tape, or screws. When a post is positioned in the sleeve section
422, the bottom end of the post rests on the top surface 426, if it
is a 4.times.4 post, or in the appropriate one of the sockets of
the universal socket section 151, according to its dimensions. As
with the post sleeves of other embodiments, water that enters the
sleeve 422 is permitted to drain from the assembly, via the notches
428, gutters 161 of the universal socket section 151, and the
aperture 115.
[0124] FIG. 22A shows a concrete half sleeve 520, according to an
embodiment. The half sleeve 520 has a joining face 525 that
includes alignment pins 522 and alignment apertures 524, a tongue
526, and a groove 528. When two half sleeves 522 are positioned
face-to-face to form a complete post sleeve 521, as shown in FIG.
22B, the alignment pins 522 and alignment apertures 524, and the
tongue 526 and groove 528 mate together and ensure correct
positioning of the half sleeves. The joining faces 525 of each half
sleeve 520 make contact, and define a central, longitudinal plane
of the post sleeve. Additionally, the half sleeve 520 includes
adhesive networks 527 comprising channels 530, inlet ports 532, and
outlet ports 534. The channels 530 are defined by lands 538, and
include distribution manifold sections 536.
[0125] To assemble a post sleeve, a user first positions the
joining faces 525 of two half sleeves 520 together so that the pins
522 of each mate with the apertures 524 of the other, thereby
correctly aligning the halves. The halves are then bound together
by appropriate means, such as, for example, straps or wire around
the outside. In some cases gravity is sufficient to hold the halves
together during the bonding process. When the two half sleeves 520
are mated together, the lands 538 of both halves contact each other
to enclose the adhesive channels 530. The user then injects an
appropriate grade of construction adhesive into the inlet ports
532. The adhesive flows into the inlet ports 532 and into the
distribution manifold sections 536. From there, the adhesive flows
into the remaining regions of the adhesive channels 530 and is
distributed throughout the channels. Eventually, the adhesive
begins to flow from the outlet ports 534, which is a positive
indication that the adhesive channels 530 are completely filled.
During injection, the highest pressure occurs in the distribution
manifold sections 536. The tongue 526 and groove 528 are positioned
opposite the manifold sections 536 to minimize leakage of the
adhesive into the internal cavity of the complete post sleeve 521.
When the adhesive has hardened, the half sleeves are permanently
joined to form the complete sleeve 521. While completely filling
the adhesive channels 530 with adhesive is not essential to
permanently join the halves, the adhesive also acts as a seal to
prevent moisture from entering the sleeve via the joint. The
adhesive may be flexible for certain applications while rigid in
others.
[0126] Although referred to in the specification as, e.g., inlet
ports and outlet ports, etc., many of the features of the joining
faces 525 are not complete until two half sleeves are placed
face-to-face with each other. Thus, a complete inlet port is formed
when an inlet port of one half sleeve is joined with an inlet port
of another half sleeve. Accordingly, in the claims, such features
of a half sleeve are referred to as sections, e.g., inlet port
section. This is to distinguish the elements of the half sleeve
from the elements formed when two half sleeves are mated.
[0127] Blind cavities 531 provide a strong mechanical engagement
with a concrete footing when the complete sleeve 521 is installed
in the ground. In cases where the installer does not use a
poured-concrete footing, the cavities 531 provide a mechanical
engagement with sand, crushed rock, or even dirt, to more firmly
fix the sleeve into the ground.
[0128] The half sleeves 520 also include utility knockouts 533 that
can be removed to provide access to the sleeve. For example, a user
may employ a post sleeve to support a lamp post, or may wish to
provide lights on a fence. In such cases, an electrical cable can
be routed into the post sleeve 531 via the knockout 533. The
knockouts comprise defined regions of the sleeve wall that are
substantially thinner than the surrounding wall. With a mallet and
chisel, the user strikes the knockout, breaking away the thinned
portion.
[0129] According to an embodiment, the complete sleeve 521 is
configured to be installed in a post hole by floating the sleeve in
freshly poured concrete. Because the density of concrete varies, in
part, according to the density of the aggregate used, it may, in
some cases, be necessary to adjust the buoyancy of the post sleeve.
Accordingly, rigid foam inserts can be placed in some of the
cavities 531, which will displace corresponding volumes of concrete
without adding appreciably to the weight, thus increasing the
buoyancy of the sleeve 521.
[0130] The half sleeve 520 is shown with a percolation chamber 540
that is defined, in part, by a degradable seal 542. While half of
the seal 542 is shown in FIG. 22, in practice, a complete seal (as
shown, for example, in FIG. 23A) is glued or snapped into place on
the complete sleeve 521 after the half sleeves 520 have been
joined. The seal 542 is configured to disintegrate after it comes
in contact with water, and can be formed from any appropriate
material, including cardboard, degradable plastics, etc. When the
sleeve 521 is fixed in the ground in a footing, the seal 442 forms
a cavity within the wet concrete. The first time water enters the
sleeve 521, the seal deteriorates (after a delay, in order to
prevent the form from failing when it first comes into contact with
wet concrete), and, preferably, eventually dissolves completely,
exposing the now-hardened surface of the concrete footing within
the percolation chamber to the water. The concrete of the footing
is selected to have a desired permeability to water, which allows
water that is collected in the cavity to percolate through the
footing and into the ground. The shape of the seal is exemplary,
and can be modified according to a desired volume, to accommodate
the amount of local precipitation and rate of percolation through
the footing, or other factors that might affect the expected volume
of water that will enter into and percolate from the cavity.
[0131] In one embodiment, the lowermost part of the sleeve is
tapered or otherwise adapted to receive an extension, substantially
increasing the effective length and surface area of the sleeve.
This can be especially helpful for added infiltration area or
lateral stability when using sand, gravel, or native dirt in place
of poured concrete to encase the sleeve.
[0132] FIGS. 23A and 23B show a half sleeve 523 and complete sleeve
525, respectively, that are similar to the half sleeve 520 and
complete sleeve 521 of FIGS. 22A and 22B, and that share many
elements in common, which are indicated by identical reference
numbers. Additionally, FIG. 23A shows a chamber 540 positioned in
the upper portion of the half sleeve 523, configured to receive any
of a number of inserts, which can be emplaced before two half
sleeves are joined, to become part of the complete sleeve 525. For
example, an annular foam insert can be provided that snugly
receives a post, and that provides a degree of resilience to
prevent or mitigate damage to the post or sleeve in the event the
post is subjected to excessive lateral force. The chamber 540 also
adds buoyancy to assist in installation. Additionally, temporary
ballast can be placed in the bottom of the complete sleeve 525.
With more buoyancy near the upper portion, the complete sleeve 525
will naturally tend to float in a more vertical position,
simplifying the task of making the sleeve plumb.
[0133] FIG. 24A shows a half sleeve 550 according to another
embodiment. The half sleeve 550 is injection molded from structural
foam. To form a complete sleeve, two half sleeves 550 are joined
together as described with reference to other embodiments. FIG. 24A
also shows a chamber vessel 560 that is configured to be attached
to any post sleeve that includes a drain hole. The chamber vessel
560 includes a cup 562 and a lid 564. The cup is made from a
degradable material, as described with reference to the seal 542 of
FIG. 22A. The lid is made from a material having sufficient
strength to withstand the forces applied during placement of a post
sleeve to which it is attached in a concrete footing. The lid can
be degradable, but this is not required. The cup 562 is configured
to disintegrate in the same manner as the seal 542, and includes a
plurality of convolutions 566 that serve to increase the surface
area of a percolation cavity that is formed around it in the
concrete footing, to improve percolation.
[0134] FIG. 24B shows a cutaway of the cup 562 to show its
interior. A ball 568 made from a resilient material, such as rubber
or the like, is placed inside the cup 562 to provide frost
protection. When installed in a concrete footing, the percolation
chamber formed by the chamber vessel 560 is about two feet below
the surface. In most climates, the ground does not freeze to that
depth, even in the coldest weather. However, in the rare event that
the frost line drops to below that depth, if there is water inside
the percolation chamber, it could easily rupture the concrete
footing when it freezes. The ball 568 reduces the likelihood of
frost damage to the footing by creating a space into which the
water can expand as it freezes. As ice forms in the chamber, the
increased pressure of the expanding ice compresses the ball 568,
instead of pushing outward to crack the footing. The amount of
change in a volume of water, from liquid to solid, is very well
known. The size of the ball is thus selected, according to the
volume of the chamber vessel 560, to provide sufficient space for
the expansion of the water in the chamber. In another embodiment
but to a similar effect, the drain channels 124 can be lined with a
cast in place cellular foam with memory, to allow for expansion as
water freezes. Alternatively, products such as foam pipe insulation
tube can be inserted alongside the smaller diameter posts for the
same purpose.
[0135] FIG. 29 shows a post sleeve 590 according to another
embodiment. The post sleeve 590 is similar in many respects to
sleeves described previously, and includes a body 592 with a post
aperture 594 configured to receive and support a post therein. The
post sleeve 590 also includes fins 596 that extend parallel to a
longitudinal axis of the sleeve, on the exterior of the body 592.
The fins 596 provide increased vertical surface area, and therefore
increased resistance to movement under lateral loads. In
applications where a post sleeve is to be installed in the native
soil without a concrete footing, the fins 596 of the post sleeve
590 provide additional stability. This kind of installation
involves positioning the post sleeve 590 in a post hole, then
filling the remainder of the hole with compaction material such as,
e.g., sand, pea gravel, or a portion of the soil removed to create
the hole. The material is then compacted, with water, in the case
of sand or gravel, or by tamping, and if desired, the top of the
hole around the sleeve is covered with sod or the like.
[0136] Turning now to FIG. 25, a sleeve core 500 is shown,
according to an embodiment. The core 500 includes an outer shell
502 made from a flexible elastomeric material such as silicone,
synthetic rubber, or the like, that has the shape of the inside of
a post sleeve. A stiffener 504 fits into a cavity 506 in the outer
shell 502. An attachment bracket 508 can be provided to attach the
sleeve core 500 to a positioning device.
[0137] The sleeve core 500 is placed in wet concrete in a location
where a post sleeve is required, and the concrete is allowed to set
around it. Once the concrete is adequately hardened, the stiffener
504 is removed from the outer shell 502. Without the stiffener, the
shell 502 is sufficiently flexible that it can be removed from the
concrete, leaving a cast-in-place post sleeve. Similarly, where a
sleeve liner lacks sufficient rigidity to withstand the lateral
pressure of wet concrete without deforming, a stiffener can be used
to support the liner until the concrete sets, whether in a factory
or in the field, with the liner being set in concrete on site.
[0138] FIG. 26 shows a post sleeve core 600 according to another
embodiment. The sleeve core 600 is made of a rigid material such as
steel, aluminum, or plastic, with a pattern draft to allow the core
to be pulled from the sleeve after the sleeve is cast in a single
piece around the core, either on site, or in a factory. The core
600 includes rib features 602 for forming standoff ribs, stop
features 604 for forming plate stops, and socket features 606 for
forming a universal socket. Of course, in practice, the specific
features and dimensions of the core 600 are selected according to
the requirements of a particular application. notches 612 are
provided, for engagement by a fastener, as described below with
reference to FIG. 26.
[0139] A drainage chamber form 610 is also shown, coupled to the
sleeve core 600. In the embodiment pictured, the chamber form 610
is configured to slip onto the bottom-most feature of the sleeve
core 600. When the sleeve core 600 and chamber form 610 are used to
form a post sleeve in the ground, the chamber form remains at the
bottom of the post sleeve after the sleeve core is removed. A
drainage aperture is formed where the drainage chamber is coupled
to the sleeve core. The chamber form 610 can be sized to fit over
any of the socket features 606 of the sleeve core 600, although it
will be recognized that if the chamber form is coupled to one of
the upper features, the features below will be inside the chamber
form when concrete is poured around the sleeve core, so
corresponding elements of the universal socket will not be formed
in the resulting post sleeve.
[0140] The chamber form 610 can be made from a material that will
degrade or dissolve when exposed to water, or can be of a
substantially non-degradable material such as metal or plastic.
Additionally, a degradable closure, like the barrier 328 described
with reference to FIG. 14, can be used to prevent concrete from
flowing up into the chamber form 610 during formation of a post
sleeve. Such a closure is not required when the chamber form 610 is
positioned directly on the soil at the bottom of the post hole, or
on drainage gravel in the hole.
[0141] As previously explained, it is not essential that a
purpose-made drainage chamber form be used. Other readily available
products can also be used, including, for example, sections of
plastic pipe, cardboard tube, steel or concrete drain pipe, and
even sections of plastic beverage bottles--although where
relatively thin-walled or non-rigid products are used, they should
be filled with sand or gravel, or otherwise reinforced, to prevent
being collapsed by the weight of the concrete during formation. It
is only necessary that the connection between the chamber form 610
and the sleeve core 600 be sufficiently tight to prevent
substantial amounts of concrete from flowing into the chamber form
during formation of the sleeve, and sufficiently loose to permit
separation from the sleeve core 600 after the concrete is
cured.
[0142] Normally, a commercially available release agent is used to
prevent wet concrete from adhering to the core 600, and to act as a
lubricant to permit removal of the core once the concrete is cured.
Alternatively, a wax coating can be used on the sleeve core 600 as
a release agent, and also as a waterproofing agent within the
sleeve that is formed thereby.
[0143] Depending on the thickness and formulation of the release
agent, there may not be a need for any draft to the core. For
example, it is known that various petroleum-based waxes can be
formulated to have selected thixotropic characteristics, so that,
at rest, they will have a given viscosity, but under stress, will
undergo shear thinning. The sleeve core 600 can be coated with such
a material, which forms a layer of a selected thickness between the
sleeve core and the concrete. After the concrete is cured, a
pulling force is applied to the sleeve core 600 to draw it from the
post sleeve. In response to the force applied, the coating
transitions to a liquid or semi-liquid phase, allowing the core to
slide easily from the post sleeve, even though the sides of the
sleeve core are perfectly parallel. Alternatively, simply by
coating the core to a sufficient thickness with a substance that
will harden--e.g., wax--to prevent displacement by the wet
concrete, a sufficient gap can be established between the concrete
and the sleeve core for later removal of the core.
[0144] On the other hand, under some circumstances, a draft may be
beneficial. For example, given a post sleeve configured to support
a 31/2 inch square post at a depth of 19 inches, and a draft of
1.degree., the dimensions of the sleeve will be about 5/8 inch
smaller at the bottom of the sleeve than at the top. If the spacing
between the standoff ribs is 3/8 inches at the top, to allow for a
slightly loose fit as a post is inserted, a true 31/2 inch post
will make full contact with the ribs a little more than half-way
down, and will require some force to drive the post to the bottom
of the sleeve. At the bottom, the standoff ribs will press into the
sides of the post about 1/8 inch on each side, thereby holding the
post firmly in place, while still allowing some flexing of the post
at the top.
[0145] It is well known that concrete continues to cure and harden
for many years after being poured. Thus, the term cure, when used
with reference to poured concrete, can be relative. For the
purposes of the specification and claims, cure, and related terms,
are to be construed as meaning sufficiently cure. Accordingly,
where a claim recites, e.g., "removing the post sleeve core from
the cured concrete," the "cured concrete" is concrete that is cured
sufficiently for removal of the core.
[0146] FIG. 27 shows a sleeve top 620 configured for use with a
sleeve core such as, for example, the sleeve core 600 of FIG. 25.
The sleeve top 620 is preferably made from high strength concrete,
and includes a post aperture 622 extending axially through the
sleeve top and configured to receive a post, and a decorative upper
surface 626. The sleeve top 620 of FIG. 27 includes one or more
grooves 624 1configured to be engaged by concrete used to form a
post sleeve. Other embodiments of the sleeve top can be provided
with other features for engagement by fresh concrete, including,
for example, cross-hatched grooves, protruding knobs, pieces of
reinforcement bar, etc. Also visible in FIG. 27 is a sleeve
aperture 628, provided for access to a fastener located inside the
sleeve top, and configured to operate in a manner similar to the
fastener 142 described with reference to FIG. 4. Additionally or
alternatively, a temporary fastener can be positioned in the
apertures 628, configured to engage the notches 612 of the sleeve
core 600, for use during formation of the post sleeve. The
embodiment shown includes a chamber 630 (see FIG. 28) similar to
the chamber 540 described with reference to FIGS. 23A and 23B.
[0147] According to various embodiments, the sleeve top 620 can
include any of the elements described with reference to previous
embodiments, at least insofar as they relate to the corresponding
upper portion of the respective post sleeve. For example, a unique
identifier can be provided on an outer surface of the sleeve top
620, or as an encapsulated RFID unit. The sleeve top 620 is
intended primarily for use with a post sleeve made from concrete
that is poured on site, though there is no reason it cannot also be
used as part of a factory-made post sleeve.
[0148] Turning now to FIG. 28, a sectional view of a post sleeve
640 is shown, made with the sleeve core 600 of FIG. 26 and
including the sleeve top 620 of FIG. 27. A main body 642 of the
post sleeve 640 is formed from concrete that is poured on-site, and
includes an inner volume 644 defined by sidewalls 646, stand-off
ribs 648, plate stops 650, and a universal socket 652, all as
defined by the shape of the post core 600. The post sleeve 640 is
buried in the ground, with an upper portion of the sleeve top 620
exposed above-ground.
[0149] To make the post sleeve 640, a user digs a post hole 654,
and, if desired, places gravel in the bottom of the hole for
drainage. A release agent is applied to the sleeve core 600, which
is then positioned in the aperture 626 of the post top 620. A
fastener in the aperture 628 of the post top 620 engages the notch
612 of the sleeve core 600, locking them together. The drainage
chamber form 610 is coupled to the bottom of the sleeve core 600 by
friction fit. The assembly comprising the core 600, the sleeve top
620, and the chamber form 610 is then positioned in the post hole
650. The assembly can be suspended in the hole 654, or can be
positioned to rest on the bottom. In the embodiment of FIG. 28, the
assembly would have been positioned to rest on the bottom, with the
open part of the chamber 610 in contact with the soil at the bottom
of the hole 654. With the assembly held in the desired position,
concrete is poured around the sleeve core 600 to fill the hole to a
level a few inches below the surrounding grade. The concrete fills
the groove 624, firmly locking the sleeve top 620 into the
freshly-poured concrete sleeve 642.
[0150] The position, elevation, and orientation of the assembly is
confirmed while the concrete in the hole 654 is still loose, to
ensure that they are within tolerances, and the assembly is held in
position. Preferably, a vibrator is used to settle the concrete and
remove entrained air, and the concrete is allowed to cure. The
fasteners in the apertures 628 are then loosened or removed, and
the sleeve core 600 is drawn out through the aperture 622 of the
sleeve top 620, leaving the inner volume 644 of the post sleeve 640
behind, ready to receive a post. After the sleeve core 600 is
removed, soil or sod is placed over the main body 642 to the edge
of the sleeve top 620, leaving only the decorative upper surface
626 visible.
[0151] When a post is positioned in the post sleeve 640, the post
passes entirely through the sleeve top portion, and is seated in
the portion formed by the post sleeve core 600. Elements described
with reference to other embodiments, such as, e.g., stop plates,
collars, etc., can also be used with the post sleeve 640.
[0152] The sleeve core 600 is shown as having notches 612 for
engagement by fasteners of the sleeve top 620. Thus, in the
embodiment shown, the distance from the top of the post sleeve 640
to the various features within the inner volume are known, as in
other embodiments. Alternatively, the sleeve core 600 can be
provided with a number of notches 612 spaced vertically for two or
three inches along each corner, so that the depth of the post
sleeve 640, relative to the sleeve top 620, can be selected when
the sleeve is formed, by engaging different ones of the notches
according to the desired depth. As a further alternative, the
notches can be entirely omitted, and the fastener configured to
engage the sleeve core 600 by friction engagement only. This
permits a wider range of adjustment for depth selection--it will be
recognized that where notches are provided, the maximum depth is
limited by the position of the bottom-most notches, which must
always be positioned inside the sleeve top so that concrete does
not engage the notches and interfere with removal of the core from
the sleeve.
[0153] The embodiment of FIGS. 26-28 provide the benefits of the
factory-made sleeve tops, including the hardened concrete and the
ability to efficiently form a wide range of shapes and
configurations, with a reduced size and weight, which reduces
freight and handling costs. Additionally, a number of different
sleeve sizes and configurations can be provided, by using various
sleeve cores, while conforming to standard dimensions for the
sleeve tops. This reduces inventory and warehousing requirements
for preformed elements without reducing the available
configurations. Finally, the main body can be placed in a smaller
post hole, thereby reducing the overall consumption of
materials.
[0154] A number of systems and methods for positioning and
supporting post sleeves in post holes are disclosed in the
co-pending U.S. patent application Ser. No. 12/403,985, filed Mar.
13, 2009, and incorporated herein by reference, in its
entirety.
[0155] In addition to the advantages outlined above, a number of
advantages are afforded in accordance with various embodiments. For
example, post sleeves permit the temporary removal and replacement
of posts. It is not uncommon for an individual to find it necessary
to remove a section of a fence in order to move a vehicle or
temporarily permit access to a normally enclosed area. Under such
circumstances, where previously it might have been necessary to dig
up two or three posts with their concrete footing, a user can
simply pull the posts out of the sleeves and re-install them
later.
[0156] Because of the protection from water damage provided by the
post sleeves, the serviceable lifespan of wood posts is extended.
Additionally, lower grades of wood, or more cheaply and
environmentally friendly finished wood can be used without
sacrificing durability.
[0157] Because of the stops and stop plates, shorter posts can be
substituted for longer ones with no loss of structural strength. At
the lumber mills, the shorter the length of the posts being cut the
greater the yield from a given trunk, and the more economical. For
example, due to the tapered shape of the trees from which most
lumber is produced, there are increased efficiencies obtained if
shorter lengths of material are cut therefrom. While eight-foot
lengths are the most commonly used, mills inevitably produce
shorter lengths, as well, either as leftover sections after a
length has been cut into eight-foot pieces, or because, when
setting out to produce eight-foot posts, many of the pieces
generated will need to be trimmed back due to end defects. Thus,
mills generally have a surplus of lumber shorter than eight feet in
length, because standard methods of construction require the
eight-foot lengths, making the shorter timbers less marketable. By
employing post sleeves to anchor the fence posts, seven-foot
lengths can be used, which, because of their availability and
recovery, are less expensive per linear foot than eight-foot
lengths and are more environmentally friendly. Furthermore, even if
demand for seven-foot lengths of fence posts increases beyond the
surplus currently available, the price will inherently remain lower
because of the better yield of shorter posts from a given length of
tree, as explained above. Due to the improved economy with respect
to both yield and trim backs, mills can sell 7 foot material for
substantially less per linear foot, and produce it in a more
environmentally friendly way, than the 8 foot material.
[0158] Many of the advantages outlined above contribute to a
significant reduction in overall environmental impact: the ability
to use shorter posts for a given size means a higher yield per
trunk and less scrap, which in turn means that fewer trunks need be
cut to produce a given number of posts; the increased useful
service life of a post means fewer replacement posts need be
provided, further reducing consumption; protection of the post from
water and most insects means that pressure treatment is no longer
necessary, which reduces chemical pollution and also enables
composting or recycling of the used posts, and which also
potentially reduces the load on solid waste landfills currently
necessary to dispose of pressure treated lumber; the permanent,
long lasting post sleeve eliminates the need to dig up and dispose
of old concrete footings, and the need to replace the concrete
footing with new concrete; which means a long-term reduction in
high energy consumption required to produce the cement of the
replacement concrete; the compatibility of the post sleeve with a
wide range of post configurations means that a change in function
that requires a change in post height or size does not necessarily
require a replacement of the concrete footing; and the tracking of
application data associated with the unique identifiers means that
large fence sections can be manufactured to order in a shop or
factory rather than on site, which results in fewer lifetime site
visits, less overall fuel consumption, and less material waste,
which further reduces the consumption of raw materials.
[0159] Embodiments of the invention are directed to sleeves
configured to support posts, e.g., fence posts, sign posts, etc.
Accordingly, many of the elements are described and claimed with
reference to a post. For example, in describing the standoff ribs
122 of FIG. 2, the post sleeve 102 is described above as
functioning "as an extension of the post." Nevertheless, unless a
claim positively recites a post as an element of the claim,
reference in a claim to a post is to be construed only as defining
the recited element as it relates to a post, and is not to be
construed as requiring the post. Therefore, if such a claim reads
on a given device with a post, it will also read on the device in
the absence of the post.
[0160] When used in the specification or claims to refer to a post
sleeve assembly or elements thereof, terms that refer to a relative
vertical position, such as upper, lower, above, below, top, bottom,
etc., are to be construed according to the normal orientation of
the referenced element in use, i.e., with an associated post sleeve
oriented to support a post vertically--see, for example, the post
sleeve assembly 100 of FIG. 3. Terms such as inside, outside,
inner, and outer are used with reference to an element's position
relative to a central axis of an associated post sleeve. Terms that
refer to an element's relative horizontal position, such as right
and left, are used for convenience and clarity in the description,
and do not limit the scope of the claims. The term longitudinal
refers to an aspect of an element along or parallel to what would
be the central axis of a post positioned in the associated post
sleeve. For example, the longitudinal dimension of the post sleeve
102 is the dimension from the top to the bottom of the post sleeve,
as viewed in the figure. Transverse refers to an aspect of an
element along an axis or in a plane that is at least approximately
perpendicular to the longitudinal axis.
[0161] Ordinal numbers, e.g., first, second, third, etc., are used
in the claims merely for the purpose of clearly distinguishing
between claimed elements or features thereof. The use of such
numbers does not suggest any other relationship, e.g., order of
operation or relative position of such elements. Furthermore,
ordinal numbers used in the claims have no specific correspondence
to such numbers used in the specification to refer to elements of
disclosed embodiments on which those claims may read.
[0162] As used in the specification and claims, the term post
sleeve refers to a structure that is configured to removably
receive a post, to hold the post in a substantially fixed and
upright position, and, after the post is removed, to removably
receive a replacement post.
[0163] The term preformed is used to refer to an element that is
formed or manufactured at one location, then moved to another
location for use.
[0164] Where a claim limitation recites a structure as an object of
the limitation, that structure itself is not an element of the
claim, but is a modifier of the subject. For example, in a
limitation that recites "a joining face that, when the half sleeve
and a substantially identical half sleeve are mated together,
defines a central longitudinal plane of a resulting post sleeve,"
the substantially identical half sleeve is not an element of the
claim, but instead serves to define the scope of the term joining
face. Additionally, subsequent limitations or claims that recite or
characterize additional elements relative to the substantially
identical half sleeve do not render that structure an element of
the respective claim, unless or until the structure is recited as
the subject of the limitation.
[0165] The abstract of the present disclosure is provided as a
brief outline of some of the principles of the invention according
to one embodiment, and is not intended as a complete or definitive
description of any embodiment thereof, nor should it be relied upon
to define terms used in the specification or claims. The abstract
does not limit the scope of the claims.
[0166] Individual elements of the various embodiments described
above can be omitted or combined with elements of other embodiments
to provide further embodiments. All of the U.S. patents, U.S.
patent application publications, U.S. patent applications, foreign
patents, foreign patent applications and non-patent publications
referred to in this specification and/or listed in the Application
Data Sheet are incorporated herein by reference, in their entirety.
Aspects of the embodiments can be modified, if necessary to employ
concepts of the various patents, applications and publications to
provide yet further embodiments.
[0167] These and other changes can be made to the embodiments in
light of the above-detailed description. In general, in the
following claims, the terms used should not be construed to limit
the claims to the specific embodiments disclosed in the
specification and the claims, but should be construed to include
all possible embodiments along with the full scope of equivalents
to which such claims are entitled. Accordingly, the claims are not
limited by the disclosure.
* * * * *