U.S. patent application number 15/408516 was filed with the patent office on 2017-07-27 for modular containment and screening system.
The applicant listed for this patent is CityScapes International, Inc.. Invention is credited to James E. Cullinan, Peter A. Gaydos, Brian P. O'Riordan.
Application Number | 20170211272 15/408516 |
Document ID | / |
Family ID | 58462994 |
Filed Date | 2017-07-27 |
United States Patent
Application |
20170211272 |
Kind Code |
A1 |
Cullinan; James E. ; et
al. |
July 27, 2017 |
MODULAR CONTAINMENT AND SCREENING SYSTEM
Abstract
A construction method and apparatus used to form a surround,
container or other structure. Posts have slots into which walls,
which may be planks or made up of planks, are inserted and
retained. Numerous posts may be used with numerous walls
therebetween to form many and varied structures. The finished
structure is modular, because the posts and walls are not damaged
when the walls mount in the slots. Therefore, if more or fewer
posts and/or walls are desired later, one need merely disassemble
the structure and add the components desired to the existing
structure. The walls may have fittings that attach to the inserted
ends that cooperate with structures in the slots formed in the
posts so the walls are held from being removed from the slots
except along the length of the slots.
Inventors: |
Cullinan; James E.; (Dublin,
OH) ; O'Riordan; Brian P.; (Ashville, OH) ;
Gaydos; Peter A.; (Hilliard, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CityScapes International, Inc. |
Hilliard |
OH |
US |
|
|
Family ID: |
58462994 |
Appl. No.: |
15/408516 |
Filed: |
January 18, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62281938 |
Jan 22, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 17/18 20130101;
E04C 2/38 20130101; E04H 2017/1456 20130101; E04H 17/1413
20130101 |
International
Class: |
E04C 2/38 20060101
E04C002/38 |
Claims
1. A modular construction system comprising: (a) an elongated first
post having at least a longitudinal first slot formed in a side,
the first slot defined by slot sidewalls spaced apart a first slot
width, and a pair of ridges extending toward one another from the
slot sidewalls and terminating in ridge tips forming a first ridge
gap, wherein the first slot width is greater than the first ridge
gap; (b) an elongated second post spaced from the first post a
predetermined distance, the second post having at least a
longitudinal second slot formed in a side, the second slot defined
by slot sidewalls spaced apart a second slot width, and a pair of
ridges extending toward one another from the slot sidewalls and
terminating in ridge tips forming a second ridge gap, wherein the
second slot width is greater than the second ridge gap; (c) a first
wall with a length about equal to the predetermined distance and a
first end with: (i) a first leg portion no wider than the first
ridge gap extending into the first slot between the ridge tips of
the first slot; and (ii) a first foot portion no narrower than the
first ridge gap extending deeper into the first slot than the first
leg portion; and (d) the first wall having a second, opposite end
with: (i) a second leg portion no wider than the second ridge gap
extending into the second slot between the ridge tips of the second
slot; (ii) a second foot portion no narrower than the second ridge
gap extending deeper into the second slot than the second leg
portion.
2. The construction system in accordance with claim 1, wherein the
first foot portion mounts integrally to the first leg portion and
the second foot portion mounts integrally to the second leg
portion.
3. The construction system in accordance with claim 1, wherein the
first foot portion removably mounts to the first leg portion and
the second foot portion removably mounts to the second leg
portion.
4. The construction system in accordance with claim 1, further
comprising: (a) an elongated third post spaced from the first and
second posts having at least a longitudinal third slot formed in a
side, the third slot defined by slot sidewalls spaced apart a third
slot width, and a pair of ridges extending toward one another from
the slot sidewalls and terminating in ridge tips forming a third
ridge gap, wherein the third slot width is greater than the third
ridge gap; (c) a longitudinal fourth slot formed in a second side
of the first post, the fourth slot defined by slot sidewalls spaced
apart a fourth slot width, and a pair of ridges extending toward
one another from the slot sidewalls and terminating in ridge tips
forming a fourth ridge gap, wherein the fourth slot width is
greater than the fourth ridge gap; (c) a second wall, which is
transverse to the first wall, having a third end with: (i) a third
leg portion no wider than the third ridge gap extending into the
third slot between the ridge tips of the third slot; and (ii) a
third foot portion no narrower than the third ridge gap extending
deeper into the third slot than the third leg portion; and (d) the
second wall having a fourth, opposite end with: (i) a fourth leg
portion no wider than the fourth ridge gap extending into the
fourth slot between the ridge tips of the fourth slot; and (ii) a
fourth foot portion no narrower than the fourth ridge gap extending
deeper into the fourth slot than the fourth leg portion.
5. The construction system in accordance with claim 1, wherein the
first wall is made of at least first and second substantially
parallel and co-planar planks, the first plank having a first
groove formed in a lateral edge and the second plank having a
second groove formed in a lateral edge that is adjacent the first
groove, and further comprising a stiffener with members inserted in
the first and second grooves.
6. A modular construction system comprising: (a) an elongated first
post having at least first and second longitudinal slots; (b) an
elongated second post spaced from the first post, the second post
having at least third and fourth longitudinal slots; (c) an
elongated third post spaced from the first and second posts, the
third post having at least fifth and sixth longitudinal slots; (d)
an elongated fourth post spaced from the first, second and third
posts, the fourth post having at least seventh and eighth
longitudinal slots; (e) a first wall with a first end extending
into the second slot, and a second, opposite end extending into the
third slot; (f) a second wall with a first end extending into the
fourth slot, and a second, opposite end extending into the fifth
slot; (g) a third wall with a first end extending into the sixth
slot, and a second, opposite end extending into the seventh slot;
and (h) a fourth wall with a first end extending into the eighth
slot, and a second, opposite end extending into the first slot.
7. The construction system in accordance with claim 6, further
comprising a foraminous grid extending from attachment to at least
one of the walls.
8. The construction system in accordance with claim 6, further
comprising a foraminous grid extending from attachment to at least
one of the posts.
9. The construction system in accordance with claim 6, wherein the
first wall is made of at least first and second substantially
parallel and co-planar planks, the first plank having a first
groove formed in a lateral edge and the second plank having a
second groove formed in a lateral edge that is adjacent the first
groove, and further comprising a stiffener with members inserted in
the first and second grooves.
10. A construction method comprising: (a) spacing an elongated
first post from an elongated second post with a gap therebetween,
wherein: (i) the first post has at least a longitudinal first slot
formed in a side, the first slot defined by slot sidewalls spaced
apart a first slot width, and a pair of ridges extending toward one
another from the slot sidewalls and terminating in ridge tips
forming a first ridge gap, wherein the first slot width is greater
than the first ridge gap; and (ii) the second post has at least a
longitudinal second slot formed in a side, the second slot defined
by slot sidewalls spaced apart a second slot width, and a pair of
ridges extending toward one another from the slot sidewalls and
terminating in ridge tips forming a second ridge gap, wherein the
second slot width is greater than the second ridge gap; (b)
extending a first end of a first wall into the first slot, the
first end having a first leg portion, which is no wider than the
first ridge gap, that is disposed between the ridge tips of the
first slot, and a first foot portion, which is no narrower than the
first ridge gap, that extends deeper into the first slot than the
first leg portion; (c) extending a second, opposite end of the
first wall into the second slot, the second end having a second leg
portion, which is no wider than the second ridge gap, that is
disposed between the ridge tips of the second slot, and a second
foot portion, which is no narrower than the second ridge gap, that
extends deeper into the second slot than the second leg portion;
and (d) displacing the first and second ends of the first wall
lengthwise along the first and second slots, respectively.
11. The method in accordance with claim 10, further comprising the
step of mounting the first and second foot portions to the first
and second ends, respectively, of the first wall.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/281,938 filed Jan. 22, 2016. The prior
application is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND
DEVELOPMENT
[0002] (Not Applicable)
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] (Not Applicable)
REFERENCE TO AN APPENDIX
[0004] (Not Applicable)
BACKGROUND OF THE INVENTION
[0005] The invention relates to containers and screening structures
for outdoor use, and more specifically to structures and methods
that permit one to combine components into containers and screening
structures.
[0006] Deck boxes, planters, fences, and other outdoor containing
and screening products have historically been made of wood, and
more recently polymer, planks and posts. Fasteners, such as nails
or screws, are used to mount the planks to posts that are either
held vertically in the ground, or simply resting upon the ground,
such as a deck or patio. The final result is useful for containing
toys, tools, outdoor deck supplies, or to screen from view entire
yards, pool areas, air conditioning units and trash receptacles,
among other items.
[0007] One difficulty with such conventional products is that they
are made with fasteners that damage the material when inserted and
removed. Screws and nails work by being inserted into the objects
to be fastened together, and when they are removed they leave holes
and cracks. Furthermore, most outdoor items require some amount of
maintenance, such as weather-proofing, in the case of wood and
corrodible metals. Still further, even outdoor items that are
weather-proof are made for their original purpose and cannot be
repaired, expanded, or reduced in size without the repair,
expansion or reduction being visible due to the damage caused by
the removal and replacement of fasteners.
[0008] Therefore, the need exists for a system of components that
permit one to construct such an item, and then later repair or
modify that item to suit later needs without wasting the materials
of the original item or making the repair or modification
apparent.
BRIEF SUMMARY OF THE INVENTION
[0009] Disclosed herein are structures and methods of combining
walls and posts to construct useful items. The structures and
methods result in furniture and other useful items including, but
not limited to, planters, raised beds, tables, storage containers,
and screen walls. In general, the disclosed structures and methods
include the use of two main components: walls and posts.
[0010] Each wall may be a plank, panel, slat and/or board, but may
be any structure that, alone or combined, forms a mechanical or
visual wall-like boundary on an item. The wall contains at least
one end or side, or a plate or other fitting attached to an end or
side, which fits into one slot in two or more cooperating posts.
Each of the walls may be made of polymer, metal, wood,
fiber-reinforced polymer composite or other rigid or semi-rigid
material. The walls may be planks with a thickness of 1/8 inch or
greater with a width of 1/2 inch or greater. Of course, these may
be larger or smaller, depending on the circumstances. The walls may
be hollow or solid panels that are from a foot or two wide and long
to several feet wide and long. Elongated walls may be aligned
horizontally or vertically.
[0011] Each post is an elongated member with at least one extruded
or milled groove or slot into which the walls' ends and/or sides
are inserted. The posts may be made of aluminum or other metal,
polymer, fiber-reinforced polymer composite, wood, or any other
suitable rigid or semi-rigid material. The posts may be solid or
hollow.
[0012] The outer contours of the posts, when viewed in
cross-section, may be square, rectangular, oval, circular or any
other geometric or other shape. A given post may be used in a
corner or along a long side in a series of posts, and therefore
each post will typically have at least one longitudinal groove or
slot into which a wall may be inserted. Furthermore, some posts may
receive two, three, four or more walls, such as a T-shaped post
that is used along a long wall, and permits the insertion of a wall
that divides. At least one side of each post has a minimum width of
about 3/4 inch to accommodate each wall, and at least one side
contains a receiving channel for the insertion of a wall.
[0013] The combination of two or more "posts" with one or more of
the "walls" mounted in the slots therein makes a finished planter,
table, storage container or other furniture piece, or a screen
around an unsightly machine or item, all of which are highly
functional, weather-resistant, require little to no maintenance,
and may be modified or repaired later with other similar parts and
no damage to the original components. The finished item is thus
modular, so it can be expanded, reduced, or repaired by the
addition or removal of one or more "walls" and/or "posts".
[0014] Each of the wall and post components must be able to be
lifted and manipulated by a typical human user. This may be a
carpenter or other skilled tradesman, or a homeowner with little
training or experience in skilled trades.
[0015] There may be stiffeners between the walls, particularly if
the walls are made of multiple planks, and the stiffeners may
function as decorative and/or strength-enhancing spacers. The
stiffeners may be extruded, milled or molded aluminum or other
metal, plastic, fiber-reinforced polymer composite or wood. A
preferred stiffener thickness is less than the thickness of the
planks to which they are attached, and so may be a width of 1/4
inch or greater.
[0016] Because of the flexibility of the design, the present
invention can be used in varied ways to create containers and
screens of various sizes and shapes. The posts form the corners and
mid-span supports for walls that are fixed in the posts. Thus, in
any circumstances in which a post can be mounted, walls (made of
planks and/or sheets) are mounted between the posts to form the
large surface area that screens something from view or holds back
items. An advantage of the materials described herein is that they
are weather-proof. By installing polymer decking boards as walls
into extruded aluminum posts, as an example, there are virtually no
requirements, such as staining, painting or sealing, to maintain
the system to keep it functional. Furthermore, the system can be
disassembled at a later time and any parts that have become broken
or worn can be replaced. The method disclosed herein requires no
removal or damage to the components, as would be the case if nails
were used in a wooden or polymer product. Thus, subsequent
modification or repair is not apparent.
[0017] The system for containing or screening is highly modular and
may be distributed in a kit of pre-cut pieces, or may be
distributed by raw materials that are cut to length by the end
user. In a preferred embodiment, posts may be extruded aluminum,
pultruded composite or other materials that resist bending and form
a strong foundation for individual planks or sheets to extend as
walls between two or more such posts. The planks or sheets hold
back soil if the system is used as a planter box, or form sides
that contain items such as toys or tools, or form fences that
screen something from view. The system can be used to form a deck
box or a planter, or to screen an HVAC unit from view, for example.
A foraminous or perforated grid can be mounted to the rear of the
system to allow plants growing in soil held by the planks to climb
up the grid. This grid may be mounted to the wall or the posts, as
described below in detail.
[0018] Because the system is modular, other walls and posts may be
added to the constructed item at a later time without damage to the
original components. Such walls and posts match the appearance of
the originals so that the added components do not have the
appearance of a later modification. Because of how the components
are attached, there is no damage to the components during original
construction or later modification.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] FIG. 1 is a top schematic view illustrating an embodiment of
the present invention.
[0020] FIG. 2 is a side view illustrating the embodiment of FIG.
1.
[0021] FIG. 3 is a side view in section illustrating the embodiment
of FIG. 2 through the line A-A with an enlarged portion.
[0022] FIG. 4 is a top view illustrating a corner of the embodiment
of FIG. 1.
[0023] FIG. 5 is a top view illustrating an alternative post.
[0024] FIG. 6 is a top view illustrating an alternative post.
[0025] FIG. 7 is a top view illustrating an alternative post.
[0026] FIG. 8 is a top schematic view illustrating an alternative
embodiment of the present invention.
[0027] FIG. 9 is a top view illustrating an alternative post.
[0028] FIG. 10 is a top view illustrating an alternative post.
[0029] FIG. 11 is a top view illustrating an alternative post.
[0030] FIG. 12 is a top view illustrating an alternative post
combined with at least one wall.
[0031] FIG. 13 is a top view illustrating an alternative post
combined with at least one wall.
[0032] FIG. 14 is a top view illustrating an alternative post
combined with at least one wall.
[0033] FIG. 15 is a side view illustrating an alternative
embodiment of the present invention.
[0034] FIG. 16 is a side view illustrating an alternative
embodiment of the present invention.
[0035] In describing the preferred embodiment of the invention
which is illustrated in the drawings, specific terminology will be
resorted to for the sake of clarity. However, it is not intended
that the invention be limited to the specific term so selected and
it is to be understood that each specific term includes all
technical equivalents which operate in a similar manner to
accomplish a similar purpose. For example, the word connected or
terms similar thereto are often used. They are not limited to
direct connection, but include connection through other elements
where such connection is recognized as being equivalent by those
skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
[0036] U.S. provisional application Ser. No. 62/281,938 filed Jan.
22, 2016, which is the above claimed priority application, is
incorporated herein by reference.
[0037] One example of the structure described herein is the
surround 8 shown in FIGS. 1-4 with four substantially identical
posts 10, 12, 14 and 16 disposed at four corners. Four sets of
three horizontally mounted, vertically-stacked planks 20a-d, 22a-d
and 24a-d are mounted at their opposing ends to respective pairs of
the posts 10-16. The planks form walls and the posts retain the
walls in position so the surround 8 can retain or screen items
behind the walls. Between the posts 10 and 12 are the planks 20a,
22a and 24a. Between the posts 12 and 16 are the planks 20b, 22b
and 24b. Between the posts 14 and 16 are the planks 20c, 22c and
24c. Between the posts 10 and 14 are the planks 20d, 22d and 24d.
The orientation of some of the planks is shown in FIGS. 2 and 3,
and the location of the planks 22b and 24b are the same as the
location of planks 22d and 24d, but between the posts 12 and 16
rather than the posts 10 and 14.
[0038] The corner posts 10-16 may be vertically oriented as shown
in FIGS. 1-4, such as by extending a lower end (not shown) into
soil, concrete or any other substrate. Alternatively, the corner
posts 10-16 may rest upon a patio 18 or other surface that is at
ground level. The corner posts 10-16 have longitudinal slots and/or
grooves into which the ends of the planks are inserted, as
described in more detail below, to retain the planks solidly and
until such time as the planks are deliberately removed
therefrom.
[0039] The planks may be mounted at their ends to the posts and
form walls, in the example shown and described, that may serve to
contain items, such as toys or tools, within the surround 8, and/or
may serve to screen from view one or more items within the walls,
such as an air-conditioning unit or a pool pump. The posts maintain
the vertical orientation of the planks, and the planks screen from
view, or restrain, items within.
[0040] As shown in FIGS. 1 and 3, the posts 14 and 16 are spaced
from the posts 10 and 12, and the planks 20c, 22c and 24c, which
are parallel to the planks 20a-24a, extend between, and are
attached to, the posts 14 and 16. Furthermore, the planks 20d, 22d
and 24d extend between, and attach to, the posts 10 and 14, and
they are parallel to the planks 20b, 22b and 24b that extend
between, and attach to, the posts 12 and 16. The posts 10-16 may be
positioned at corners of an imaginary rectangle, with predetermined
distances between next adjacent posts, and with the planks of
similar lengths mounted to and disposed between the posts forming
the sides of the surround 8. In this manner, a containment system
is formed that, when viewed from the top, is rectangular. This
containment system may form a flower box or any other
container.
[0041] A section view through the line A-A of FIG. 2 is shown in
FIG. 3, in which the planks 20c-24c and the planks 20a-24a held in
the posts 10 and 14 are sectioned. FIG. 3 shows a magnified view of
an encircled portion. A stiffener 34 is placed between, and
inserted into grooves 40a and 42a formed in, the edges of the
adjacent planks 20a and 22a, respectively, to stiffen the entire
wall made up of the planks 20a-24a. The stiffener 34 mechanically
attaches the planks 20a and 22a that are adjacent to one another,
thereby binding the planks 20a and 22a together so they reinforce
one another. The stiffener 34 also stiffens the wall by having
substantial thickness, thereby functioning as an "I-beam" that is
added to the planks 20a and 22a. The stiffener 34 may be made of
extruded aluminum, stainless steel, fiber-reinforced polymer
composite or other strong material.
[0042] Other similar stiffeners are attached to, and stiffen, all
adjacent pairs of planks. Thus, just as the planks 20a and 22a each
receive a tongue 30a and 32a, respectively, of the stiffener 34 as
shown in FIG. 2, all plank edges that are adjacent another plank
edge may be slotted to receive a similar stiffener. The stiffeners
stiffen the walls, and prevent soil and/or other particulate matter
contained in the surround 8, so that particulate matter does not
flow past the planks and stiffeners. The stiffeners prevent items
hidden by the planks from being visible through cracks between
adjacent planks. The stiffener 34 and its identical cousins shown
herein are optional.
[0043] As shown in FIG. 4, the corner post 10 is shown from a top
view with the planks 20a and 20d mounted at their ends to the post
10. A post cap may cover the top of the post 10 during normal use
so the interior thereof is not visible or exposed to weather. The
corner post 10 with attached planks is representative of the posts
12-16 and their respective attached planks, and therefore these
other posts and planks are not described herein in detail.
[0044] The ends of each of the planks 20a and 20d may insert into
longitudinal slots or channels 50a and 50d that are formed in
adjacent sides, and along the entire length, of the post 10. The
channels may be integrally formed in the post 10, such as during
manufacture, and the post 10 may be made of aluminum extruded
through a mold having a void cross section similar to the shape of
the post 10 shown in FIG. 4. The channels 50a and 50d are defined
by the post material having a cross-sectional shape shown in FIG.
4, which channels 50a and 50d receive the ends of the respective
planks 20a and 20d. In this manner, the ends of the planks 20a and
20d may simply be retained in the channels 50a and 50d,
respectively, by friction, such as between the opposing channel
sidewalls.
[0045] Alternatively, each plank may have a fitting removably or
integrally (such as by simultaneous molding during manufacture)
mounted to each end thereof, with each fitting cooperating
mechanically with structures that define the channels 50a and 50d.
It is contemplated that two or more planks may be mounted to or
within a single fitting, and the fitting mounted in a channel in a
post.
[0046] In a preferred embodiment, the fittings 60a and 60d are
mounted to the respective ends of the planks 20a and 20d, and
similar fittings are mounted to all other plank ends that are
retained within channels in the posts 10-16. The fittings 60a and
60d, which may be generally U-shaped in cross-section, mount to the
ends of the planks 20 and 20a, respectively, by inserting the end
of the plank into the void formed therein. A respective fastener,
such as the screws 62a and 62d, extend through the fittings 60a and
60d into a respective end of each of the planks 20a and 20d. Any
fastener is contemplated, but screws, adhesive and rivets are
examples. The ridges 52a,d and 54a,d project inwardly from the
respective channels 50a and 50d, defining pairs of ridges with tips
spaced apart substantially equal to, or slightly greater than, the
thickness of the planks 20a and 20d, but less than the width of the
fittings 60a and 60d. The distance between a pair of tips is
referred to as the ridge gap.
[0047] The fittings 60a and 60d are the same width or are narrower
than the portions of the channels into which they are inserted in
an operable position, but are at least as wide as the ridge gaps,
which are the spaces between the tips of the ridges 52a,d and
54a,d. This relationship causes the fittings 60a and 60d to be
retained in the channels 50a and 50d, respectively, on the opposite
side of the ridges from the remainder of the planks. In the
embodiment illustrated, the end of the plank may be considered a
leg with the fitting considered a foot that forms an enlarged
portion that prevents the wall from coming out of the channel along
the plane of the wall, other than along the length of the channel.
This configuration permits the fittings and their respective planks
to be slid along the length of the channels 50a and 50d into place
in the post 10 during installation and removal. Typically, this is
a tight fitment that allows sliding along the length of the
channels 50a and 50d under the force of average human strength, but
prevents substantial movement of the planks relative to the posts
in any direction except along the lengths of the channels. Once the
planks are in position, they remain there due to the requirement
for deliberate sliding along the channels for removal. Each wall
end that is mounted in a post slot may have a fitting that provides
a leg portion and a foot portion.
[0048] Thus, a method of constructing the surround 8 may include
the positioning of each post 10-16, preferably spaced from one
another, and each of the planks being placed with one end in one
channel and an opposite end in a facing channel of another post.
This process is repeated until the surround is complete. If
desired, a fitting may be mounted to the end of each plank, and the
insertion step carried out by inserting the leg portion and foot
portion at a side of a slot or channel, and then forcing the wall
along the slot's length with the foot portion deeper than the leg
portion, until the wall is in the desired longitudinal position in
the slot. In a contemplated method, the first, typically lowest,
layer of planks is inserted into the channels of opposing posts,
and a stiffener is placed on the exposed top edge of each plank, if
needed. Then another plank is placed on top of the first (lowest)
plank with its slot receiving the stiffener. This process is
repeated for the entire second layer of planks. This process of
inserting a stiffener is repeated by placing a stiffener in the
slot on a top edge of the second layer of planks, and a third layer
of planks is installed with slots in their lower edges receiving
the top of the second stiffeners. This can continue for each
desired layer. Top and bottom planks typically do not have a
stiffener on top and bottom sides, respectively, but each plank
that is adjacent two other planks may have a stiffener on both of
its sides. A floor or cover may be mounted to one or more of the
posts or planks, and such cover may be hinged. A clasp or other
structure that permits locking of the surround 8 may also be used
in a conventional manner.
[0049] It is contemplated that a single fitting may be mounted to
two or more planks and one or more stiffeners. Thus, a method of
constructing a surround may include the positioning of each post,
preferably spaced from one another. Each of the planks is placed
with one end in a first fitting and an opposite end in a second
fitting. In a contemplated method, the first, typically lowest,
plank is inserted into the fittings, and a stiffener, if needed,
may be placed in a slot on the exposed top edge of the first plank.
Then a second plank is placed on top of the first (lowest) plank
with the second plank's slot receiving the stiffener. This process
of inserting a stiffener is repeated by placing a stiffener in the
slot on a top edge of the second plank, and a third plank is
installed with the slot in its lower edge receiving the top of the
second stiffener. Once the fitting is mounted to all the planks
(and stiffeners, if desired), the fittings at opposite ends of the
wall may be mounted in the post channels by inserting the first and
second fittings at sides of slots or channels in the posts. The
entire wall is then forced along the slots' lengths with the foot
portion deeper than the leg portion, until the wall is in the
desired longitudinal position in the slots.
[0050] If the span between corner posts is too long for the
strength of the planks, even if stiffeners are used, one or more
mid-posts, such as the mid-post 70 shown in FIG. 5, may be used.
The mid-post 70 is substantially similar to the posts 10-16, except
that it has structures on opposite sides that form opposing
channels 70e and 70f. The planks described herein may mount to
mid-posts 70, and all other posts described herein, in the same
manner as described herein for the corner post 10. The ends of the
planks are inserted into the channels 70e and 70f as described
above for insertion into the channels of the corner posts 10-16.
However, instead of the planks being oriented at about a 90 degree
angle to one another, the planks are aligned in a single plane that
intersects the mid-post 70. The mid-post 70 may be inserted into
the ground or attached to another structure as with the corner
posts 10-16.
[0051] The surround 8 is shown and described above in relation to
FIGS. 1-4, a surround or container that is useful for any purpose
may be readily constructed using four posts 10-16 and a plurality
of planks 20-24a-d. In an even more basic embodiment, a fence may
be constructed according to the invention, and such a fence may use
a structure that resembles one side of the surround 8, such as that
shown in FIG. 2 with two posts 14 and 16, and one wall. This fence
may be used to screen from view an unsightly mechanical item, such
as an air-conditioning unit. In this case, the fence is formed of
two end posts and a wall, such as can be made up of three planks
inserted in the posts. The corner posts 10-16, and the mid-post 70,
all of which have two channels, would not be as attractive for such
a purpose as posts that have only a single channel, such as the
member 80 shown in FIG. 6. The member 80 has a single channel 80g
that is substantially the same as the channels 50a and 50d formed
in the post 10.
[0052] The member 80 may also be used as a top and/or bottom rail
that extends horizontally between vertical posts, as shown in the
fence 500 of FIG. 16. A wall may be made of one or more vertical
planks 520 with lower ends that rest in the member 80 with its
channel 80g upwardly oriented and serving as a bottom rail. Another
member 510, which may be identical to the member 80, may serve as a
top rail and is disposed with its channel downwardly oriented with
the top ends of the vertical planks 520 inserted in the channel.
Stiffeners 530 may be inserted into slots formed in the adjacent
edges of the vertical planks 520 to eliminate any leaks in the
wall. The top and bottom rails 510 and 80 are inserted at their
ends into channels formed in the vertical posts 512 and 514, which
channels are similar to the channels shown in FIG. 4. In the
embodiment of FIG. 16, the wall is made up of the top and bottom
rails 510 and 80, the planks 520 and the stiffeners 530, if
stiffeners are used.
[0053] FIG. 7 shows a T-shaped post 90 that has structures defining
the channels 90h,i,j that receive three walls at 90 degree angles
to one another. Such a post 90 may be used as a mid-post in a
structure in which perpendicular divider walls are desired. The
T-shaped post 90 allows one to construct a container or surround
with walls that divide the container into multiple sections, as
shown in FIG. 8. Four posts 110, 112, 114 and 116 may be mounted at
corners of an elongated rectangle, and two T-shaped posts 90 and
100 may be mounted midway along longer, opposing walls 120a, 120b,
120c, 120d, 120e and 120f between the corners. Thus, a surround 108
may be constructed having two or more chambers 92 and 94 with a
wall 96 separating the chambers. The wall 96 inserts into the
channels of the posts 90 and 110 in a manner described herein.
[0054] With regard to the embodiment shown in FIGS. 1-4, any number
of planks can be oriented vertically along the height of the posts
10-16, and this variability illustrates the modularity of the
system. One example of a plank is a 1.times.6 polymer deck board,
with three such boards making the wall with a height of about 18
inches taking into consideration the stiffeners and the fact that a
1.times.6 board is nominally 5.5 inches wide. Any planks of any
common dimension, such as 1.times.4, 2.times.6, etc., or any
dimension that is not common, may be used with the posts 10-16 to
construct a container or surround of virtually any size. A single
sheet, such as plywood or glass, may be used as an alternative to
the planks. Polymer decking planks are contemplated, as are
virtually any material known to be suitable to outdoors use.
[0055] Alternative posts are shown in FIGS. 9-13. For example, a
corner post 200 for use with a wall that has essentially the same
thickness as the post 200 is shown in FIG. 9. A similar corner post
210 is shown in FIG. 10 having a larger radius of curvature on the
corner facing away from the two channels. The post 220 of FIG. 11
is similar to the post of FIG. 9, but with a larger depth and
thickness than the wall that inserts into the channels. The posts
mid-post 300, corner post 310 and end post 320 shown in FIGS. 12,
13 and 14, respectively, match the corner posts 10-16 of FIGS. 1-4,
and are shown with walls inserted therein.
[0056] Another alternative embodiment of the present invention is
shown in FIG. 15. As noted above, the post and wall components can
be combined to form a planter 410, and a foraminous or perforated
grid 420 can be mounted to one side of the planter 410. Such a grid
420 may be screen or "hardware cloth" mounted within a rigid,
rectangular frame that is mounted to the planter 410. The grid 420
allows climbing plants growing in soil held by the planter 410 to
climb up the grid 420. This grid 420 may be mounted to the wall or
the posts. In an example, posts that are similar to the post 220
shown in FIG. 11 are used in the planter 410, and the grid 420 is
mounted by screwing the grid to the protuberance 222 on two of the
adjacent posts of the planter 410.
[0057] This detailed description in connection with the drawings is
intended principally as a description of the presently preferred
embodiments of the invention, and is not intended to represent the
only form in which the present invention may be constructed or
utilized. The description sets forth the designs, functions, means,
and methods of implementing the invention in connection with the
illustrated embodiments. It is to be understood, however, that the
same or equivalent functions and features may be accomplished by
different embodiments that are also intended to be encompassed
within the spirit and scope of the invention and that various
modifications may be adopted without departing from the invention
or scope of the following claims.
* * * * *