FIELD
The present disclosure relates to decking systems, and more particularly to structural connections between composite joists/beams and posts, among other components of composite decking systems.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Referring to FIGS. 1 and 2, a decking system 10 typically includes deck boards 12 secured to a structural support system 14, which generally distributes loads from the deck boards 12 to the ground. The structural support system 14 includes a plurality of posts 16 anchored to the ground and a plurality of beams/joists 18, which are secured to the top portions of the posts 16. The beams/joists 18 distribute loads from the deck boards 12 to the posts 16, which then distribute the loads to the ground.
While conventional decking systems primarily use treated wood for the deck boards 12, structural support system 14, posts 16, and beams/joists 18, newer decking systems are employing engineered plastics and composite materials for one or more of these components for improved strength and durability. For example, the deck boards 12 may include a glass reinforced thermoplastic core with a co-extruded thermoplastic cap stock/exterior. Further, the posts 16 may also be an engineered plastic material having integral internal stiffening members for strength and light weight. However, when high structural loads are applied to the posts 16, via the deck boards 12 and through the beams/joists 18, the posts 16 may cause plastic deformation of the beams/joists 18, leading to degradation of the structural integrity of the overall decking system 10.
These issues related to load distribution throughout the components of a decking system, whether manufactured from conventional or engineered materials, are addressed by the present disclosure.
SUMMARY
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form of the present disclosure, a post-beam cap for an upper end portion of a post in deck construction is provided. The post-beam cap comprises a continuous load-bearing upper surface, wherein the continuous load-bearing upper surface is configured to abut and distribute loads from a beam to the post. A lower flanged portion is configured to engage the upper end portion of the post, and a plurality of contoured tabs extending from a lower surface of the post-beam cap, wherein the plurality of contoured tabs are configured to engage more than one of a plurality of internal slots of the post.
In variations of the post-beam cap set forth above, which may be implemented individually or in any combination: a central fitting extends from a lower surface of the post-beam cap, wherein the central fitting is configured to engage an internal central conduit of the post; the lower flanged portion comprises opposed flanges configured to mate with opposed side walls of the post; the lower flanged portion comprises a continuous external flange extending around the lower surface of the post-beam cap and configured to mate with at least one side wall of the post; opposed vertical walls extend upwardly from the continuous load-bearing upper surface; the contoured tabs define a hexagonal geometry; and the contoured tabs define a square geometry.
In another form of the present disclosure, an assembly having the post-beam cap (and its variations) set forth above includes a post having an upper end portion and a lower end portion, the post defining a plurality of internal slots, and a base secured to the lower end portion of the post, wherein the post-beam cap is secured to the upper end portion of the post, and the post distributes the loads to the base.
In variations of this assembly, which may be implemented individually or in any combination: a number of the internal slots of the post is greater than a number of the contoured tabs; the base further comprises a plurality of contoured tabs extending from an internal surface of the base, wherein the plurality of contoured tabs are configured to engage internal slots of the post; the base further comprises a central fitting extending from an internal surface of the base, wherein the central fitting is configured to engage an internal central conduit of the post; the base further comprises a peripheral flange and an internal cavity configured to receive the lower end portion of the post; a support bracket is secured to an external sidewall of the post, the support bracket comprising a ledge and a sidewall, wherein the ledge and sidewall are configured to receive a joist; the internal slots of the post define a hexagonal geometry; the internal slots of the post define a square geometry; the assembly further comprises at least one secondary post and a post cap secured to an upper end portion of the at least one secondary post; and the post cap is lighted.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
FIG. 1 is a perspective view of a decking system constructed in accordance with the prior art;
FIG. 2 is a schematic side cross-sectional view of posts and a beam of the decking system of FIG. 1 secured to the ground in accordance with the prior art;
FIG. 3 is a perspective view of one form of an assembly for deck construction according to the teachings of the present disclosure;
FIG. 4 is a perspective view of a post and post-beam cap of the assembly of FIG. 3;
FIG. 5A is an enlarged perspective view of the post-beam cap of FIG. 4 supporting a beam according to the teachings of the present disclosure;
FIG. 5B is a top perspective view of the post-beam cap of FIG. 5A;
FIG. 5C is a bottom perspective view of the post-beam cap of FIG. 5A;
FIG. 5D is a top perspective view of a portion of a post according to the teachings of the present disclosure;
FIG. 5E is a bottom view of a post-beam cap secured to a post with mechanical fasteners according to the teachings of the present disclosure;
FIG. 5F is a top view of a post-beam cap illustrating a continuous load-bearing surface and load paths according to the teachings of the present disclosure;
FIG. 5G is a top view of a comparative post-beam cap illustrating a discontinuous load-bearing surface and corresponding discontinuous load paths;
FIG. 6 is a perspective view of another form of an assembly for deck construction according to the teachings of the present disclosure;
FIG. 7 is a perspective view of a post and a variation of a post-beam cap of the assembly of FIG. 6;
FIG. 8A is an enlarged perspective view of the post-beam cap and an upper end portion of the post of FIG. 7;
FIG. 8B is an enlarged perspective view of the post-beam cap of FIG. 7 supporting a beam according to the teachings of the present disclosure;
FIG. 8C is a top perspective view of the post-beam cap of FIG. 7;
FIG. 8D is a bottom perspective view of the post-beam cap of FIG. 7;
FIG. 9A is a perspective view of a lower end portion of a post and a base constructed in accordance with the teachings of the present disclosure;
FIG. 9B is a top perspective view of the base of FIG. 9A;
FIG. 9C is a top view of the base of FIG. 9A;
FIG. 10A is a perspective view of a lower end portion of a post and another form of a base constructed in accordance with the teachings of the present disclosure;
FIG. 10B is a bottom perspective view of the base of FIG. 10A;
FIG. 10C is a top perspective view of the base of FIG. 10A;
FIG. 11A is a bottom perspective view of a lower end portion of a post with an installed base and a sleeve constructed in accordance with the teachings of the present disclosure;
FIG. 11B is a perspective view of the sleeve of FIG. 11A installed over the base;
FIG. 11C is a top perspective view of the sleeve of FIG. 11A;
FIG. 11D is a bottom perspective view of the sleeve of FIG. 11A;
FIG. 12A is a perspective view of a variation of the present disclosure having a support bracket secured to a post and constructed according to the teachings of the present disclosure;
FIG. 12B is an interior perspective view of the support bracket of FIG. 12A;
FIG. 12C is an exterior perspective view of the support bracket of FIG. 12A;
FIG. 13A is a perspective view of an upper end portion of a post and a post cap constructed in accordance with the teachings of the present disclosure;
FIG. 13B is a top perspective view of the post cap of FIG. 13A;
FIG. 13C is a bottom perspective view of the post cap of FIG. 13A;
FIG. 14 is a perspective view of an upper end portion of a post and a lighted post cap constructed in accordance with the teachings of the present disclosure;
FIG. 15A is a bottom perspective view of a post-beam cap having contoured tabs defining a square geometry and constructed according to the teachings of the present disclosure;
FIG. 15B is a top view of a post having square shaped internal slots configured to receive the contoured tabs of the post-beam cap of FIG. 15A and constructed according to the teachings of the present disclosure;
FIG. 16A is a bottom perspective view of a post-beam cap having contoured tabs defining a hexagonal geometry and constructed according to the teachings of the present disclosure; and
FIG. 16B is a top view of another form of a post having hexagonal shaped internal slots configured to receive the contoured tabs of the post-beam cap of FIG. 16A and constructed according to the teachings of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to FIG. 3, an assembly for deck construction is illustrated and generally indicated by reference numeral 20. The assembly 20 generally includes a plurality of posts 22 spaced apart at predetermined distances, which generally distribute loads from a beam or joist 18, or multiple beams/joists 18, to the ground. (The deck boards illustrated and described above are not shown for purposes of clarity). The assembly 20 further comprises a plurality of post-beam caps 24, which are secured to upper end portions 26 of each of the posts 22. As described in greater detail below, the innovative post-beam caps 24, and variations thereof, are configured to abut and more evenly distribute loads from the beams/joists 18 to the posts 22.
Referring to FIG. 4 and FIGS. 5A-5C, one form of the post-beam caps 24 is illustrated and now described in greater detail. As shown, the post-beam cap 24 includes a continuous load-bearing upper surface 30, which extends between opposed lateral faces 32 and opposed vertical walls 34. The continuous load-bearing upper surface 30 is configured to abut and distribute loads from the beam/joist 18 (shown in a 2-ply configuration by way of example) to the post 22. Because the continuous load-bearing upper surface 30 is “continuous,” loads applied from the beam/joist 18 are more evenly distributed, thereby reducing stress concentrations in areas where more load may be applied than in other areas. Therefore, as used herein, the term “continuous” with respect to a load-bearing surface should be construed to mean a surface that provides a continuous/single load path along its length and across its width, without multiple loads paths, as set forth in greater detail below.
The teachings of the present disclosure are particularly advantageous with the use of a beam/joist 18 that is made from a composite construction, e.g., glass reinforced thermoplastic core with a co-extruded thermoplastic cap stock/exterior. Unexpected results were discovered when using the innovative assembly 20 as illustrated and described herein, and more particularly, plastic deformation of the beam/joist 18 from the post 22 was inhibited with the unique load distribution system of the teachings of the present disclosure.
Referring to FIGS. 5F and 5G, further clarification of a continuous/single load path and a continuous load-bearing upper surface is illustrated in greater detail. The continuous load-bearing upper surface 30 is shown in FIG. 5F, along with arrows labeled “L” to indicate the distribution of loads, or load paths, from the beam/joist 18 (not shown). Because the continuous load-bearing upper surface 30 is “continuous”, the load paths L are distributed throughout the entire continuous load-bearing upper surface 30 and are as a result more evenly distributed to the post 22 below (not shown). In contrast, a discontinuous upper surface 31 is shown in FIG. 5G, in which loads from the beam/joist 18 are distributed across two discrete surface sections, which are not continuous as indicated by the void between opposed vertical walls 34. In preliminary testing, the unique design of the continuous load-bearing upper surface was shown to increase the maximum compressive stress to failure of the beam/joist 18 by about 60% compared with conventional construction.
As a further example, the post-beam cap 24 in this form also includes an optional aperture 36 (FIGS. 5B and 5F) extending through the continuous load-bearing upper surface 30, which is generally used for routing of electrical wires/conduits. Even with the aperture 36, the continuous load-bearing upper surface 30 is “continuous” because loads that are applied to this surface from the beam/joist 18 are distributed along the continuous load-bearing upper surface 30 without interruption and can flow around the aperture 36 as shown. Thus, the “continuous” surface extends along an entire length of the beam/joist 18 that abuts the continuous load-bearing upper surface 30 and is uninterrupted along that length.
Referring back to FIGS. 5A-5C, the opposed vertical walls 34 extend upwardly from the continuous load-bearing upper surface 30 to define a space therebetween to receive the beam/joist 18. The opposed vertical walls 34 also include pockets 38, which reduce the amount of material required for fabrication of the post-beam caps 24, thereby reducing costs. One or more apertures 40 may also be formed through one or both of the opposed vertical walls 34, which are configured to receive a mechanical fastener (e.g., bolt or screw, not shown) to further secure the beam/joist 18 to the post-beam cap 24. As further shown, optional pilot holes 41 may be formed through the opposed vertical walls 34 (or through any wall of the post-beam cap 24) to accommodate additional mechanical fasteners for increased joint strength. The opposed vertical walls 34 further stabilize the beam/joist 18, and more specifically inhibit the beam/joist 18 from laterally deflecting (normal/perpendicular to the opposed vertical walls 34) under loads. This lateral deflection could include rotation, buckling, or twisting of the beam/joist 18, by way of example.
As best shown in FIG. 5C, the post-beam cap 24 in this form also includes a lower flanged portion 50 that is configured to engage the upper end portion 26 of the post 22. More specifically, the lower flanged portion 50 includes a continuous external flange 52 extending around a lower surface 54 of the post-beam cap 24. The continuous external flange 52 is configured to mate with each of the sidewalls 23 of the post 22, and in this form, the continuous external flange 52 fits over the upper end portion 26 of the post 22 as shown. The continuous external flange 52 includes optional apertures 56, which are configured to receive mechanical fasteners (e.g., bolts or screws, not shown) to further secure the post-beam cap 24 to the post 22. It should be understood, however, that other fastening means may be used, such as by way of example, adhesive bonding, to secure the post-beam cap 24 to the post 22 while remaining within the scope of the present disclosure. Further, adhesive bonding, or other fastening means, may be employed between any of the connections/joints illustrated and/or described herein while remaining within the scope of the present disclosure.
Referring specifically to FIGS. 5C and 5D, the post-beam cap 24 further comprises a plurality of contoured tabs 60 extending from the lower surface 54 of the post-beam cap 24. The contoured tabs 60 are generally configured to engage internal slots 62 of the post 22. Accordingly, the contoured tabs 60 may take on a number of sizes and geometries as a function of the shape and number of internal slots 62 in the post 22, and thus the configuration illustrated herein is merely exemplary and should not be construed as limiting the scope of the present disclosure. It should be understood that the number of contoured tabs 60 may be less than the number of internal slots 62 of the post 22. For example, the post-beam cap 24 may include only two opposed contoured tabs 60 with the number of internal slots 62 illustrated while remaining within the scope of the present disclosure.
Referring specifically to FIGS. 5C-5E, the contoured tabs 60 in one form include optional apertures 64 to receive mechanical fasteners 65. The contoured tabs 60 thus serve an additional function of being a structural doubler to support the sidewalls 23 of the post 22 and inhibit cracking from the compressive loads of the mechanical fasteners 65. More specifically, as the sidewalls 23 of the post 22 deform under fastening loads, the contoured tabs 60 support the sidewalls 23 and inhibit further deformation towards the interior of the post 22. Further, the contoured tabs 60 also support the lateral faces 32 of the post-beam cap 24 during mechanical fastening and inhibit deformation and cracking. Therefore, the innovative contoured tabs 60 serve multiple functions, namely, for locating the post-beam cap 24 onto the post 22, for structural support during loading, and to inhibit cracking of the sidewalls 23 of the post 22 and the lateral faces 32 of the post-beam cap 24 with the use of mechanical fasteners 65.
In this form, a central fitting 66 extends from the lower surface 54 of the post-beam cap 24. The central fitting 66 is configured to engage an internal central conduit 68 of the post 22. Optional ribs 69 may be provided on the central fitting 66 to improve the mechanical connection between the post-beam cap 24 and the post 22, and more specifically with the internal central conduit 68. As further shown, the central fitting 66, in this form, is hollow and is in communication with the aperture 36 in the continuous load-bearing upper surface 30, thereby providing passage for the electrical wires/conduits as previously set forth.
Referring now to FIGS. 6, 7, and 8A-8D, another form of a post-beam cap is illustrated and generally indicated by reference numeral 70. Similar to the previous version, the post-beam cap 70 is secured to the upper end portion 26 of the post 22 and is configured to abut and distribute loads from the beams/joists 18 to the posts 22. The post-beam cap 70 also includes a continuous load-bearing upper surface 72, which extends across an entire width, and beyond as shown, of the post 22. The continuous load-bearing upper surface 72 is similarly configured to distribute loads more evenly from the beam/joist 18 (shown in a 2-ply configuration by way of example) to the post 22.
The post-beam cap 70 also includes a lower flanged portion 74, which comprises opposed flanges 76 configured to mate with opposed sidewalls 23 of the post 22. More specifically, the opposed flanges 76 fit over and are disposed alongside the opposed sidewalls 23. The opposed flanges 76 include optional apertures 78, which are configured to receive mechanical fasteners (e.g., bolts or screws, not shown) to further secure the post-beam cap 70 to the post 22. It should be understood, however, that other fastening means may be used, such as by way of example, adhesive bonding, to secure the post-beam cap 70 to the post 22 while remaining within the scope of the present disclosure. As further shown, the continuous load-bearing upper surface 72 may optionally include a pattern of apertures 80, which are configured to receive mechanical fasteners (e.g., bolts or screws, not shown) to secure the beam/joist 18 to the post-beam cap 70.
Referring specifically to FIGS. 8C and 8D, the post-beam cap 70 further comprises a plurality of contoured tabs 82 extending from a lower surface 84 of the post-beam cap 70. The post-beam cap 70 also includes a central fitting 86 and an aperture 88 extending through the continuous load-bearing upper surface 72. The contoured tabs 82, the central fitting 86, and the aperture 88 function the same as the previously illustrated and described elements relative to the post-beam cap 24, and thus the description of these elements is omitted here for purposes of brevity.
Referring now to FIGS. 6, and 9A-9C, one form of a base of the assembly 20 of the present disclosure is illustrated and generally indicated by reference numeral 90. The base 90 is secured to a lower end portion 28 of the post 22, and as shown, a plurality of bases 90 are employed at each of the lower end portions 28 of the plurality of posts 22. Generally, the loads from the beams/joists 18 are transferred to the post-beam caps 24/70, down through the posts 22, and the posts 22 distribute the loads to the bases 90. The bases 90 then distribute the loads to the ground.
In this form, the base 90 comprises a lower internal surface 94 configured to abut the lower end portion 28 of the post 22, which is where the loads are transferred from the post 22 to the base 90. A plurality of contoured tabs 92 extend from the lower internal surface 94 of the base 90, and as with the previously described contoured tabs 60/82, the plurality of contoured tabs 92 are configured to engage internal slots 62 (FIG. 5D) of the post 22 and to serve the functions as described in detail above. As shown, some of the contoured tabs 92 may include apertures 96 to receive mechanical fasteners as set forth above. In this form, the base 90 also includes a central fitting 98 extending from the internal surface 94, which is configured to engage the internal central conduit 68 of the post 22 (FIG. 5D). Optional ribs 99 may be provided on at least a portion of the outer periphery of the central fitting 98 to improve the mechanical connection between the base 90 and the post 22. As further shown, the central fitting 98 in this form is hollow and is in communication with the internal central conduit 68, thereby providing passage for the electrical wires/conduits as previously set forth.
The base 90 further includes a plurality of slots 100, which are configured to receive concrete anchors 102. (Concrete anchors 102 are generally known in the art and are not described herein for purposes of clarity). The slots 100 are configured as such to allow for dimensional variation in the placement of the concrete anchors 102. In this form, the base 90 also includes a pair of opposed recesses 104 extending into the lower internal surface 94. The opposed recesses 104 are configured to drain water or moisture that may accumulate within the posts 22. It should be understood that the number and location of recesses/drains may different than the opposed recesses 104 illustrated herein while remaining within the scope of the present disclosure.
Referring now to FIGS. 10A-10C, another form of a base is illustrated and generally indicated by reference numeral 110. The base 110 in this form comprises a peripheral flange 112 and an internal cavity 114 configured to receive the lower end portion 28 of the post 22. The peripheral flange 112 extends around the entire base 110 and upwardly to create the internal cavity 114. Accordingly, the post 22 fits down inside the internal cavity 114 as shown. Optionally, a plurality of apertures 116 may be provided through side walls 118 of the peripheral flange 112. The apertures 116 are configured to receive mechanical fasteners 120 to firmly secure the base 110 to the post 22. The base 110 also includes optional recesses 122 extending into a lower portion 124 of the base 110. Similar to the recesses 122 previously set forth, the recesses 122 are configured to drain water or moisture that may accumulate within the posts 22.
The base 110 also includes contoured tabs 126, which function the same as the previously set forth contoured tabs. Further, the contoured tabs 126 may also be provided with apertures 128 to accommodate mechanical fasteners 120. In one form, the mechanical fasteners 120 extend through the apertures 116 in the peripheral flange 112, through the sidewall 23 of the post 22, and through the apertures 128 of the contoured tabs 126. Similarly, this base 110 also includes a central fitting 129 as previously illustrated and described, among other similar features that are not further described for purposes of brevity.
Now turning to FIGS. 11A-11D, an optional sleeve according to the teachings of the present disclosure is illustrated and generally indicated by reference numeral 130. The sleeve 130 is configured to extend around and cover the base 110 (FIG. 11B), primarily for improved aesthetics. The sleeve 130 includes a chamfered upper surface 132, which assists with diversion of moisture/water away from the base 110 during use. Further, the sleeve 130 defines internal grooves 134, which are configured to provide clearance for the heads 121 of the mechanical fasteners 120 during installation of the sleeve 130 over the base 110. The internal grooves 134 are thus exposed on a lower surface 136 of the sleeve and extend upwardly to an internal flange 138. The internal flange 138 is configured to abut a top edge 111 of the base 110 (best shown in FIG. 10C) to properly locate the sleeve 130 in the vertical direction. The internal grooves 134 may also assist with the diversion of water/moisture if any such water/moisture were to enter the space between the sleeve 130 and the base 110.
Referring to FIGS. 12A-12C, a support bracket according to the teachings of the present disclosure is illustrated and generally indicated by reference numeral 140. The support bracket 140 is mounted to a post 22, and more specifically secured to the sidewall 23 of the post 22, at any suitable location, and functions to receive and support a joist 19 as shown. The loads from the joist 19 are thus transferred to the support bracket 140 and into the post 22.
The support bracket 140 comprises a ledge 142, on which the joist 19 rests, and a sidewall 144 extending upwardly from the ledge 142. The sidewall 144 generally provides lateral support for the joist 19 and may be provided with a plurality of apertures 146. The apertures 146 are configured to receive mechanical fasteners (e.g., bolts or screws, not shown), to firmly secure the joist 19 to the support bracket 140. The mechanical fasteners may extend into the joist 19 only, or the mechanical fasteners may extend through the joist 19 and into the post 22 while remaining within the scope of the present disclosure. Additional apertures 148 are provided through a lower flange 150 of the support bracket 140, which receive mechanical fasteners to secure the support bracket 140 to the post 22. Yet another aperture 152 is provided through the ledge 142, which receives a mechanical fastener to further secure the joist 19 to the support bracket 140. It should be understood that the support bracket 140 is an optional component of the decking system 10 and load distribution system as illustrated and described herein.
Referring to FIGS. 3, and 13A-13C, another optional component of the assembly 20 of the present disclosure includes a post cap 160. The post cap 160 is primarily decorative and can include a variety of styles to suit a particular consumer. The post cap 160 is secured an upper end portion 162 of at least one secondary post 164, i.e., a post that does not transmit any appreciable loads to the beams/joists 18. The post cap 160 includes an internal recess 166 that is sized to fit over the top of the secondary post 164. The post cap 160 may be sized for an interference fit with the top of the secondary post 164, or other fastening means such as mechanical fasteners or adhesives may be employed. The post cap 160 may also include a central fitting 168, which functions similar to the central fittings illustrated and described above.
Now referring to FIG. 14, a variation of a post cap is illustrated and generally indicated by reference numeral 170. The post cap 170 in this form is lighted, which in this form includes a light source (e.g., LED, not shown) mounted to an interior of the post cap 170 (and receiving electrical energy via the electrical wires previously set forth) and windows 172 formed on sides of the post cap 170. It should be understood that any number and configuration of windows may be employed while remaining within the scope of the present disclosure, and thus the particular design illustrated herein is merely exemplary.
Referring to FIGS. 15A-15B and 16A-16B, additional and nonlimiting forms of the present disclosure are illustrated with the different geometries for the internal slots of the post 22, as well as the corresponding contoured tabs for both the post-beam caps 24/70 (and bases 90/110, which are not shown in this group of figures for purposes of clarity). It should be understood that only one form of the post-beam cap is illustrated in order to describe the different contoured tabs. The different geometries of contoured tabs thus should be construed as being applicable to all forms of post-beam caps and bases illustrated and contemplated herein while remaining within the scope of the present disclosure.
Referring specifically to FIGS. 15A and 15B, contoured tabs 60′ of the post-beam cap 24 define a square geometry, while corresponding internal slots 62′ of the post 22 define a square geometry. As set forth above, the contoured tabs 60′ are generally configured to engage internal slots 62′ of the post 22. In this form, there are nine (9) total contoured tabs 60′ and a corresponding nine (9) internal slots 62′, forming a 3×3 grid. It should be understood, however, that any number of square contoured tabs 60′ and square internal slots 62′, which may not necessarily be the same number for each of the post-beam cap 24 and post 22 may be employed while remaining within the scope of the present disclosure. For example, the post-beam cap 24 may have only four (4) contoured tabs (e.g., corner contoured tabs indicated by the letter “C”) while the post 22 maintains the illustrated 3×3 grid. These and other variations should be construed as falling within the scope of the present disclosure.
Referring now to FIGS. 16A and 16B, contoured tabs 60″ of the post-beam cap 24 define a hexagonal geometry, while corresponding internal slots 62″ of the post 22 also define a hexagonal geometry. As set forth above, the contoured tabs 60″ are generally configured to engage internal slots 62″ of the post 22. In this form, the contoured tabs 60″ and the corresponding internal slots 62″ resemble a honeycomb pattern. and any number of contoured tabs 60″ and internal slots 62″ may be employed while remaining within the scope of the present disclosure. As shown, partial contoured tabs 61 and corresponding partial internal slots 63 are formed in this variation of the present disclosure, which are a function of the respective geometries of the post 22, post-beam cap 24, contoured tabs 60″, and internal slots 62″. Similar to the form with square contoured tabs and internal slots as illustrated and described above, any number of hexagonal contoured tabs 60″ and hexagonal internal slots 62″, which may not necessarily be the same number for each of the post-beam cap 24 and post 22, may be employed while remaining within the scope of the present disclosure. Further, some of the internal slots 67 may not receive any contoured tabs 60″. It should also be understood that other features of the post-beam caps 64/70 and the bases 90/110 illustrated and described above may be employed with these variations of contoured tabs and internal slots while remaining within the scope of the present disclosure.
While various geometries have been illustrated and described relative to the internal slots of the post 22 and the corresponding contoured tabs of the post-beam caps 24/70 and bases 90/110, it should be understood that geometries other than those shown and described may be implemented while remaining within the scope of the present disclosure. For example, geometries such as round, triangular, or any other arcuate or polygonal shapes may be implemented while remaining within the scope of the present disclosure.
Each of the post-beam caps, bases, sleeves, support brackets, and post caps (i.e., “parts”) as illustrated and described herein may be formed from any of a number of materials and with a number of different fabrication processes. For example, injection molding is one process used for one or more of the parts, although other processes such as extrusion, pultrusion, blow molding, stamping, or additive manufacturing, among others, may be employed while remaining within the scope of the present disclosure. In one form, the material used for one or more of the parts is a thermoplastic polymer such as nylon 12, which may be neat or fiber-reinforced (e.g., glass). In another form, one or more of the parts may be a metal material such as aluminum or steel. Further any of the interfaces between the components may be sealed with caulk or a discrete sealing member (e.g., gasket) to inhibit intrusion of moisture, insects, or other undesirable substances.
Further it should be understood that one or a variety of the components of the assembly 20 as illustrated and described herein may be implemented in any combination while remaining within the scope of the present disclosure. For example, both forms of the post-beam caps 24/70 may be employed in the same assembly 20 (FIG. 6), with or without support brackets 140, and with different forms of bases 90/110. These and other variations should be construed as falling within the scope of the present disclosure.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
Patent Application
20250122718
