In the construction of buildings, outdoor structures, or the like, it is often desirable to utilize a beam or column which includes a plurality of boards rather than an integral post made from a single piece of building material such as wood. Many embodiments of composite assemblies use one or more connectors to connect the plurality of component boards into the composite assembly. The composite assembly made from a plurality of board can serve as a less expensive substitute for integral posts made from a single piece of wood. Additionally, due to the laminated structure of the composite assembly, such columns can often be stronger than a similarly dimensioned column constructed from a single piece of material.
It is also known to provide a composite assembly that includes a series of elongated layers which are secured together in a lengthwise fashion but are also secured to an elongated ground-engaging member. In such composite assembly, particularly a column, the upper elongated members are normally constructed of a non-treated wood, while the lower elongated member is typically constructed of a decay inhibitive or resistive material. Previously this had been provided by chemically treated wood, for example wood infused with a chemical compound for example, chromated copper arsenate (CCA) to prevent the natural process of decay of the ground-engaging wood. Restrictions on the use of this and other potentially hazardous chemicals have prompted the development and use of other solutions for providing the ground-engaging portion of composite construction columns. Recently, the applicant has developed a composite assembly for a support column that uses a ground-engaging portion that is constructed of a plastic or plastic containing material. The support columns are described in further detail, for example in U.S. Pat. No. 9,719,257, previously published as Application Publication No. 2017/0073972 and entitled Friction Fit Composite Column, which is incorporated herein by reference in its entirety.
An exemplary embodiment of a building support column includes a lower assembly and an upper assembly. The lower assembly includes a connection bracket with a bottom plate and first and second connection blades extending away from the bottom plate in a first direction. A hole through the bottom plate is in a position between the first and second connection blades. A plurality of support rods are secured to the connection bracket and extend away from the bottom plate in a direction opposite the connection blades. A body includes plastic and defines an exterior perimeter about the plurality of support rods. A center hole is oriented along a central axis of the body and is aligned with the hole of the bottom plate. The upper assembly includes a plurality of elongated layers of wood. The plurality of elongated layers of wood are secured to each other along elongated faces of the layers of wood. The connection bracket secures the upper assembly to the lower assembly with a connection blade extending between the elongated faces of adjacent elongated layers of the upper assembly. A reinforcement plate includes a plate and a plurality of teeth extend away from a first side of the plate. The teeth of the reinforcement plate engage into a single elongated layer of the plurality of elongated layers.
In additional exemplary embodiments, the connection bracket also includes first and second lips that extend from opposite edges of the bottom plate and are oriented perpendicular to the first and second connection blades. Drainage holes are formed into respective corners between the bottom plate and the first and second lips and are located between the first and second connection blades. The lower ends of the plurality of elongated layers of wood may be notched to accommodate the first and second lips so as to provide a consistent exterior perimeter between the upper assembly and the lower assembly.
In further exemplary embodiments, the reinforcement plate is a first reinforcement plate and is secured into a first elongated face of a center elongated layer of the plurality of elongated layers of wood. A second reinforcement plate includes teeth that engage into a second elongated face of the center elongated layer. Notches may be positioned along interior elongated faces of exterior elongated layers of the plurality of elongated layers. The notches are dimensioned to accommodate the connection blades. The first reinforcement plate is positioned between the first connection blade and the center elongated layer. The first reinforcement plate extends along the first connection blade and beyond an upper end of the first connection blade. The second reinforcement plate is positioned between the second connection blade and the center elongated layer and the second reinforcement plate extends along the second connection blade and beyond an upper end of the second connection blade. Exemplary third and fourth reinforcement plates are secured to respective exterior faces of the exterior elongated layers.
The composite assembly 100 further includes a lower assembly 104. The lower assembly 104 is designed for ground contact and is exemplarily constructed of a combination of metal and plastic materials as described in further detail herein. In exemplary embodiments, the lower assembly 104 is constructed of materials that are suitable for ground contact without risk or susceptibility to rot or decay and which do not include CCA or similar chemicals.
The lower assembly 104 includes a body 106 that is exemplarily constructed of a plastic material. Examples of such a plastic material include, but are not limited to high molecular weight polypropylene (HMWPE), polypropylene (PP), low density polyethylene (LDPE). In further exemplary embodiments, the body 106 is constructed of a combination of materials, including, but not limited to an exemplary construction with at least 66% polypropylene (PP) and at least 9% low density polyethylene (LDPE). In still further exemplary embodiments, about 15% fiberglass shorts and/or about 1% color may be added to the mixture. In still further exemplary embodiments some or all of the body 106 may be constructed of recycled plastic. In other embodiments, the body 106 may further include other filler or binder materials in addition to the plastic. These may include plant and/or wood fibers.
The connection bracket 110 is exemplarily includes a bottom plate 114. One or more, and exemplarily two, connection blades 116 extend from the bottom plate 114. It will be recognized that the exemplary embodiment depicted is configured to connect to an upper assembly comprised of three plys, or elongated layers, of wood. These may exemplarily be 2×6 wooden boards. The two connection blades 116 are exemplarily configured to extend between adjacent layers as depicted. Other embodiments may include other numbers of elongated layers in the upper assembly and have a corresponding increase in the number of connection blades. The wooden boards of the upper assembly 102 (
In embodiments as depicted in
The center hole 130 exemplarily extends along the entire length of the body 106. In an embodiment, the center hole 130 is cast or molded into the lower assembly 104 while in another embodiment, the center hole 130 may be machined into the body 106 of the lower assembly 104 as a separate manufacturing step. The center hole 130 is exemplarily aligned with a hole 132 located in the bottom plate 114.
In an exemplary embodiment, the exterior of the adjustment leg 126 may further include ribbing and/or surface texture which facilitates the friction fit between the adjustment leg 126 and the material of the body 106 as the adjustment leg 126 is located in the center hole 130. Additionally, a plastic, malleable, deformable, or otherwise resilient property of the material of the body 106 further increases the friction between the body 106 and the adjustment leg 126 to hold the adjustment leg 126 and the foot 128 in a position relative to the connection bracket 110.
In an exemplary embodiment, the friction fit between the body 106 and adjustment leg 126 is exemplarily strong enough to support the weight of the entire lower assembly 104 such that the adjustment leg 126 can be moved to a desired position between the bottom plate 114 and the foot 128. In an exemplary and non-limiting embodiment, the body 106 may be 48 inches long and the adjustment leg, may exemplarily be 24 inches long. Therefore, an exemplary and non-limiting embodiment, may be adjustable for example between 54 inches and 66 inches while other embodiments may be dimensioned to be adjusted along other ranges.
When the lower assembly 104 is positioned within the hole H, the foot 128 engages the ground at the bottom of the hole and the bottom plate 114 of the connection bracket 110 is located at the predetermined position above the foot 128 established by the friction fit between the adjustment leg 126 and the body 106. The friction fit between the adjustment leg 126 and the body 106 is further strong enough to support the lower assembly 104, and in particular to support the combined weight of the connection bracket 110, the skeleton 108, and the body 106 from moving downward into the hole H while the footing F is poured, set, and cured or partially cured about at least a portion of the lower assembly 104, and in particular the foot 128. The support rods 112 extend exterior of the bottom of the body 106 at an end opposite the connection bracket 110. The support rods 112 end in end projections 134 which are oriented in a direction non-axial to the rest of the support rod 112. In embodiments the end projections 134 are oriented in a direction towards perpendicular from the rest of the support rod 112. In an exemplary embodiment, the footing F extends upwards to cover at least a portion of the end projections 134. In another exemplary embodiment, the footing F extends upwards to cover at least a portion of the body 106.
While the friction fit between the adjustment leg 126 and the body 106 resiliently hold the adjustment leg 126 in a predetermined position, installation personnel may use the hole 132 through the bottom plate 114 to access the adjustment leg 126, for example with a rod (not depicted) to apply a force to the end of the adjustment leg 126 that is internal to the body 106 to increase the distance between the foot 128 and the connection bracket 110. The installation personnel may decrease the distance between the foot 128 and the connection bracket 110 by applying a force against the foot 128 to move the foot 128 closer to the connection bracket 110.
The boards 118, and particularly exterior elongated layers formed by the outer boards 118A include face notches 152 placed into respective interior faces of the board 118A. In an exemplary embodiment, the face notches 152 accommodate the connection blades constructing the connection bracket 110. These series of notches help to accommodate the connection bracket 110 and facilitate a secure connection of the upper assembly 102 to the lower assembly 104 at the connection bracket 110 in a manner that facilitates a secure construction of the upper assembly without forcing the plies of the upper assembly apart which can reduce the strength or effectiveness of the upper assembly.
An embodiment of a reinforcement plate is depicted at
Contrary to other uses, the arrangement described herein is secured only to one board and the tooth pairs do not extend into two or more boards. Despite the tooth pairs only extending into one board, this has been found to improve overall structural integrity of the upper assembly by distributing the moment force about the connection bracket 110 and particularly about the ends of the connection blades 116 of the connection bracket 110 against the center board 118B. Additionally, the reinforcement plates 154 are arranged in this manner on the center board 118B help to maintain the integrity of the wood of the center board 118B against the torque and the rotative forces about the connection bracket 110. Incorporation of the reinforcement plates 154 has been found to reduce failure and increase overall strength of the upper assembly. While in embodiments, the additional width added to the center board 118B may be negligible or may be the thickness of the plates 156 of the reinforcement of the plates 156 of the reinforcement plates 154, in embodiments, the connection blades 116 maybe spaced with additional width therebetween the combined center board 118B and reinforcement plates 154.
In exemplary embodiments, the reinforcement plate 154 may extend to position above the terminus of the connection blade 116. In one exemplary embodiment this may be three inches above the terminus of the connection blades while in another embodiment this may be twelve inches above the connection blade although it will be recognized that a wide variety of distances above the connection blade may be used for the terminus of the reinforcement plate 154.
Further as depicted in
As further shown in
In an embodiment, the body 106 further includes a grade indicia 168 which may exemplarily be molded or machined into the body 106. The grade indicia 168 may exemplarily be a hole that is configured to receive a nail within the hole to mark the grade relative to the composite assembly. In an exemplary embodiment, the grade indicia 168 is located at position twelve inches below the bottom plate 114 of the connection bracket 110. In use, the installation personnel may secure a nail within the grade indicia 168 and the sill plate (not depicted) may be supported by the nails placed in the created indicia across a plurality of composite assemblies to hold it in position prior to being secured to each of the composite assemblies.
Additionally, in
In an exemplary embodiment, the outer boards 118A are provided with pilot holes 162 which are in alignment with respective holes 164 in the connection blades 116 (see
The foot 128 may exemplarily include apertures (not depicted) that are configured to receive the fastener(s) therethrough. In an example, the apertures may be holes, slots, or cut outs extending into the foot 128 from an edge thereof. These apertures provide a manner by which the fasteners 174 can be inserted through the foot 128 into the ground, to retain the foot 128 in position while a footing is established around the foot 128. In an embodiment, a fastener 174 with a head 184 may engage the foot 128 with the head 184 to retain an engagement between the foot 128 and the fastener 174. In a further embodiment, the fastener 174, when positioned relative to the foot 128, extends beyond the plate of the foot 128 in both directions, both into the ground, but also above the foot 128. In an embodiment, the footing is formed about the foot 128, the adjustment rod 126 and one or more of the fasteners 174.
The foot 128 is exemplarily curved as previously described, although as depicted in
As previously described, the adjustment leg 126 may include ribs, ridges, scoring, or other texture to facilitate a friction fit between the adjustment leg 126 and the material of the body 106. In a further embodiment, the adjustment leg 126 includes a threaded portion 194. In one embodiment, the threaded portion 194 provides the engagement features of the adjustment leg 126 which increase friction between the adjustment leg and the material of the body 106 as the adjustment leg 126 is moved within the center hole 130. This may occur in the same manner as previously described by increasing an interference fit between the adjustment leg 126 and the material of the body 106 within which the center hole 130 is defined.
In another embodiment, the adjustment leg 126 is provided with a connection feature 196. The connection feature 196 may either be a male or female end of a socket connection and may be any of a variety of known cross sectional shapes, including, but not limited to, square, hexagon, or star shapes. In such an exemplary embodiment, the adjustment rod (not depicted) inserted through the hole 132 in the connection bracket 110 and into the center hole 130 of the body 106 is fitted with the mating portion of the connection feature 196 and maybe rotated either manually or with a tool for example a drill or air compression tool to threadingly extend or retract the adjustment leg 126 within the center hole 130. Due to the resilient nature of the material of the body 106, the threaded portion 194 of the adjustment leg 126 may embed into the material of the body 126 due to the interference fit and dimensioning of the center hole.
In a further embodiment, the center hole 130 may be molded with receiving threads 198, at least along a portion of the center hole 130 that is likely or potentially to engage with the adjustment rod 126. The receiving threads 198 may be molded into the body 106 during the construction of the body 106 or may be drilled into the body 106 in a separate manufacturing process. In an embodiment, preproviding the receiving threads 198 into the center hole 130 can help to facilitate the extension and retraction of the adjustment leg 126 into and out of the center hole 130 of the body 106. In an exemplary embodiment, the interference between the center hole 130 and the adjustment leg 126 may be increased with the provision of the receiving threads 198 to provide an increased interference while the receiving threads 198 ease the extension and retraction of the adjustment leg 126 with the center hole 130.
In a still further exemplary embodiment, the receiving threads 198 may be provided in the center hole 130 while the adjustment leg 126 is provided with a smooth surface or a surface with an engagement feature other than the threaded portion 194 as described above. In such an embodiment, the interference fit between the adjustment leg 126 and the center hole 130 can be provided with a greater interface by reducing the diameter of the center hole 130 while the movement of the adjustment leg 126 within the center hole is facilitated by the reduced material in the interference between the adjustment leg 126 and the center hole due to the threads. The size and depth of the threads may further be adjusted or selected relative to the dimensions and or engagement features of the adjustment leg 126 to provide a desired tightness of the interference fit.
The connection bracket 110 includes a bottom plate 114. Two connection blades 116 extend upwards from the peripheral edges of the bottom plate 114. The connection blades 116 are configured to be secured against exterior faces of an upper assembly (not depicted). Support rods 112 are secured, for example by welding, to the bottom of the bottom plate 114. A center tube 200 extends from the bottom of the bottom plate 114, between the support rods 112. The center tube 200 is exemplarily constructed of metal and defines an axial hole down the middle of the tube 200. The tube 200 is in alignment with a hole (not depicted) in the center of the bottom plate 114. In exemplary embodiments, the center tube 200 extends along the center hole 130. The body 106 surrounds the center tube 200 and the support rods 112.
The lower assembly 104 includes two embodiments of support extensions 202A and 202B. The support extensions 202A and 202B radially extend away from the center tube 200 in the direction of the outer faces of the body 106 of the lower assembly 104. Each support extension 202A and 202B exemplarily includes four arms 204, one extending in a direction orthogonal to each of the faces of the body 106. Support extension 202A includes a support ring 206, which is exemplarily in the shape of a circle and secured around the center tube 200. The arms 204 extend from the support ring 206. Support extension 202B further includes a mounting nut 208. The support ring 206 is exemplarily in the shape of a hexagon or other matching shape to the exterior of the mounting nut 208. The mounting nut 208 is secured to the center tube 200, and the support extension 202A or 202B secured to the mounting nut 208.
The lower assembly 104 further includes an adjustment leg 126. The adjustment leg 126 is exemplarily the same as described above with respect to
Citations to a number of references are made herein. The cited references are incorporated by reference herein in their entireties. In the event that there is an inconsistency between a definition of a term in the specification as compared to a definition of the term in a cited reference, the term should be interpreted based on the definition in the specification.
In the above description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different systems and method steps described herein may be used alone or in combination with other systems and methods. It is to be expected that various equivalents, alternatives and modifications are possible within the scope of the appended claims.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
The present utility application relates to and claims priority to U.S. patent application Ser. No. 16/148,610 filed Oct. 1, 2019, which claims priority to U.S. Provisional Patent Application Ser. No. 62/566,847 filed Oct. 2, 2017, which is herein incorporated in entirety.
Number | Date | Country | |
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62566847 | Oct 2017 | US |
Number | Date | Country | |
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Parent | 16148610 | Oct 2018 | US |
Child | 16584459 | US |