Post Anchor

This application is a continuation of U.S. patent application Ser. No. 18/413,827 filed Jan. 16, 2024, now allowed, which is a continuation of U.S. patent application Ser. No. 17/401,499, filed Aug. 13, 2021, now U.S. Pat. No. 11,891,826, which issued on Feb. 6, 2024, which, in turn, claims the benefit of U.S. Provisional Patent Application No. 63/069,249, filed on Aug. 24, 2020, all of which are incorporated herein by reference in their entireties.

Fencing or railings are usually constructed from posts and rails attached together using fasteners such as nails or screws. Typically, a number of spaced apart posts are coupled to a surface like a concrete floor or wooden deck. The posts typically extend vertically from the surface and have rails that extend between the posts. The rails are often generally parallel to at least part of the surface to which the posts are mounted. Optionally, pickets can then be nailed, screwed, or welded to the rails such that the pickets are generally perpendicular to top and bottom rails.

A post anchor can be utilized to secure a post to a surface. A fence or railing installation is often dependent on the structural integrity of the post attachment. Aspects of the present disclosure relate to a post anchor that receives a post and attaches to a surface in such a manner that the installation passes the International Building Code (IBC) or the International Residential Code (IRC) per structural and deflection requirements. Such surfaces can be, but are not limited to, concrete flooring, wood decking, composite decking, stone flooring, porcelain tiles or any other kind of indoor and outdoor flooring, decking, patio, platform, or slab.

All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, secured, fastened, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

While “a set of” or “a plurality of” various elements will be described, it will be understood that “a set” or “a plurality” can include any number of the respective elements, including only one element.

As used herein, the term “generally perpendicular” defines an angle between two objects, elements of objects, or linear extensions of elements or objects that defines an angle approximately between 80 degrees and 100 degrees between the respective two objects. Similarly, the term “generally parallel” describes two objects, elements of objects, or linear extensions of the elements or objects forming an angle between the respective objects, elements of objects, or linear extensions of the elements or objects, with the defined angle having a measure that is at or between 0 and 15 degrees between the respective objects.

illustrates a perspective view of a bracket or post anchor. It will be understood that the post anchorcan be formed in any suitable fashion. The post anchorcan be a unitary monolithic component. That is, the post anchorcan be, for example, formed by injection molding, cast, or additively manufactured. The term “additively manufactured” can include, but is not limited to, powder bed fusion, binder jetting, directed energy deposition, material extrusion, material jetting, sheet lamination, or vat polymerization.

The post anchorcan be created with multiple material types such as, but not limited to, cast metals or injection molded plastic. Optionally, fiberglass or other additives can be combined with the plastic. The mixture of plastic to fiberglass or other additives can be of any combination as needed to pass building code requirements such as but limiting to IBC or IRC. For example, the mixture can include one or more polyamides and fiberglass. The polyamides can be PAnylon or PAnylon plastic. It is contemplated that the loading of glass fiber in the material used to form the post anchorcan be between 0%-70%. For example, if the loading of glass fiber is 30%, then the post anchorcomprises 30% glass fibers and 70% other material. By way of further example, the 70% of other material can include 65% PAnylon and 5% other additives. The combination of fiberglass reinforced plastic is advantageous because it can increase flexural strength (also known as modulus of rupture or MOR) and flexural modulus (also known as modulus of elasticity or MOE) within the post anchor. The combination of plastic and fiberglass also can withstand elevated temperatures and extended ultra-violet (UV) exposure. It is contemplated that the ratio of plastic to fiberglass and the percent of fiber loading can vary based on the desired length of the post to be mounted to the post anchor. It is further contemplated that the post anchorcan include longer glass fibers, carbon fiber, or other fillers as needed to strengthen the post anchor. The mixture of the post anchorcan depend on the surface to which it is mounted, the application or length of the post mounted to the post anchor, or to meet building code requirements in different regions.

The post anchorcan include a base or base plateand a collar, extending from the base plate. The base plateincludes a lower surfaceand an upper surface. A side surfaceconnects the between the lower surfaceand the upper surfaceto define the base plate.

A base thicknesscan be measured from the upper surfaceto the lower surface. The base thicknessof the base platecan be of any thickness, which is needed to pass building code requirements such as IBC or IRC. While any thickness required to meet building code is contemplated, the base thicknesscan be approximately ⅝ of an inch (approximately 16 millimeters).

As illustrated, by way of non-limiting example, the side surfaceincludes a rounded or contoured portionand a linear or flat portion. However, it is contemplated that the side surfacecan include any number of linear or flat portions or rounded or contoured portions. While any radius of curvature is contemplated, the contoured portionof the side surfacecan have a radius of curvature less than or equal to half of the base thickness. It is further contemplated that the contoured portioncan be a convex curve, concave curve, or any combination therein.

Base mounting holes or a set of base plate aperturescan extend between the upper surfaceand the lower surfaceof the base plate. While illustrated as having four base plate apertures, any number of base apertures are contemplated. The base plate aperturescan be of uniform cross section or diameter as the base plate aperturesextend from the upper surfaceto the lower surface. However, it is contemplated that the cross section or diameter can increase, decrease, or change shape as the base plate aperturesextend from the upper surfaceto the lower surface. It is further contemplated that the base plate aperturescan be threaded or otherwise formed to receive or secure one or more portions of a fastener such as, but not limited to, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor.

A set of sidesof the collarcan extend generally perpendicular to the base plate, however other angles are contemplated. The collarand the base platecan be unitarily formed to define the post anchor. Alternatively, the collarcan be welded or otherwise fastened to the base plate.

While illustrated as four identical or equal sides, any number of sidesor variation in dimensions of the sidesof the collarare contemplated. Each of the sidesinclude an interior surfaceand an exterior surface. A top surfaceconnects each interior surfaceto the corresponding exterior surface.

As illustrated, by way of non-limiting example, the top surfaceincludes an inner shoulder, an outer shoulderand a linear or flat portion. However, it is contemplated that the top surfacecan include any number of linear or flat portions or rounded or contoured shoulder portions. It is further contemplated that the contoured shoulder portions can be a convex curve, a concave curve, linear or flat, or any combination therein.

Each of the set of sidesabut another of the set of sidesat corners. That is, the intersection or abutting of the sidescan define the corners. The sidescan include top protrusionsextending away from the base plate. The sidescan abut such that the top protrusionsof each of the sidesalso abut. The top protrusionsof the sidesincreases height of the sidesat the corners. That is, the top protrusionsincrease the distance the sidesextend away from the base plateat and near the corners.

A benefit of the inclusion of the top protrusionsis to make the sidesat the cornershigher or taller, relative to a direction moving away from the base plate. The increase in height adds structural integrity to strengthen the corners.

Side holes or a set of side wall aperturescan extend between the exterior surfaceand the interior surfaceof at least one of the sidesof the collar. While illustrated as having a set of three side wall aperturesin one the sides, four side wall aperturesare contemplated. It is further contemplated that any number of side wall aperturescan be located at one or more of the sides. While illustrated as being aligned, the set of side wall aperturescan be located in any portion of one or more sides. That is, the set of side wall aperturesdo not have to be equally spaced from the base plate.

A filletcan be located at the intersection of the upper surfaceof the base plateand the exterior surfaceof the sidesof the collar. The radius or radius of curvature between the exterior surfaceof the collarand the upper surfaceof the base plateacts as structural gusset. Stress concentration is a problem of load-bearing mechanical parts, which can be reduced by the inclusion of the filleton points and lines of expected high stress including at the juncture of the sidesof the collarand the base plate. The filletsdistribute stress over a broader area and effectively make the post anchormore durable and capable of bearing larger loads.

The filletscan minimize potential for stress risers or concentrated tensions at sharp corners dependent on the size of the fillets. While any radius of curvature is contemplated, the filletcan have a radius of curvature less than or equal to half of the base thickness. Additionally, if the post anchoris created with injected molding, the filletscan allow for casier flow of the casting material during the molding process to reduce molded-in stresses.

An interior cavity or receivercapable of receiving a post(see) can be defined by the interior surfacesof the sidesand at least a portion of the upper surfaceof the base plate. Ribscan extend away from the at least a portion of the upper surfaceinto the receiverfrom the sides.

A drain or an openingcan be located at the center of the receiverthat extends from the lower surfaceto the upper surfaceof the base plate. The opening, while illustrated as circular, can be any shape such as, but not limited to, oval, rectangular, diamond, or hexagon. It is further contemplated that the openingcan have a cross section of any regular or irregular polygon and can include or be combined with curved shapes. While illustrated as a single opening, any number of drains or openings in the upper surfaceof the base plateare contemplated.

A funnelcan be defined by a portion of the upper surfaceof the base platethat circumscribes the opening. The funnelcan have a decreasing thickness between the upper surfaceand the lower surface, as measured from a radially outer edgeof the funnelto or toward the opening. The decreasing thickness defines a slope allowing fluid that enters the receiverto be drained out of the receivervia the opening. By way of non-limiting example, the decrease in thickness from the radially outer edgeof the funnelto the openingcan be 10% or less of the base thickness. It is contemplated that the ribbingor the at least a portion of the upper surfaceof the base platecan also change thicknesses at any point in the receiver.

A set of corner memberscan be located at each of the corners. The corner membersextend from the upper surfaceof the base plateand are formed with or coupled to the exterior surfaceof the sidesat each of the corners. That is, the corner membersprovide additional material that surround the outside of each of the cornersto provide structural support at each of the corners.

Each of the corner memberscan include, by way of non-limiting example, a set of flared protrusions,. While illustrated as two flared protrusions,, the set of flared protrusions,can include any number of flared protrusions. Each flared protrusion,of the set of flared protrusions,can have a horizonal cross section that has the shape of a truncated trapezoidal prism with rounded edges.

The set of flared protrusions,can extend away from the base platea distance that is shorter than the distance extended by the portions of the sideshaving the top protrusion.

The set of flared protrusions,can add additional strengthening support to the cornersbecause the set of flared protrusions,add to the overall thickness of each corner.

At least one flat facecan partially define the corner members. The flat facecan extend from the base plateadjacent the intersection of the sidesat each of the corners. As illustrated by way of non-limiting example, the flat facecan be located between two members of the set flared protrusions,. The flat facecan have a similar height as the set of flared protrusions,. Optionally, the flat facecan define one or more portions of the set of flared protrusions,. That is, it will be understood that the flat faceneed not be a separate feature from the set of flared protrusions,and that instead the flat facecan be formed from two adjoining flared protrusions,abutting one another at the corner.

A set of corner member aperturescan creating a passage or opening that extends from a corner exterioror the flat faceto the interior surfaceof the sides. That is, each of the set of corner membersincludes at least one corner member aperturethat extend from the corner exteriorto the interior surface. As illustrated, by way of non-limiting example, the corner member aperturescan have a corner inletlocated at the corner exterioror the flat faceof the corner memberand a corner outletlocated at the interior surfaceof one or more of the corners. While illustrated as each corner memberhaving one of the corner member apertures, the corner memberscan include any number of corner apertures. The corner member aperturescan be of uniform cross section or diameter as the corner member aperturesextends from the corner exterioror the flat faceto the interior surface. Alternatively, it is contemplated that the cross section or diameter can increase, decrease, or change shape as the corner member apertureextends from the corner exterioror the flat faceto the interior surface. It is further contemplated that the corner member aperturecan be an angled passage. That is, the corner inletand the corner outletare not aligned as compared to the lower surfaceof the base plate. The corner member aperturecan be threaded or otherwise formed to receive or secure one or more portions of a fastener or one or more fasteners such as, but not limited to, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor.

Corner filletscan be located at the intersection of the upper surfaceof the base plateand the corner memberor corner exterior. The corner filletsprovide structural support and can improve manufacturing. The radius or radius of curvature between the corner exteriorand the upper surfaceof the base plateacts as structural gusset. Stress concentration is a problem of load-bearing mechanical parts, which can be reduced by the inclusion of the corner filletson points and lines of expected high stress including at the juncture of the corner membersof the collarand the base plate. The corner filletsdistribute stress over a broader area and effectively make the post anchormore durable and capable of bearing larger loads.

The corner filletscan minimize potential for stress risers or concentrated tensions at sharp corners dependent on the size of the corner fillets. While any radius of curvature is contemplated, the corner filletscan have a radius of curvature greater than or equal to the radius of curvature of the fillets. Alternatively, the radius of curvature of the corner filletscan be less than the radius of curvature of the fillets. Additionally, if the post anchoris created with injected molding, the corner filletscan allow for easier flow of the casting material during the molding process to reduce molded-in stresses.

illustrates the postlocated in the receiverof the post anchor. The cornersand corner memberscan act as a guide for insertion of the postinto the receiver. When mounted in the receiver, the postcan contact one or more of the ribs. The ribscan prevent the postfrom resting on the upper surfaceof the base plateas well as stiffen the base plate.

The postcan be made up of multiple materials and sizes that meet or exceed code regulations set forth in IBC or IRC. For example, the postcan be a treated 4×4 wooden post made of #2 Southern Yellow pine or better, having a width and a length of 3.5 inches (approximately 89 millimeters) and a height of 36 inches (approximately 915 millimeters). In another example, the postcan be a 4×4 wood post comprising of western red cedar, having a width and a length of 3.5 inches (approximately 89 millimeters) and height that is 42 inches (approximately 1067 millimeters). Further still in another non-limiting example the postcan be a 4×4 wooden post comprising of pressure-treated cedar tone, having a width and a length of 3.5 inches (approximately 89 millimeters) and a height of 48 inches (approximately 1219 millimeters).

A side thicknesscan be measured from the interior surfaceto the corresponding exterior surfaceof the sides. The side thicknesscan be of any thickness, which is needed to pass building code requirements such as IBC or IRC. While any thickness that meets building codes is considered, the sidescan have an approximate thickness of ⅝ of an inch (approximately 16 millimeters). While illustrated as having the same side thickness, it is contemplated that thickness of the sidescan vary from one sideto another or from one portion of the sidesto another. The inner shoulderor the outer shoulderof the top surfacecan have a radius of curvature less than or equal to half of the side thickness.

A first set of fastenerscouple the post anchorto the post. The first set of fastenerscan be, by way of non-limiting example, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor. By way of further non-liming example, the first set of fastenerscan be screws, such as exterior construction screws. A first non-limiting example of a screw can include, a #14×3.5 inches screw. Another non-limiting example of a screw can include an approximately 6.3 millimeter thread diameter, approximately 89 millimeters in length, screw. Yet another non-limiting example of a screw can include a 4 inch (approximately 102 millimeter) screw. Yet another non-limiting example of a screw can include any structural wood screws of predetermined strength and durability.

The set of side wall aperturescan be threaded or otherwise formed to receive or secure one or more portions of the first set of fasteners. The side wall aperturescan be of uniform cross section or diameter as the side wall aperturesextend from the exterior surfaceto the interior surface. It is contemplated that the cross section or diameter can increase, decrease, or change shape as the side wall aperturesextend from the exterior surfaceto the interior surface. It is further contemplated that the side wall aperturescan be angled as they pass through the at least one side of the sides. That is, the passage or through hole defined by the set of side wall aperturescan have an inletat the exterior surfaceand an outletat the interior surfacethat are not aligned. The number of the side wall aperturesprovided in the collarcan depend on the desired length of the postto be seated in the receiverof the post anchor. Additionally, or alternatively, the number of the side wall aperturesprovided in the collarcan depend on the height or location of structures coupled to the post, such as, but no limited to, a railing or guardrail.

The set of side wall aperturesare configured such that the first set of fastenerscan be inserted into the postat an angle(see) to the postthat is less than or equal to ninety degrees. It will be understood that the set of side wall aperturescan be oriented to provide the first set of fastenersat any suitable angle including, but not limited to, a preferred range between and including thirty-five degrees to fifty-five degrees. In the illustrated example, the set of side wall aperturesprovide each of the first set of fastenersat the same angle within the post, wherein, by way of example, that angle is a forty-five-degree angle. The angled entry of the first set of fastenersinto the postincreases the amount of threads engage with wood fibers. Increased engagement with the wood fibers allows the load of the fence or rail supported by the postto be evenly distributed between the postand the post anchor. While illustrated as being mounted at the same angle, each of the set of fastenerscan be fastened to the postat varying angles.

As further illustrated in, the corner memberslocated at the cornersdefined by the abutting of the sidescan include the corner member apertures. A second set of fastenerscan couple the post anchorto the postvia the corner member apertures. The second set of fastenerscan be, by way of non-limiting example, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor. By way of further non-liming example, the second set of fastenerscan be can be #12×2.5 inches exterior construction screws (approximately 5.5 millimeter thread diameter, approximately 63.5 millimeters in length). Alternatively, they can be 2.5 inch (approximately 63.5 millimeter) structural wood screw capable of replacing a ⅜ inch (approximately 9.5 millimeters) lag screw.

When the postis mounted to the post anchor, a portion of the second set of fastenerspasses through the corner member aperturesto fasten the collaror corner memberto the post. The second set of fastenersare positioned or angled with respect to the postsuch that the second set of fastenersdo not contact the first set of fasteners. By way of non-limiting example, the second set of fastenersare illustrated as being inserted generally perpendicular to the post. By way of further non-limiting example, the second set of fastenersare mounted generally perpendicular to the flat faceof the corner member.

A benefit of the inclusion of the top protrusionis to make the sidesat the cornershigher. The increase in height adds structural integrity to strengthen the corners. Further, the increase in height at the corner allows the second set of fastenersto be located farther away from the base plate, which deters splitting of the post.

Gapscan be defined as a region bound by one or more portions of the ribs, the post, one or more portions of the interior surfaces, and a portion of the upper surfaceof the base plate. That is, fluid that enters the receivercan be directed to the openingvia at least the gaps. The gapscan have a downward directed sloped shape at the upper surface. That is, the post anchorcan have a drainage system that includes one or more of the gaps, the ribs, the funnel, or the opening. Pulling fluid away from the postcan help maintain and extend the structural integrity of the post.

During installation, the postcan be inserted into the receiverof the post anchor. The postrests on ribs, adjacent to the upper surfaceof the base plate. In some instances, one or more shims (not shown) can be inserted between the interior surfaceof the sidesand the post. Once the desired angle of the postin the post anchoris obtained, the postis fastened to the post anchor. The second set of fastenersare inserted to the corner member apertures. By way of non-limiting example, the second set of fastenerscan be driven into the post. Optionally, the second set of fastenerscan be driven into pre-drilled holes in the post. The second set of fastenerscan be generally perpendicular to the postor corner member, or generally parallel to the lower surfaceof the base plate.

Next, the first set of fastenersare inserted into the side wall apertures. By way of non-limiting example, the first set of fastenerscan be driven into the post. Optionally, the first set of fastenerscan be driven into pre-drilled holes in the post. The side wall aperturescan align the first set of fastenersat a predetermined mounting angle(see) relative to the post.

is a cross-sectional view of the post anchorwithin a post mounting system or a railing system, wherein the post anchorsecures the postto a surface. The surface can be, by way of non-limiting example, concrete flooring, wood decking, composite decking, stone flooring, porcelain tiles or any other kind of indoor and outdoor flooring, decking, patio, platform, or slab.

further illustrates the angleat which the first set of fastenersare positioned relative to the post. The side wall apertures, through which at least a portion of the first set of fastenerspass, can align the first set of fastenersat the desired anglerelative to the post. The anglecan be measured as the acute angle between an outside wall of the postand at least one of the first set of fasteners.

A third set of fastenerscouples the post anchorto the surface. The third set of fastenerscan be, by way of non-limiting example, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor. By way of further non-limiting example, the third set of fastenerscan be 5/16×4 inches (approximately 8 millimeters by 102 millimeters) lag screws or through-bolts. The third set of fastenersare inserted into the base plate aperturesand extend into or through the surface. The length of the third set of fastenerscan be determined based on the surfaceand structural requirements. For example, if the surfaceis wood decking, as illustrated by way of non-limiting example, the third set of fastenersare selected to extend into 3 inches (approximately 76 millimeters) of solid wood. Therefore, the post anchorcan be positioned on the surfaceover at least one joist, so that at least a subset of the third set of fastenerssecure the post anchorto the surfaceand the joistwhile extending into at least 3 inches (approximately 76 millimeters) of solid wood.

Wood blockingcan be added below the surfacebetween two or more joists, such that another subset of the third set of fastenerssecure the post anchorto the surfaceand the wood blockingwhile extending into at least 3 inches (approximately 76 millimeters) of solid wood.

illustrates a perspective view of a fencing system, wherein the railing systemfurther including bracketsand railing. The bracketsare illustrated as being positioned between a pair of top protrusionsand mechanically coupled to the railingvia a fourth set of fasteners. The fourth set of fastenerscan be, by way of non-limiting example, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor. By way of further non-limiting example, the fourth set of fastenerscan be #8×1 inch (approximately 4.1 millimeters thread diameter, approximately 25.4 millimeters in length) which are used to couple the bracketto the rail.

A fifth set of fastenerscouples the bracketto the post. The fifth set of fastenerscan be, by way of non-limiting example, a screw, bolt, washer, gasket, grommet, nut, nail, rivet, or anchor. By way of further non-limiting example, the fifth set of fastenerscan be #8×2 inches (approximately 4.1 millimeters thread diameter, approximately 51 millimeters in length).

A recessed portioncan be located between the top protrusions. That is, portions of the sidesthat do not include the top protrusionscan define the recessed portion. The bracketsand railingare configured to fit together and be received by the recessed portionbetween at least two of the top protrusions. When located between the at least two of the top protrusions, the railingis positioned in relationship to the postand post anchor. The positioning provided by the bracketsseated in the recessed portionallows for the railingto be properly located with little to no measurements.