Note: Descriptions are shown in the official language in which they were submitted.
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POST COUPLER
This invention relates to post couplers and in particular to couplers for
coupling together the ends of two posts vertically oriented with respect each
other, the lower end of an upper post resting on the upper end of a lower post
in
vertical orientation.
Corner posts used, for example, in shelving are made from any
suitable material, such as steel, and are typically formed of relatively thin
sheet metal with two flanges disposed in an angular configuration, such that
one flange of the post is oriented generally at ninety degrees to the other
flange. These flanges may be either of a single layer of post material or may
comprise two layers bent back on themselves for a somewhat thicker or more
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rigid post, than a post made from single layer flanges of the same material,
for
example.
It is desired to provide posts in certain varied lengths to satisfy varied
needs. A particular application may require a corner post of a height in
excess of a standard length, requiring one post to be set onto another for the
overall length desired. Accordingly, it is desired to provide a way to couple
the ends of two posts together to form a unitary structure with one post
vertically oriented on top of another.
Another objective of the invention has been to provide an improved
simple post coupler easily fitted to respective ends of two posts for coupling
said ends together to form a unitary post.
To these ends, one preferred embodiment of a post coupler according
to the invention comprises a coupler having two flanges disposed generally at
90 degrees to each other, or at approximately the same angle as the flanges
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of the angular formed corner posts with which the coupler will be used. The
flanges of the couple each have turned back a reverse fold edges or return
flanges disposed along one side of the respective flanges, with a gap
=
therebetween.
In use, the coupler is slid over the flanges of one post to be coupled,
preferably to about one-half the coupler length. The other post is slid into
the
coupler so the reverse fold flanges of the coupler capture the edges of the
respective post flanges, coupling the two posts together, end to end. The
coupling thus facilitates assembly of a unitary post, longer in length than
the
two original posts, and highly useful in a wide variety of applications, such
as
in shelving, enclosures and other environments.
Details on the coupler serve to frictionally engage one or both post
ends to secure the coupler in longitudinal position with respect to the
longitudinal extent of one or both posts.
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The coupler may be apertures or holes for receiving fasteners through
the shelf or other handling holes of the posts in order to fasten the couplers
onto the posts and strengthen the coupled joint.
In an alternative embodiment, the post flanges are formed with return
flanges and the couple is preferably of single layer sheet metal material. The
coupler is inserted into the gaps formed by the return flanges of the post
with
its major flanges, and with an end extending therefrom for disposition within
the end of a complimentary post.
Detents for positioning and apertures for optional fasteners can also be
provided in this alternate coupler.
The post couplers provide simple efficient coupling joints at the
complimentary ends of two posts to provide a unitary post of desired length.
=
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According to one aspect of the present invention there is provided a
shelving unit having at least two angularly formed vertically oriented and
aligned posts, each having two post flanges disposed at an angle to each other
with each post flange having a thickness and an elongated edge, an end of one
post proximate an end of another post, and a post coupler for coupling
together ends of the vertically-oriented and aligned posts, wherein the
coupler
comprises a pair of connected coupler flanges, each coupler flange having an
interior surface defining an included angle with respect to the interior
surface of
the other coupler flange, and each coupler flange having an outside surface;
each one of the coupler flanges having a respective additional flange
extending
from and along end positions of the coupler flanges; each the respective
additional flange comprising a reverse bend flange extending alongside the
respective coupler flange from which the respective reverse bend flange is
extended and from proximate but short of one end of a coupler flange of the
pair of connected coupler flanges to proximate but short of another end
thereof, the outside surface of the respective coupler flange facing the
respective reverse bend flange; and a gap defined by and between each the
respective reverse bend flange and the outside surface of the respective
coupler
flange from which the reverse bend flange extends, the gap having a width
approximately equal to the thickness of a single one of the post flanges, and
less than twice the thickness of the single post flange and being sized to
accept
one of the flanges of a single one of the two angularly formed posts therein,
wherein one end of the coupler is configured to receive one of the two
angularly formed posts and the other end of the coupler is configured to
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receive the other one of the angularly formed posts to permit the two posts to
be secured in an abutting, end-to-end vertically oriented relationship with
one
another; the first and second end portions of the coupler flanges engaging
respective flanges of the posts, with the reverse bend flanges of the coupler
extending outwardly around edges of respective flanges of the two posts.
According to a further aspect of the present invention there is
provided a composite post comprising a first angularly formed post member
having at least two flanges disposed at an angle to each other, each flange
having elongated edges; a second angularly formed post member having at
least two flanges disposed at an angle to each other, the second angularly
formed post member being disposed in an abutting, end-to-end vertical
relationship with the first angularly formed post member; a coupler; the
coupler
comprising a pair of connected coupler flanges, each having an interior
surface
defining an included angle with respect to the interior surface of the other
flange, and each having an outside surface; each one of the coupler flanges
having a reverse bend flange extending from an edge portion thereof; each the
reverse bend flange extending alongside the respective flange from which it
extends, the outside surface of the respective flange facing the respective
reverse bend flange; a gap defined by and between the reverse bend flange
and the outside surface of the respective flange from which it extends; the
coupler having first and second ends; a first end of the connected coupler
flanges of the coupler operatively engaging the flanges of the first post
member
with the reverse bend flanges extending outwardly around elongated edges of
the first post member; a second end of the connected coupler flanges of the
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coupler operatively engaging the flanges of the second post member with the
reverse bend flanges extending outwardly around elongated edges of the
second post member; the coupler coupling the first and second post members
in a vertically oriented composite post; each of the post member flanges
comprising a plurality of apertures, the coupler further comprising a
plurality of
apertures, each the aperture of the coupler being aligned with one of the
apertures of the post member flanges for passage of a fastener through the
aperture of the coupler and the respective, aligned one of the apertures of
the
post member flanges.
According to another aspect of the present invention there is
provided in a shelving unit having a vertical post comprising at least two
post
members disposed end-to-end; a post connector for holding the ends together;
the post members having ends defining post flanges with inwardly facing
surfaces at a first angle to each other and outer surfaces and having
elongated
edges; the post connector having two connector flanges disposed at a second
angle to each other such that the connector flanges are parallel to the post
flanges; reverse bend flanges on the post connector wrapped around edges of
the post members and onto the outer surfaces of the post member flanges,
respectively; the post members having a plurality of apertures therealong for
receiving shelf support means; the post connector having a plurality of
apertures therealong, wherein respective ones of the plurality of apertures in
the post connector aligned with respective apertures of the plurality of
apertures in the post members when the post members are in abutting vertical
orientation and respective abutting ends of the post members are each held
together by portions of the post connector.
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According to a still further aspect of the present invention there is
provided in a shelving unit, at least two angularly formed vertically oriented
and aligned posts, each having two post flanges disposed at an angle to each
other with each post flange having a thickness and an elongated edge, an end
of one post proximate an end of another post, and a post coupler for coupling
together the ends of the posts, wherein the coupler comprises a pair of
connected coupler flanges, each coupler flange having an interior surface
defining an included angle with respect to the interior surface of the other
coupler flange, and each coupler flange having an outside surface; each one of
the coupler flanges having a respective additional flange extending from and
along edge portions of the coupler flanges; each the respective additional
flange comprising a reverse bend flange extending alongside the respective
coupler flange from which the respective reverse bend flange is extended and
from proximate but short of one end of the coupler flange to proximate but
short of another end thereof, the outside surface of the respective flange
facing
the respective reverse bend flange; and a gap defined by and between each the
respective reverse bend flange and the outside surface of the respective
coupler
flange from which the reverse bend flange extends, the gap having a width
approximately equal to the thickness of a single post member flange, and being
sized to accept one of the flanges of a single one of the two angularly formed
post members therein, wherein one end of the coupler is configured to receive
one of the two angularly formed posts and the other end of the coupler is
configured to receive the other one of the angularly formed post members to
permit the two post members to be secured in an abutting, end-to-end
vertically oriented relationship with one another.
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According to another aspect of the present invention there is
provided a composite post comprising a first angularly formed post member
having at least two flanges disposed at an angle to each other, each flange
having elongated edges; a second angularly formed post member having at
least two flanges disposed at an angle to each other, the second angularly
formed post member being disposed in an abutting, end-to-end vertical
relationship with the first angularly formed post member; a coupler; the
coupler
comprising a pair of connected coupler flanges, each having an interior
surface
defining an included angle with respect to the interior surface of the other
flange, and each having an outside surface; each one of the coupler flanges
having a reverse bend flange extending from an edge portion thereof; each the
reverse bend flange extending alongside the respective flange from which it
extends, the outside surface of the respective flange facing the respective
reverse bend flange; a gap defined by and between the reverse bend flange
and the outside surface of the respective flange from which it extends; the
coupler having first and second ends; a first end of the connected coupler
flanges of the coupler operatively engaging the flanges of the first post
member
with the reverse bend flanges extending outwardly around the elongated edges
of the first post member; a second end of the connected coupler flanges of the
coupler operatively engaging the flanges of the second post member with the
reverse bend flanges extending outwardly around the elongated edges of the
second post member; the coupler coupling the first and second post members
in a vertically oriented composite post.
According to a further aspect of the present invention there is
provided in a shelving unit, at least two angularly formed vertically oriented
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and aligned end-abutting posts, each having two post flanges disposed at an
angle to each other with each post flange having a first thickness and an
elongated edge, an end of one post proximate an end of another post and a
coupler for coupling together ends of the posts to form a composite post,
wherein the coupler comprises first and second end portions, a pair of
connected coupler flanges, each coupler flange having a respective interior
surface defining an included angle with respect to the interior surface of the
other coupler flange, and each coupler flange having an outside surface and
elongated portions each one of the coupler flanges having a respective
additional flange comprising a reverse bend flange attached thereto along the
edge portion and extending partially along the length of the respective
outside
surface of the respective coupler flange from which the respective reverse
bend
flange is extended and wherein each reverse bend flange extends partially but
short of the height of the coupler from proximate the first end portion of the
coupler to proximate but short of the second end portion thereof, which
provides in the first and second end portions of the coupler a central portion
of
the coupler which is free of the reverse bend flange; wherein the outside
surface of the respective flange facing the respective reverse bend flange;
and a
gap defined by and between each the respective reverse bend flange and a
respective outside surface of the respective coupler flange from which the
reverse bend flange extends, the gap having a width approximately equal to
the first thickness of a single post flange and being sized to accept one of
the
flanges of a single one of the two angularly formed posts therein, wherein one
end portion of the coupler is configured to receive one of the two angularly
formed posts and the other end portion of the coupler is configured to receive
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the other one of the angularly formed posts to permit the two posts to be
secured in an abutting, end-to-end vertically oriented relationship with one
another; and the first and second end portions of the coupler flanges engaging
respective flanges of the posts, with the reverse bend flanges of the coupler
extending outwardly around elongated edges of respective flanges of the two
posts.
According to yet another aspect of the present invention there is
provided a coupler for coupling two post sections together to form a single
composite post of both post sections, each post section comprising a pair of
post flanges intersecting at a bend therebetween and each post flange having
an outer edge, the coupler comprising two coupler flanges intersecting at a
bend therebetween, each such flange having extended end portions
comprising end portions of the coupler proximate the bend between the two
coupler flanges and extending longitudinally from opposite ends of the coupler
beyond other second end portions of the coupler flanges oriented proximate
outer edge portions thereof, the extended end portions defining coupler ends;
a reverse bend flange connected to each coupler flange along the outer edges
thereof and extending therealong to the second end portions of the coupler
flanges, terminating short of the first end portions of the coupler flanges
and
the coupler ends.
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These and other objects and advantages will become even more
readily apparent from the following detailed description and from the
drawings in which:
Fig. 1 is a perspective view of one embodiment of the coupler
invention;
Fig. 2 is an end view taken along lines 2-2 of Fig. 1;
Fig. 3 is a plan view of the developed coupler of Fig. 1;
Fig. 4 is an exploded perspective view illustrating orientation of the
coupler of Fig. 1 with two posts;
Fig. 5 is a perspective view of a unitary post provided by the coupler
of Fig. 1 coupling the two posts of Fig. 4;
Figs. 6, 7 and 8 are views of an alternate coupler according to the
invention analogous to Figs. 1, 2 and 3;
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Fig. 9 is a perspective exploded view of the alternate coupler of Fig. 7
analogous to Fig. 4; and
Fig. 10 is a perspective view of the alternate coupler in use, facilitating
provision of a unitary post provided by the coupler of Figs. 6-8 coupling the
two posts of Fig. 9. =
The present invention contemplates two different embodiments for
coupling such posts together. In a first embodiment (Figs. 1-5), a coupler 10
is provided for a formed post with segments P1 and P2, each segment having
two flanges 20a, 20b and 21a, 21b, respectively, essentially oriented at
ninety
degrees (shown) or some other useful angle with respect to each other. To
this end, a coupler 10 is shown in Fig. 1 in its completed configuration.
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The coupling 10 has two flanges 11, 12, oriented at ninety degrees
(shown) with respect to each other at some other useful angle consistent with
the orientation of the post flange's. Each of the flanges 11, 12 has a reverse
bend flange 13, 14, respectively, reverse folded back parallel along the
respective flanges 11, 12 as shown in the Figs. 1 and 2 and with a gap " G:
therebetween.
As shown in Figure 2, each of flanges 11 and 12 include ends 70 and
72, respectively. Flange 11 includes interior and outside surfaces, 74 and 76,
respectively, and flange 12 includes interior and outside surfaces, 78 and 80,
respectively. Also shown in Figure 2 is the included angle 82, between the
interior surfaces 74, 78 of flanges 11, 12, respectively.
Fig. 4 and Fig. 5 illustrate the use of the coupler 10. In Fig. 4, the
upper end 20 of a lower post P1 is oriented vertically and the coupler 10 is
tapped down onto the upper end 20, approximately half its length, that is the
vertical length of the coupler 10, so one end of the coupler operatively
engages one post. Thereafter, the lower end 21 of an upper post P2 is tapped
into the coupler 10 until the lower end 21 of the upper post rests on the
upper
end 20 of the lower post P1. Another end of the coupler operatively engages
the other post at juncture 22. In this configuration, the flaps or flanges 13,
14
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at the coupler ends, wrap around the ends of the upper and lower post ends
20, 21 and secure the posts P1 and P2 against lateral movement with respect
to each other, forming a unitary post.
One or more holes 15 are optionally provided in coupler 10.
Fasteners (not shown) are extended through these holes 15 and may be
tightened to increase the strength, rigidity and integrity of the unitary post
formed of coupled posts P1, P2. Where the posts P1, P2 are provided with
slots "S1" or other apertures (as shown in Figs. 4-5), the holes 15 are
preferably provided in coupler 10 so as to index with such slots to facilitate
fastener application.
In addition, one or more detents 16 extending from a surface of
coupler 10 for frictionally engaging the respective posts P1, P2 to hold the
coupler 10 relative to them, respectively. Four additional shallower detents
18 may also be incorporated on opposite sides of the detents 16. These
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additional detents 18 could be used to also enhance engagement with the
post segments P1, P2, but their shallower extension facilitates initial
joining of
the coupler 10 to a post segment.
Another embodiment is shown in Figs. 6-10. In Fig. 6, a coupler 30
has two flanges 31, 32 oriented approximately at ninety degrees (shown) with
respect to each other, or at some other useful angle relative to the angle of
the
post flanges with which it will be used.
Detents at 35 and 36, respectively, are slight offsets, depressions or
upsets formed in the material of the coupler 30 and extending from its major
surface for the purpose of securing the coupler within the posts as will be
described.
Looking now at Figs. 9 and 10, a coupler 30 is utilized to couple two
angularly formed posts P3, P4 together. Posts 133, P4 each include two
flanges 42, 43 and two additional flanges, 44, 45, respectively reverse bent
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from flanges 42 and 43 to form a formed or structural post. A gap G2 is
formed between the respective reverse and major flanges.
=
It will be seen in Fig. 9 that the coupler 30 can be inserted into the
= upper end 40 of post P3 with the flanges 31, 32 of the coupler 30
residing
respectively between the parallel flange elements 42, 44 on one side of the
post P3 and parallel flange elements 43, 45 on the other side. In this
condition, the coupler 30 is tapped down into the post P3, about half the
length of the coupler 30. An upper post P4 is then slid over the coupler 30 so
that the lower end 41= of the post P4 adjoins the upper end 42 of the post P3
at the juncture 49 (Fig. 10). See the coupler 30 shown in the dotted lines of
Fig. 10.
In this manner, the posts P3 and P4 are held together, end-to-end, in
vertical orientation with the dimples, detents or upsets 35, 36 in any
suitable
location in the middle of and/or at both upper and lower ends of the coupler
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30, providing friction for holding the coupler 30 within the respective post
flange elements of the respective posts P3 and P4.
Like in the first embodiment, it will be appreciated that each of the
posts P3, 134: include a plurality of slots, such as keyhole slots "S2 "in
Figs. 9
and 10. These slots can be used, for example, for mounting brackets,
shelving or other accessories on the upright post as may be desired.
Moreover, the coupler 30 has two respective ends 50, 60. Each end is
tapered, as at end 50 with tapered edges 51, 52 and at end 60 with tapered
edges 61, 62, to facilitate insertion of the coupler into the gaps defined by
the
respective flanges of the respective posts, and thus forming a unitary post.
The scope of the claims should not be limited by the preferred
embodiments set forth in the examples, but should be given the broadest
interpretation consistent with the description as a whole.
