Note: Descriptions are shown in the official language in which they were submitted.
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STRUCTURAL POST AND BEAM CONNECTION DEVICE WITH
FRICTION RELEASE BRACKET
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices and methods of support structures for
decks,
sheds and similar small buildings that are not connected to a frost and heave
resistant
superstructure, in particular structural post and beam connection devices and
methods
having a friction release mechanism.
2. Description of the Related Art
Decks and other structures that are supported in the manner to be explained
are known
in the art as "floating" in the sense that they rest on the surface of the
grade and are
free to move up or down as the soil expands or contracts annually as a result
of frost or
imposing loads on a given footing that exceeds the soil bearing capacity. It
is this
uncontrollable independent movement of each footing that can cause destructive
forces
to certain connections in the support structure. Some examples of footings for
deck
structures include concrete piers buried in the soil, helical piers screwed
into the
ground, or ground spikes impaled into the ground. A problem arises, however,
when
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the bottoms of posts of the deck or structure are rigidly attached to the
footings, such as
for example via an intermediary post bracket that has a lower appendage
embedded
into the footing material, usually concrete, and the top ends of posts are
securely
attached to the underside of beams of the overlying construction by toe-nail
screwing
methods or metal structural connectors. This is a practical and common way to
build a
support structure for a floating deck, and in so doing a system is created
comprising
three elements; the footing and its relative holding power in the soil, the
post bracket
connecting to the post, and the post connecting to the beam. The connection
points
between each of these three elements are not designed to have any flexibility
when the
system is under load or stress in the field. So long as any movement upward or
downward in the soil is imposed equally on each footing under each beam that
supports
the deck or similar construction, the forces imposed on the connection points
will be in
balance and no connection will be under more or less stress than another. In
such a
state, there is little if any risk that any of the connection points within
the system will
break.
As used herein, a frost resistant footing means a pier buried in the soil or
support device
the underside of which is located below the frost line in the soil. The
alternative is a
non-frost resistant footing which is located within the frost zone or directly
on the
surface of the soil. What often occurs in the field with non-frost resistant
footings
among the prior art is that the connections are put under stress when
asymmetrical
forces are generated as a result of variable freezing in the soil or variable
soil bearing
capacity from one footing to the next in a plurality of footings under a
single beam.
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Thus the forces imposed on any given footing and its elements, as defined
earlier, are
unequal. This is because each connection among the three elements in the prior
art
systems is rigid and intentionally designed not to move or flex. The prior art
system will
hold until the force imposed on any connection surpasses its load capacity,
and when
this occurs, the weakest link or connection in the system will give way and
break.
Examples of this would be post to beam connections separating to relieve and
balance
the stress in the system. Or screws in the post bracket that secure the post
may shear
in order that the post may lift up out of the post bracket to relieve the
stress. Or if none
of these connections fail, the footing may be pulled up from the soil. Any of
these
scenarios is not desirable since the integrity of the structure will have been
compromised. The only way to entirely avoid this destructive scenario is to
forego the
simplicity and cost savings of a floating deck and install frost resistant
footings; be they
concrete piers with footings extending below the frost line or engineered
helical piers
which can be screwed in to the ground well below the frost line. In such
cases, the deck
is no longer floating but rather it is immobile. And because it is immobile,
all connection
points described above are protected. Such methods require more labor and
materials
and are considerably more expensive than a floating deck structure. The very
desirability of using a floating deck style of construction is to simplify and
reduce costs
of the construction process. If a floating deck is built using the prior art
devices and
methods, costs savings and convenience of installation are enjoyed, but the
critical
connections described that form the support structure system are at risk of
failing due to
uneven forces acting on the various support connections.
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An example of a prior art support system that is not vulnerable to the uneven
force issue
is taught by Hoffman in U.S. Patent Nos. 5,392,575, 5,953,874 and 6,609,346.
The
systems therein do not cause connections to break as described above, but
neither do
they provide a secure connection between the ground and the support posts.
This
system comprises a concrete block, sometimes referred in the art as "deck
blocks".
These are simple in design and concept and are shaped like a pyramid but with
a flat
top, wherein there are cavities formed within the top surface in order to fit
a post or joist.
If one block is lifted by frost and another is not, the post under the beam
above the
block that did not rise would simply lift up out of the cavity in the block.
This ensures no
connection is ever broken, but the entire structure is only held in place by
its own
weight. However, many jurisdictions prohibit the use of such blocks because
high winds
(for example as in tornado or hurricane situations) may lift the entire deck
or may pick
up and toss the blocks. Hence, while concrete blocks as taught by Hoffman
address
one aspect of the problem at hand, they leave structures vulnerable in other
ways.
In the field of construction for outdoor structures such as decks, sheds,
stair landings
and the like, a number of alternatives to traditional concrete piers and large
surface area
footings (dug into the soil and set so that the underside of said footing is
below frost
depth) have been developed. These devices have been developed in an effort to
avoid
the labor and expense of digging holes either for securing posts to the ground
for
fencing or for supporting structures and bearing weight. The field of prior
art devices for
post brackets, post spike devices and the like is crowded, therefore it may be
helpful to
review the progression of the development of the various devices over the last
century
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in order to understand the problems that each device was intended to address.
By
observing the steady and constant advancement it will be clear to see where
the various
groupings of devices have headed and also expose new problems that have arisen
in
different segments of the art and which remain to be adequately solved.
The prior art devices that became the precursors to some of the common
structural
connectors we now see in the field of wood construction is exemplified by
Yeager in
U.S. Patent No. 1,699,557, which resembled an H shape whereby two opposing
boards
could be connected and firmly held in place within the H shaped vertical and
opposing
flanges. Small apertures were defined on the flanges to permit nails or screws
to be
driven perpendicularly through the flange and into the wood board to lock it
in place.
The boards so joined were not intended to ever move again. A similar device is
taught
by Krabiel in U.S. Patent No. 1,816,226, which also shows similar physical
characteristics to Yeager but in the form of a U shaped connector. Apertures
are
defined in the flat surface of the U shaped rather than the vertical and
opposite flanges
which permit nails or screws to be guided as they are driven into a wooden
member.
The vertical flanges are then embedded into wet cement and left to cure in
place.
Bierbach in U.S. Patent No. 2,191,979 advanced the concept taught in Yeager by
introducing various curves and formed convex shapes to the metal. Legs with
embossments are present and used to provide better holding power once set into
wet
cement. A beam is set into the upper vertical flanges and small apertures in
these
flanges are provided to guide any nails or screws used to secure the beam in
the
device. In 1973, Howell in U.S. Patent No. 3,727,358 added to this genre of
metal
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connector by virtue of its unique folding method of manufacture and its
ability to
compensate for sloped surfaces while orienting a post vertical relative to its
surroundings. Common to the Howell device are the numerous apertures for nails
or
screws locking the post in place and rendering it immobile.
In U.S. Patent No.
4,906,677, Gib teaches a further manufacturing refinement using a single sheet
of steel
and configured so that two looping appendages could be set into wet cement
while
providing a stand off base to keep the wood post elevated above the concrete
surface
and upstanding legs or flanges to encapsulate and hold the post secure with
bolts. The
post is intended to remain immobile once secured within the anchoring bracket.
Structures using this method of anchoring are intended to be stable and
immobile by
virtue of the concrete footing that the structure rests upon also intended to
be immobile.
Further examples of similar style post holder brackets include devices taught
by Han in
U.S. Patent No. 4,958,470, Colonias in U.S. Patent No. 4,995,206, Reed in U.S.
Patent
No. 5,143,472 and Leek in U.S. Patent No. 5,333,435. There are aspects to each
device which vary from the other and these tend to be in the way the metal is
shaped
and bent. But among them all, it is clear to see that they all have very
similar
upstanding legs or flanges between which a post is cradled and precise
circular
apertures through which fasteners are aligned and driven into the wood post to
lock it in
place permanently.
The permanency of the fitting is intended to address the use of the device in
the field.
All of these solutions are themselves secured permanently to an immobile
substrate or
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footing of concrete. Mobility of the underlying concrete footing is not
intended nor is it
desirable for the building applications these devices are designed to be used
in.
Continuing with a review of the prior art we now move in a slightly different
direction
where we see a myriad of devices designed to make the installation of fence
posts
easier and simpler by employing spikes or helixes impaled or screwed into the
ground
with post brackets on the upper remote end of the device resembling the
similar
physical features of the earlier prior art discussed. Mills in U.S. Patent No.
4,588,157
and Brown in U.S. Patent No. 5,090,656 both employ inwardly directed tangs
specifically formed to permit slicing into the material of the post bottom
being urged into
the cavity of the post bracket. The tangs are intended to secure the post more
effectively than screws alone as well as secure posts which may be undersized
relative
to the post bracket cavity. However, consistent with the prior art, circular
apertures are
defined in the upper walls of the post bracket for screws or nails to be
driven and
permanently secure and render the post immobile. Idland in U.S. Patent No.
4,614,070
uses a means of adjusting the width between the upstanding legs or flanges of
the post
bracket to adjust to the variance in width from one post to another within a
defined
range of post sizes. It too uses circular apertures for screws to pass through
and
permanently affix or lock the post into the post bracket. Meyer (U.S. Patent
No.
6,273,390), Speece (U.S. Patent No. 5,927,577) and Walker (U.S. Patent No.
7,219,872) developed post support solutions for driving fence posts into the
ground.
While all of these devices function as a post ground spike, they all attempt
to make it
easier to finely adjust the vertical attitude of the post in situations where
the spike can
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not be driven perfectly perpendicular into the ground or if the spike is
installed on a
slope. They employ various styles of ball joint connections between the lower
spike and
upper post bracket portion of their respective devices. Common among these
three
devices is the known prior art post bracket styles of a defined inner cavity
with an open
portion with flanges at one corner of the defined cavity that can be clamped
together
thus compressing the cavity walls around the post. Circular apertures are
defined in the
cavity walls to align screws or nails which may be driven into the post and
permanently
locking it in place. Opposing flanges at an open corner of the post bracket
are also
found in the Zhu device (U.S. Patent No. 8,322,678) although the main
advancement
with the Zhu device is the concept of using thinner sheet metal for the lower
spike
appendages and adding stamped and embossed reinforcement lines shapes running
along the longitudinal axis of the spike so as to render the thinner metal
more rigid.
Other devices which go further in trying to create one size of post support
bracket that
may fit tighter with a greater range of post sizes are the Hill device (U.S.
Patent No.
7,730,675) and the Callies device (U.S. Patent Publication No. 2005/0279896).
Both
teach a device whereby impressions are embossed into the vertically defined
walls
inside of the bracket which hold the post. These impressions protrude inwardly
into the
cavity of the post bracket from the inside planar surfaces defining the
cavity. One
variant device from this grouping of prior art devices is the Teeters device
(U.S. Patent
No. 4,199,908) which employs an elongated aperture running horizontally so
that the
post supporting portion of the device may be easily moved horizontally and
then affixed
at the desired location by nuts and bolts. Vertically opposing and upstanding
legs then
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fit snuggly against the post. Screws or nails may be driven through circular
apertures
and into the post locking the post permanently in this position. The elongated
apertures
address the desire of users to have a degree of horizontal motion while
determining the
final position of the post. But once that final location is found, the post is
intended to be
precisely but permanently secured in position.
A further nuance among the ground anchor genre of devices is the Boulay device
(U.S.
Patent Publication No. 2011/0036025). Boulay teaches the use of a helical
anchor
common among the prior art but with a cap plate with a central circular
aperture through
which the top threaded remote upper end of the anchor protrudes. The underside
of the
cap plate rests on the upper surface of an ring integrally formed around upper
shaft of
the helical anchor rod just below where the threads terminate. The cap plate
is
compressed against the ring but with two nuts having differing outer diameters
above it.
A conventional post bracket similar to the prior art devices can be screwed on
to the
remote end of the threaded rod if a similar threaded female nut or aperture is
located
underside of the post bracket. Additionally, any other kind of attachment
could be
screwed onto the threaded rod such as a loop shaped device enabling the device
to
function as an anchor for guy wires and the like. The claimed unique
characteristics of
the Boulay device are the two different size nuts which are used to screw
tightly
together. Once locked together and so long as the fit is very tight with the
threads on
the rod and the nuts, different sizes of sockets can be fitted over either the
larger lower
nut or smaller upper nut and drive the anchor downward or upward from the
soil.
However, the proficiency and reliability of using two nuts to screw tightly
against one
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another along a common inner threaded rod that defines a longitudinal rod with
helical
blades to screw into the ground and such that the resulting union of the two
nuts
functions as a fixed point along the rod critically allowing the entire rod to
turn forward or
reverse is proven to be low. All elements of the union of the nuts, the
threads and the
rod must function perfectly for the rod to screw down or into the ground and
if any
element fails such as the nuts turning in unison or in synchronization with
each other
around the threaded rod or the threads of a single nut or along the rod are
stripped, the
rod will no longer be capable of being rotated under the driving torque forces
of the
impact wrench rendering it useless in the field. It has been discovered that
the only
reliable structure for driving or rotating an anchor such as in Boulay into
the ground is to
incorporate a direct drive structure integral to the rod itself, such as a
square, hexagonal
or similar as in the present invention as described and illustrated herein.
Lastly, Boulay
does not address the problem of uneven vertical movement caused by ground
movements, and it does not teach or suggest any structural features in post
receiving
bracket of his device that would permit the post to move vertically if
subjected to soil
movement and pressures generated from other natural movement or subsidence.
Structures built with the Boulay device would have no means to safely release
such
energy, and leave at risk any of the critical elements of both the device and
the structure
that is supports for the possibility of breaking.
The concept of a helical anchor as a ground anchor was also used by Alexander
(U.S.
Patent No. 4,803,812) and Cockman (U.S. Patent No. 4,863,137). Alexander
taught the
use of a helical anchoring device that could be easily driven into the ground
using power
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tools rather than heavy equipment. A horizontal plate for stabilization or
load bearing is
integral to the device, not unlike the Boulay device. A prop or vertically
oriented tube or
solid cylindrical member protrudes upward from a second horizontal platform
also
integral to the anchoring rod. It is intended for hollow metal posts or wood
posts with
hollowed cores to be fitted over the prop and thus secured in place. While
such a
device and method provides a desirable means of attaching posts to the ground
with
greater ease than the prior art at the time, Alexander does not touch upon the
problem
of uneven soil movement nor how this device would alleviate the risks of post
and beam
connections failing were the device to used among a plurality of said devices
under a
common beam intended to support compressive loads upon soil subject to frost
or other
natural movements or subsidence. Cockman proposed using a helical anchoring
rod
similar to the prior art but taught the use of a compression disk integral to
the upper
remote end of the rod and the use of a post bracket using the common vertical
side
panels but with the ability to slide in an outward to accommodate varying
sizes of posts.
The compression disk was intended to compress soil downward after it had been
churned by the turning helical blades. The post bracket uses similar design
and
function attributes seen among the entire prior art. That is to say, opposing
vertical
flanges between which a post is placed and numerous circular apertures through
which
screws or nails can be driven through and securing the post into the bracket.
The post
is permanently secured and the entire anchor and post are intended to never
release
from one another. Likewise Cockman did not address the issue of soil movement
and
uneven forces created in system of ground anchored posts. Such forces are
known to
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destroy post and beam connections when footings under a common beam are
subject
to differing movements.
In 2009, Hill (U.S. Patent Publication No. 2009/0133337) proposed an
adaptation to the
his earlier device (U.S. Patent No. 7,730,675). This adaptation utilized a
load bearing
plate through which the cross shaped fins of the ground spike could fit
through. Hill
teaches to drive the ground spike into the ground using a sledge or jackhammer
thereby
compressing the soil underneath the load bearing plate. The larger surface
area of the
bearing plate spreads the weight of any structure above it over a larger area
than if the
post anchor spike were used without the plate. As discussed previously, the
upper post
bracket portion of the device employs inwardly embossed zones to compensate
for a
known variance in post size and circular apertures through which screws are
driven and
permanently locking the post into place. The Hill device is a means of
installing load
bearing posts when the load bearing plate is used. However the Hill device
lacks the
ability for any single post among a plurality of posts supporting a common
beam to
release by virtue of a friction triggered method or any other method which
would relieve
uneven stresses built up in the post, beam and footing system caused by uneven
soil
movement. As a result decks or other structures using this system in areas
where frost
of uneven soil bearing capacity exists are subject to the risks of destruction
discussed
herein.
Although there have been devices and methods taught over nearly a century in
the field
of ground driven post anchoring means, none of the prior art teaches or
contemplates a
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solution for the problem of uneven soil movement and a simple and effective
means of
protecting the integrity of the post and beam connections among a plurality of
support
posts under a common beam. The original use for these devices and their
adaptations
particularly the ground spikes and helical anchors, was most commonly intended
for
single fence posts or single ground anchors. However, because of the continued
desire
to find easier and less expensive means of building footings and foundations
for
lightweight structures, the use of these prior art devices in situations such
as support
posts under common beams began to expose their limitations.
Accordingly, there is a need for devices and methods of support structures for
decks,
sheds, small buildings and similar light weight constructions that are capable
of
compensating for asymmetrical uplift forces acting on any single footing
within a
plurality of footings under a common beam such as may occur, for example, due
to
differing frost conditions in the soil or variable soil bearing capacity.
SUMMARY OF THE INVENTION
In order to address some of the shortcomings in the prior art, some aspects of
the
present invention provide a post anchoring support device for anchoring an end
of a
support post of a deck or similar construction to the ground, the post
anchoring support
device comprising: a ground anchor having a shaft with a lower portion and an
upper
portion, the upper portion having an externally threaded portion and
terminating in an
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upper end having at least one planar vertical wall for enabling the upper end
to being
engaged and rotated by a drive tool for rotating the shaft about a vertical
axis, the lower
portion having a lower end for insertion into the ground and at least one
helical blade
circumscribing the shaft above the lower end for boring the lower portion into
the ground
as the shaft is rotated about the vertical axis; a post receiving bracket
having base with
an elongate aperture adapted to receive the externally threaded portion of the
shaft and
enable lateral movement of the threaded portion within the elongate aperture,
a
support portion defining a support surface for abutting the end of the post,
the support
surface being located vertically on the receiving bracket to be above the
upper end of
the shaft when post anchoring support device is in an operable configuration,
at least
two vertical planar walls extending above the support surface, each planar
wall having
an inside surface for abutting a vertical side of the post and an outside
surface, and
each planar wall defining a plurality of vertically oriented elongate holes
and having a
raised portion on the outside surface adjacent each elongate hole adapted to
abut a
lower surface of a head of a fastener passing through the elongate hole and
into the
post to allow the fastener to travel within the elongate hole upon the
application of a
vertically force to the post anchoring support device sufficient to overcome a
coefficient
of friction between the head of the fastener and the raised portion; and a
threaded nut
for engaging the externally threaded portion of the shaft and securing the
post receiving
bracket to the ground anchor.
In some embodiments, the post anchoring support device may further comprise a
horizontal plate member adapted to being received about the shaft of the
ground
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anchor, sandwiched between the ground and the base of the post receiving
bracket
when the ground anchor has been driven into the ground and the post receiving
bracket
is connected to the external threaded portion of the ground anchor.
In some
embodiments, a second hole may be provided on the horizontal plate dimensioned
to
accommodate the shaft, a circumferential platform on the upper portion of the
shaft
below the externally threaded portion for abutting a bottom surface of the
horizontal
plate about the second hole, and a second nut complementary to the externally
threaded portion for engaging an upper surface of the horizontal plate about
the second
hole and securing the horizontal plate against the circumferential platform.
In some embodiments, the support portion may comprise a first and second
horizontal
platforms and a recessed platform in between the first and second horizontal
platforms,
the recessed platform defining the elongate aperture therein to accommodate
the shaft,
wherein the recessed platform is positioned below the first and second
horizontal
platforms by a distance sufficient to provide clearance between the upper end
of the
shaft and first and second horizontal platforms when the post receiving
bracket is
connected to the external threaded portion of the ground anchor.
In some embodiments, each raised portion may comprise a narrow edge portion of
highest elevation adjacent the elongate hole for abutting the lower surface of
the head
of the fastener, and tapers in elevation away from the elongate hole.
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The devices and methods of the present invention compensate for a degree of
asymmetrical uplift forces on any single footing within a plurality of
footings under a
common beam resulting from differing frost conditions in the soil or variable
soil bearing
capacity. Such differences can occur due to differing moisture retention in
the soil
proximate to each footing. Moisture retention in soil may differ based on its
permeability
or lack thereof. The present invention relates to attributes of a post bracket
or "saddle
bracket" as they are also known, or similar style post connector that when
affixed to the
end of a post, said post may slide up and down within the saddle bracket,
without
resulting in structural failure, as compared with prior art brackets which
offer no means
for such release and movement. For example, when one or more footings under a
common beam is lifted upwards by soil expansion caused by freezing, said
footing in
turn pushes the beam upwards generating tension forces among the other post to
beam
connections (whose footings are stationary relative to the first footing
described) and
when one or more of these other footings under the common beam are not
subjected to
the same uplifting forces thereby remaining stationary, the post connected to
the post
bracket in the stationary footing may release and slide up in the post
bracket, relieving
the stress and preserving its connection with the beam above it. It also
preserves the
footing connection in the soil and alleviates any upward pulling force from
the soil that
would have existed if the other two connection points in the system did not
fail and
relieve the stress.
An embodiment of the invention comprises a ground anchor, a load distribution
plate
and a post receiving bracket. In this embodiment the ground anchor, load
distribution
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plate and post bracket are separate pieces which assemble together during
installation
to provide a device from which the stated benefits and heretofore unavailable
advantages are derived. In an embodiment the ground anchor comprises an auger
rod
with at least one helical blade at the lower terminus. The load distribution
plate has an
aperture in its center through which the rod may pass through. At the upper
terminus
the rod has a hex shaped head to be received in a socket, a threaded portion
below the
hex head and an embossed ring or stop washer like shape protruding outwards
perpendicularly from the longitudinal axis of the rod such that the load
distribution plate
may rest upon the embossed ring or stop washer. The post bracket has a female
threaded region in the form of a nut or other similar formation defined in the
underside
of the post bracket into with the upper threaded terminus of the rod can be
threaded into
for all three parts to mate securely together. In an embodiment the post
bracket has at
least two vertical upstanding flanges whose inner surfaces are opposite each
other and
allow a post to fit between. The flanges have defined in them elongated holes
vertically
aligned parallel to the vertical axis of the flanges and an embossed region
around the
perimeter of the holes. The embossed area rises outward from the outside
surface of
the flanges. Furthermore, the elongated holes are offset from each other on
the surface
of the flange in a staggered fashion, one lower and the other higher with
respect to each
other. These three structures may be installed together and connected to the
underside
of a common carrier beam by posts secured into each post bracket.
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BRIEF DESCRIPTION OF DRAWINGS
For a better understanding of the present invention and to show more clearly
how it may
be carried into effect, reference is made by way of example to the
accompanying
drawings in which:
Fig 1 is a perspective view of the complete device of one embodiment including
a
ground anchoring auger rod, load plate and post bracket;
Fig 2 is a top down view of the load plate showing the center aperture and the
folded
corner and sides of the plate generally defining a convex upper surface;
Fig 3 is a perspective view of the auger rod showing the at least one helix,
the stop
washer, threaded rod and hex shaped terminus;
Fig 3A is a perspective close up view of the threaded rod, nut and hex shaped
terminus
of the auger rod;
Fig 4 is a perspective view of the post receiving bracket showing the vertical
sides and
the vertically elongated fastener holes with outwardly embossed region
circumscribing
the holes;
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Fig 5 is a section view of the post bracket showing the vertical side of the
bracket and a
cross sectional view of the middle;
Fig 6 is a cross sectional view of the ground anchoring auger rod with load
distribution
plate and the post receiving bracket;
Fig 7 is a cross sectional view of the post receiving bracket with a post
secured by a
screw where the post is fully seated and the screw is set in the lowest
position in the
elongated aperture;
Fig 8 is another side view cross sectional view of the post receiving bracket
with a post
secured by a screw where the post is risen within the bracket as would occur
with
upward forces from the attached beam and the screw has moved upward along the
elongated aperture permitting post movement;
Fig 9 is a perspective view of the device when installed on the ground and
with the post
in its lowest flush position;
Fig 10 is a perspective view of the device when installed on the ground and
with the
post in its highest position;
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Fig 11 is a side view of a plurality of devices supporting a common beam and
depicts
the ground or soil conditions which are disposed to risk of uneven movement or
expansion in freezing environmental conditions;
Fig 12 is another side view of a plurality of devices supporting a common beam
and
depicts the ground or soil movement during freezing conditions and how the
device
absorbs uneven forces;
Fig 12A is a close up side view of the middle device of Fig. 12;
Fig 13 is a close up side view of the threaded rod, nut and hex shaped
terminus of the
auger rod shown with a portion of the load distribution plate received on the
threaded
portion;
Fig 14 is a close up side view of the threaded rod, nut and hex shaped
terminus of the
auger rod shown with a portion of the load distribution plate received on the
threaded
portion;
Fig 15 is a perspective view from the top of another embodiment of the post
bracket
showing an elongated aperture for the hexagon head of the rod to pass through
and a
deeper cavity without a nut welded to the underside of the lower surface;
CA 02925809 2016-04-01
Fig 16 is a perspective view from the top of the post bracket in Fig 15 shown
as
transparent to reveal the underlying structure;
Fig 17 is a cross sectional view of the ground anchoring auger rod with load
distribution
plate and the embodiment of the post receiving bracket shown in Fig 15;
Fig 18 is a top plan view of a plurality of the assembled devices, having the
post
brackets of Fig 15, as they may appear in the field ready to accept a common
beam and
the range of positions of the post bracket relative to the load plate are
depicted; and
Fig 19 is a top view of a plurality of the assembled devices, having the post
brackets of
Fig 15, as they may appear in the field once a common beam is set in place
while
showing how the plates may be imperfectly aligned relative to one another.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles of the
invention,
reference will now be made to the exemplary embodiments illustrated in the
drawings,
and specific language will be used to describe the same. It will nevertheless
be
understood that no limitation of the scope of the invention is thereby
intended. Any
alterations and further modifications of the inventive features herein, and
any additional
applications of the principles of the invention as illustrated herein, which
would occur to
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one skilled in the relevant art and having possession of this disclosure, are
to be
considered within the scope of the invention.
Referring to Figures 1-10, there is depicted an embodiment of post anchoring
support
device 1 in accordance with the present invention. The post anchoring support
device
comprises a post receiving bracket 2 that permits placement of a post 4 set
inside the
inner cavity of said device, said cavity defined by at least two opposing and
upwardly
standing walls or flanges 5 rising from a base and first common horizontal
planar
surface 6 which said post 4 would rest downward upon, to be connected to the
upward
flanges 5 by screws 10 passing through vertical aligned and elongated holes 8
of the
flanges, said flanges are further defined by a raised portion or embossed
region 9
circumscribing the elongate holes 8 in an upwardly sloping direction and away
from the
outside planar surface 11 of the flange such that when a screw 10 is driven
into the post
the underside of the screw head rests at the first point of surface contact
with the
elevated or embossed edges of the holes; said embossed surface slopes from its
highest elevation downwards toward the greater planar surface 11 of the flange
at an
approximate 45 degree angle so as to direct the compression force of the screw
as far
away from the penetration point and over as large a surface area as possible.
Figures 7, 8 show the elongated embossed regions 9 circumscribing the holes 8
that
dissipate the otherwise highly concentrated compression force of the screw 10
thus
reducing the compression force of the flanges 5 and screws 10 against the post
4 which
in turn reduces the coefficient of friction and results in a lower force
applied to initiate
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vertical movement of the post against the inner flange surfaces. This allows
the post
and flanges to slide against each other as the post is pulled up or pushed
back down
within the flanges when used in conjunction with three or more devices and
posts
secured to the underside of a common carrier beam in situ and anchored to
frost prone
soil; said soil possessing differing moisture content from one zone of soil
below any
given device and the next and thus subject to differing degrees of soil
expansion and
contraction when water is frozen in the soil and later thaws.
Figures 9, 10 show perspective views of the post 4 and the assembled device 1
of the
present invention as it would appear when installed on the ground. Fig 10
further
depicts when soil movement occurs and the post movement is restricted to
vertical
movement only, creating a space 12 underneath the post within the range that
the
screws 10 may freely move and defined by the length of the elongate holes 8
and to
slide back downward if certain discreet downward forces are subsequently
exerted on
the post.
Referring again to Figures 4-6, in some embodiments the post receiving bracket
2
include a first flat planar surface 6 upon which the bottom of the post may
rest and a
second planar surface 7 parallel to the first surface but lower such that a
cavity 26 is
created when the post 4 is fully seated on the first surface 6, said cavity is
intended to
allow for the hex head 28 upper terminus of the auger rod 40 to pass through
aperture
29 defined in surface 7 and through first threaded upper nut 19 welded to
underside 30
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of surface 7 into which a threaded rod with corresponding male threads may be
secured.
Post anchoring support device 1 as shown in Figs 2 and 6 comprises a load
plate 3 with
an upper surface 13 and an underside surface 14, said load plate featuring
bending
lines 16 and 17 upon the upper surface 13 such that a convex upper surface is
defined
or a concave underside surface 14 with corners 15 bent at less than
perpendicular from
the upper surface 13. An aperture 18 is located in the center of the load
plate 3 of
sufficient diameter as to allow the threaded rod 27 to clear and pass through
such that
the plate is free to rotate independently of the auger rod 40.
Post anchoring support device 1 as shown in Figs 1, 3 and 3a further comprises
a
cylindrical ground anchoring auger rod 40 preferably made of hollow tubing
with stop
washer 22, at least one small helix 24 and optional second larger helix 25. A
lock
washer 21 and second nut 20 fit over the threaded rod 27 portion, and a lower
terminus
cut at an angle 23. The auger rod 4 further defined by a hexagon portion 28
formed into
the upper terminus and beginning after the male threads 27 end, said hexagon
portion
28 short enough that its top flat end does not rise above the upper flat
planar surface 6
of the post receiving device 2 and conflict with the post bottom when fully
threaded into
the upper nut 19, said nut welded or formed integrally with the female
aperture 29 of
second lower planar surface 7. The rod further defined such that it passes
through an
aperture 18 in the load plate 3, mating with the upper nut 19 of the post
receiving
bracket 2, and said bracket possessing a perimeter dimension that is less than
the
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perimeter defined by the load plat 3. The stop washer 22 formed outwardly or
transversely from the longitudinal axis of cylindrically shaped rod 40 so that
underside of
plate 14 can rest on the upper surface of said stop washer 22 while male
thread of rod
27 is long enough to mate with the upper nut 19 forming female aperture 29. In
this
manner, the post receiving bracket device 2, the load plate 3 and the rod 40
can be
screwed together until the lower edges of the lower peripheral walls of the
device 2
firmly contact the upper planar surface 13 of the plate; the lower terminus of
the rod 40
having a helical shape of one or more independent helixes 24, 25 thus
permitting the
rod to be screwed into the ground by a socket attached to the hexagon shaped
upper
terminus 28.
In some embodiments rather than helical blades, a spike may be impaled into
the
ground whereby male threads are similarly defined in an upper remote portion
of the
spike such that it may thread into a female threaded aperture part as defined
in the
underside of device 2 so the two may be connected. Such embodiment would
differ in
its utility as an impalement method of installing the ground anchoring portion
would be
required demanding greater force to install and require a sledge hammer or
jack
hammer rather than a simple lightweight pneumatic or electric impact wrench as
taught
with the preferred embodiment. However, in such an alternate embodiment, the
post
receiving bracket would function similarly as it would allow or compensate for
uneven
soil movements among adjacent support posts supporting a common beam by virtue
of
the unique features of the flanges 7 specifically the elongated holes 8 and
the
embossed region which spreads the force of the penetrating screws 10 over a
larger
CA 02925809 2016-04-01
surface area thus lower the coefficient of friction value at which point the
posts may
slide vertically and safely within the flanges 11.
Referring to Figures 11 and 12 the functionality of the physical features of
the
completed invention 1 and the method of installation in the field shows how
posts and a
beam supporting a structure can adjust for uneven soil movements from one
footing to
the next and thereby protect the post to underside of beam connections from
separating. Referring to Figure 11 a non-freezing environment is depicted
or
immediately after the devices 31, 32 and 33 have been installed into the
ground and the
posts and beam 30 have been interconnected. Often unknown to the installer is
whether the soil below is homogeneous or heterogeneous. Some soils may differ
enough in terms of porosity and within close proximity that is not uncommon in
the field
to encounter situations where soil zone 34 and 36 are predominantly composed
of clay
or similar soil such that it retains moisture and where an adjacent soil zone
35 may be
of differing composition such that is composed of sand or granular stone such
that it
does not retain as much or any moisture. If the ground never freezes or is
never
subjected to any other natural subsidence the positions of the devices
relative to one
another will not change and the forces exerted on the posts and beam will
remain
unchanged. However referring to Figure 12, when freezing conditions occur, the
soil
zones retaining higher amounts of water will expand upwardly with great force.
Devices
supporting posts 31 and 33 are pushed upwards in direction A from the frost
expansion
in soil zones 34 and 36. Posts 31 and 33 in exert upward force on beam 30
causing it
to rise and create a tension force on post 32. With all prior art devices,
there would be
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no release mechanism to permit post 32 to move freely upward and preserve the
post to
beam connection. If the post to beam receiving bracket connection were strong
enough
to resist the tension from the beam connection the post to beam connection
would fail.
Alternatively if the post to beam connection were strong enough to resist the
tension
force the buried lower portion of the anchor rod or spike as referred to in
alternate
embodiments would be pulled up from the soil. This latter scenario is less
likely in the
instance of a helical blade within the soil if frost surrounds the entire
anchor rod in the
ground. But this would then result more likely in failure of the post to
bracket or post to
beam connections. In any of the possible scenarios the entire system is placed
under
stress and to preserve or protect the system there must be a means of
releasing said
stress or forces to prevent any damage to the system.
Over the course of seasons a structure built using an embodiment of the
present
invention in a plurality of connections supporting a common beam will be best
designed
to absorb and release the powerful and potentially destructive forces
generated by most
often frost but also any natural subsidence that may occur. The present
invention
performs this task very efficiently.
In the field a typical installation occurs as follows. An area of soil is
prepared by
removing any grass (sod) and exposing the soil below. It is preferable to
remove any
obviously soft or disturbed soil and this is usually achieved by removing
three to four
inches (8-10 cm) of loose soil. Crushed granular stone is set in place as it
tends to be
porous and the polygonal shapes of the stone interlock as they compress making
them
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well suited to not erode if heavy rains or water flows over the surface. This
soil
preparation is done for each area where a device will be located and in common
line to
support a single beam. An impact wrench with a socket is then used to drive
the helical
blades of the rod 4 into the soil in a vertical orientation, perpendicularly
to the prepared
surface below.
Referring to Figures 13 and 14 the load plate 3 can be placed over the
threaded rod 27
and rest loosely on the stop washer 22. The lock washer 21 would rest loosely
on
surface 13 of the load plate 3 and the second nut 21 would be turned down on
the
threaded rod 27 only to the intersection point between the hex head 28 and
threads 27
the reasons for which will be explained.
As the impact wrench rotates the helical blades into the ground the load plate
3 is free
to remain stationary and not spin wildly in concert with the revolving rod 4.
Eventually
the underside 14 of the load plate 3 will make contact with the soil and the
rod will
continue to be driven downwards until the top surface 13 of the load plate
contacts the
lock washer 21 and in turn the underside of the second nut 21. This state is
depicted in
Figure 13.
A larger socket is then placed on the impact wrench and engaged with the
second nut
20. The nut is turned downward and forces the load plate 3 to compress the
soil below
it until the underside 14 contacts the stop washer 22. The threads of rod 27
now remain
exposed and are of sufficient height above the top surface 13 of the load
plate as to
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engage into the threaded aperture 19 of upper nut 20 so that post receiving
bracket 2
can be secured with the rod 4 and plate 3 forming the completed device.
Posts 4 are then inserted between the flanges 11 and screwed in place. Tops of
said
posts are then secured to the underside of the beam 30. In order for the
device to
function as designed at least three posts must be connected to a common beam,
said
beam posts and devices them forming a complete system for supporting
structures and
being capable of absorbing uneven forces from subsidence of the ground.
Referring to Figures 15-19, there is depicted another embodiment of a post
receiving
bracket 102 that accommodates imperfect linear alignment of a plurality of
post
anchoring support devices on the soil when used to support a beam such as
support
beam 30. The post receiving bracket 102 includes at least two opposing and
upwardly
standing walls or flanges 105 rising from a base and first horizontal planar
surface 106
upon which the post or beam would rest downward, and a second planar surface
107
parallel to the first surface but lower such that a cavity 126 is defined when
the post or
beam is fully seated on the first surface 106. The cavity 126 accommodates the
hex
head 28 upper terminus of the auger rod 40 so that it does not interfere with
the post or
beam. The post or beam is connected to the upward flanges 105 by screws
passing
through vertical aligned and elongated holes 108 of the flanges, said flanges
further
include a raised portion or embossed region 109 circumscribing the elongate
holes 108
in an upwardly sloping direction and away from the outside planar surface 111
of the
flange such that when a screw is driven into the post the underside of the
screw head
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rests at the first point of surface contact with the elevated or embossed
edges of the
holes. The embossed surface curves or slopes from its highest elevation
downwards
toward the greater planar surface 111 of the flange 105 so as to direct the
compression
force of the screw over a larger surface area. In the aforementioned manner,
post
receiving bracket 102 is similar to post receiving bracket 2 described above
herein. The
principal differences in post receiving bracket 102 are that the central
aperture in the
lower surface 107 is an elongate aperture 129, the threaded upper nut is not
welded to
the underside of the surface 107 but is rather a separate nut 119, and the
cavity 126 is
deeper to accommodate the additional length of the upper end of the auger rod
40
required to secure the post receiving bracket 102 to the auger rod 40.
The elongate aperture 129 in the surface 107 is adapted to receive the
threaded rod
portion 27 of the auger rod 40 and provides some travel of the threaded
portion therein.
The travel of the threaded portion 27 within the elongate aperture 129 enables
a degree
of movement of the post receiving bracket 102 relative the auger rod 40 (which
is
secured to the soil in use of the device) to accommodate imperfect linear
alignment of a
plurality of post anchoring support devices by enabling each post receiving
bracket 102
to be moved laterally in relation to the linear direction of an intended
common support
beam 30, whether or not the beam 30 is received directly on the horizontal
surface 106
of the brackets 102 or secured upon posts 4 set within the flanges 105.
Referring to Figure 17 post anchoring support device 1 comprises a load plate
3 as
described herein though which the threaded rod 27 of auger rod 40 passes such
that
CA 02925809 2016-04-01
the plate 3 is free to rotate independently of the auger rod 40. Washer 21 and
nut 20 fit
over the threaded rod 27 portion and secure the plate 3 against the lock
washer 22 on
the auger rod 40. The elongate aperture 129 of post receiving bracket 102 is
fit over the
remaining threaded rod portion 27 such that the portions of the planar member
with
surface 107, adjacent to the elongate aperture 129, abut the top of nut 20. A
washer
121 and the threaded nut 119 are fit over the remainder of threaded rod
portion 27 and
tightened to secure the post receiving bracket 102 against the nut 20 on the
auger rod
40. Prior to the nut 119 being tightened, the post receiving bracket may be
moved
laterally within the range provided by the elongate aperture 129 as required
for
alignment purposes.
Referring to Figures 18 and 19, a linear arrangement of post anchoring support
devices
1 having post receiving brackets 102 are shown from a top view in order to
demonstrate
the lateral mobility of the post receiving device 102 relative to each load
plate 3. A
common beam 30 is shown set into each adjacent receiving device 102 in an
application where the support devices were misaligned during installation.
Although the preferred embodiments of the device and method have been shown in
the
attached drawings and detailed description, it is understood that the
invention is not
limited to the embodiments disclosed, but is capable of other modifications
without
departing from the spirit of the invention set forth and defined in the
following claims.
31
