Field of the invention

The present invention relates to a post support, a method of forming a post support and a method of securing a post to a mounting surface.

Background

Post supports are a cost-effective way of securing a generally vertical post to a surface such as concrete. When it is not possible to set the post support into the surface when forming the surface, the post support is required to be fixed thereto with fasteners. This results in part of the fasteners being exposed, which need to be accommodated within the support and which can be visually unappealing.

It has previously been proposed to provide a two-part post support having a base or saddle with a cap received therein, the cap providing an offset base on which the post can be received to conceal the fasteners from view. However, such an arrangement does not provide access to the fasteners for adjustment, requiring a separate cap to be provided if adjustment of the fasteners is required.

There is a need to address the above, and/or at least provide a useful alternative.

Summary

According to one aspect of the invention there is provided a post support having a base securable to a surface and a cap for concealing fasteners used for securing the base to the surface, wherein:

the base has two upstanding portions with a central base portion therebetween, the cap has a central support portion between two downwardly extending portions, the cap being receivable within the base and rotatable between a first condition of use in which the said fasteners are accessible and a second condition of use in which the fasteners are concealed, and

at least one protuberance is provided, the protuberance being associated with the upstanding portions and the downwardly extending portions for retaining the cap within the base.

According to preferred embodiments of the invention, the tabs are formed on the upstanding portions of the base and extend inwardly to engage the downwardly extending portions of the cap. Preferably, the base is formed from a sheet of material, with the tabs being folded inwardly.

Preferably, the central base portion is formed with a central aperture through which the said fasteners can be received. The central aperture may be larger than the fastener to allow the position of the post support to be adjusted as required.

Preferably, the post support further includes a washer having an outer diameter larger than the aperture in the base portion.

According to another aspect of the invention, there is provided a post support of the above described type and a threaded fastener pair, the threaded fastener pair including :

a first threaded fastener with a male threaded portion; and a second threaded fastener with a female threaded portion, the female portion being configured to receive the male threaded portion,

wherein the first threaded fastener is formed with a shank having an outer diameter approximately equal to an outer diameter of the second threaded portion, the second threaded fastener has a length equal to or greater than that of the first threaded fastener and at a base of the female threaded portion is an unthreaded bore.

According to another aspect of the invention, there is provided a method of forming a post support, including the steps of: forming a base from a sheet of material, the base having two upstanding portions with a central base portion therebetween,

forming a cap from a sheet of material, the cap having a central support portion between two downwardly extending portions, the cap being receivable within the base and rotatable between a first condition of use in which fasteners securing the post support to a surface are accessible and a second condition of use in which the fasteners are concealed, and

forming at least one protuberance on the cap or the base, the at least one protuberance being associated with the upstanding portions and the downwardly extending portions for retaining the cap within the base.

According to preferred embodiments, the at least one protuberance is a pair of inwardly extending tabs formed on the upstanding portions on either side of the base According to another aspect of the invention, there is provided a method of installing a post on a post support, including the steps of:

providing a post support of the above described type;

securing the post support to a surface;

installing the cap in the desired orientation; and

securing a post to the post support.

Brief description of the drawings

In order that the invention may be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a post support according to a preferred embodiment of the invention

Figure 2 is a side view of the post support;

Figure 3 is an exploded perspective view of the post support, Figure 4 is an exploded perspective view of the post support in another condition of use;

Figure 5 is a perspective view of a base of the post support;

Figures 6, 7 and 8 are respective first side, plan and second side views of the base; Figure 9 is a perspective view of a cap of the post support;

Figures 10 to 12 are respective first side, second side and plan view of the cap;

Figures 13 and 14 are side and plan views of a large washer for use with the post support;

Figures 15 and 16 are side and plan views of a small washer for use with the post support; and

Figures 17 to 19 are perspective views of a threaded fastener pair for use with the post support.

Detailed description

A post support 10 according to a preferred embodiment of the invention is shown in Figure 1. The post support 10 is configured for securing a post to a ground surface.

The post support 10 has a base 12 securable to a surface and a cap 14 for concealing fasteners used for securing the base 12 to the surface. A large washer 16 is used to allow for adjustment in the position of the post support 10 so that dimensional variances in the position of the post can be accommodated. A small washer 18 is provided along with the large washer 16 to increase the effective thickness of the washer 16 and improve uplift or pull-out resistance of the post support.

The base 12 has two upstanding portions 20 with a central base portion 21. The central base portion 21 is receivable against the surface and has a central aperture 22 through which at least one fastener may be received. Aperture 22 is larger than an external diameter of the fastener to allow for adjustment of the position of the post support 10, as will be described in further detail below. Alternatively, apertures 23 may be used to secure the post support 10 to the surface.

The two upstanding portions 20 are configured to extend on either side of the post to allow the post to be secured to the post support 10. This may be achieved via the traditional method of using bolts 38 that extend through apertures 25, though a threaded fastener pair 24 as illustrated in Figures 17 to 19 may also be used.

The threaded fastener pair 24 includes a first fastener 32 with a male threaded portion 33, and a second fastener 34 with a female threaded portion 35. The female threaded portion 35 is configured to receive the male threaded portion 33.

In the illustrated embodiment, the fasteners are of equal length and length A2 equals length B2. Also, length A1 equals length Bl, with B1 being the length of which fastener 34 extends past the midpoint or centreline x between the heads of each fastener.

The first fastener 32 is formed with a shank 36 having an outer diameter approximately equal to an outer diameter of the second fastener 34. In a preferred form, the shank 36 of the first threaded fastener 12 is at least 10mm long and has a diameter of at least 10mm.

In preferred embodiments, the second threaded fastener 34 has a length equal to or greater than that of the first threaded fastener 32 and the length of the first threaded fastener 32 is at least 50mm. In preferred forms, the first threaded fastener 32 is available in lengths of 50mm, 70mm and 110mm, though it will be appreciated that longer lengths may also be possible.

By providing a first threaded fastener 32 with a shank 36 having an outer diameter that is approximately equal to an outer diameter of the second fastener 34, and the fasteners 32, 34 being of equal length, an inner bore of a through hole formed in the post is well supported on the fastener pair with the shank 36 and outer diameter of the second fastener contacting the upstanding sides 20. Advantageously, a neat connection without exposed ends of threads is provided, without compromising the strength of the connection between the fastener pair 24 and the post support 10. Threaded fastener pair 24 is further described in Australian provisional patent application no. 2019901647, also to the present applicant, and the entire contents of which are incorporated herein for reference.

The cap 14 has a central support portion 26 for supporting an end of a post. The central support portion 26 is disposed between two downwardly extending portions 28, that are provided to offset the central support portion 26 from the base 12.

Large washer 16 is formed from the cap 14 from a punching process, resulting in a central aperture 30 being formed in the cap 14.

As can be seen in Figures 1 to 4, the cap 14 is receivable within the base 12 and rotatable between a first condition of use (Figure 3) in which the said fasteners are accessible and a second condition of use (Figure 4) in which the fasteners are concealed. The method of securing the support 10 to a surface will be described in further detail below.

To keep the cap 14 retained within the base, at least one protuberance is provided, the protuberance being associated with the upstanding portions 20 and the downwardly extending portions 28 for retaining the cap 14 within the base 12. It will be appreciated that the protuberance may take different forms and may extend from either the upstanding portions 20 or the downwardly extending portions 28.

In the illustrated embodiments, the protuberance is a pair of tabs 26 formed on the upstanding portions 20 and extending inwardly to engage the downwardly extending portions 28 of the cap 14. As can be seen in Figure 7, two tabs 26 are provided on either side of the post support 10 (four total) to prevent sideways movement on the cap 14 in the base 12.

Advantageously, a single post support 10 may be provided which is adaptable between a first condition of use (Figure 3) where fasteners used to secure the post support 10 to the surface are accessible for adjustment after installation, and a second condition of use (Figure 4) where the fasteners are hidden, thereby providing a cleaner, finished look.

Figures 13 and 14 illustrate large washer 16, which preferably has an outer diameter which is larger than aperture 22 in the base portion 21. Although shown with washer 16 having an aperture 17 formed therein at a location which is offset from a centre of the washer 16, which would allow that when a fastener is received through the aperture 17 in the washer 16 at least a portion of the washer 16 will always overlap the base portion 21 to ensure retention, in other embodiments the aperture 17 may be centrally disposed. The use of washer 16 allows for adjustment in the position of the post support 10 to accommodate a varying location of a post.

Small washer 18, as illustrated in Figures 15 and 16, is provided to increase the effective thickness of the washer 16 to increase pull out strength.

Base 12 and cap 14 of the post support 10 may be formed of galvanised steel, though may be formed of other materials. In some embodiments, the base and cap are formed from a sheet of material, with the tabs being folded inwardly.

In installing the post support 10, the base 12 may first be positioned on the surface and a position of securing fasteners located. Once the fasteners have been installed, the base 12 is then secured to the surface and cap 14 installed in the desired position, which may be the first condition of use shown in Figure 3 where access to the securing fasteners is provided, or the second condition of use of Figure 4, where the securing fasteners are hidden. A post (40) may then be installed and secured to the post support 10, as shown in Figure 1.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.