MODULAR CONTAINMENT AND SCREENING SYSTEM

Abstract

A construction method and apparatus used to form a surround, container or other structure. Posts have slots into which walls, which may be planks or made up of planks, are inserted and retained. Numerous posts may be used with numerous walls therebetween to form many and varied structures. The finished structure is modular, because the posts and walls are not damaged when the walls mount in the slots. Therefore, if more or fewer posts and/or walls are desired later, one need merely disassemble the structure and add the components desired to the existing structure. The walls may have fittings that attach to the inserted ends that cooperate with structures in the slots formed in the posts so the walls are held from being removed from the slots except along the length of the slots.

Claims

1. A modular construction system comprising: (a) an elongated first post having at least a longitudinal first slot formed in a side, the first slot defined by slot sidewalls spaced apart a first slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a first ridge gap, wherein the first slot width is greater than the first ridge gap; (b) an elongated second post spaced from the first post a predetermined distance, the second post having at least a longitudinal second slot formed in a side, the second slot defined by slot sidewalls spaced apart a second slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a second ridge gap, wherein the second slot width is greater than the second ridge gap; (c) a first wall with a length about equal to the predetermined distance and a first end with: (i) a first leg portion no wider than the first ridge gap extending into the first slot between the ridge tips of the first slot; and (ii) a first foot portion no narrower than the first ridge gap extending deeper into the first slot than the first leg portion; and (d) the first wall having a second, opposite end with: (i) a second leg portion no wider than the second ridge gap extending into the second slot between the ridge tips of the second slot; (ii) a second foot portion no narrower than the second ridge gap extending deeper into the second slot than the second leg portion.

2. The construction system in accordance with claim 1, wherein the first foot portion mounts integrally to the first leg portion and the second foot portion mounts integrally to the second leg portion.

3. The construction system in accordance with claim 1, wherein the first foot portion removably mounts to the first leg portion and the second foot portion removably mounts to the second leg portion.

4. The construction system in accordance with claim 1, further comprising: (a) an elongated third post spaced from the first and second posts having at least a longitudinal third slot formed in a side, the third slot defined by slot sidewalls spaced apart a third slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a third ridge gap, wherein the third slot width is greater than the third ridge gap; (c) a longitudinal fourth slot formed in a second side of the first post, the fourth slot defined by slot sidewalls spaced apart a fourth slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a fourth ridge gap, wherein the fourth slot width is greater than the fourth ridge gap; (c) a second wall, which is transverse to the first wall, having a third end with: (i) a third leg portion no wider than the third ridge gap extending into the third slot between the ridge tips of the third slot; and (ii) a third foot portion no narrower than the third ridge gap extending deeper into the third slot than the third leg portion; and (d) the second wall having a fourth, opposite end with: (i) a fourth leg portion no wider than the fourth ridge gap extending into the fourth slot between the ridge tips of the fourth slot; and (ii) a fourth foot portion no narrower than the fourth ridge gap extending deeper into the fourth slot than the fourth leg portion.

5. The construction system in accordance with claim 1, wherein the first wall is made of at least first and second substantially parallel and co-planar planks, the first plank having a first groove formed in a lateral edge and the second plank having a second groove formed in a lateral edge that is adjacent the first groove, and further comprising a stiffener with members inserted in the first and second grooves.

6. A modular construction system comprising: (a) an elongated first post having at least first and second longitudinal slots; (b) an elongated second post spaced from the first post, the second post having at least third and fourth longitudinal slots; (c) an elongated third post spaced from the first and second posts, the third post having at least fifth and sixth longitudinal slots; (d) an elongated fourth post spaced from the first, second and third posts, the fourth post having at least seventh and eighth longitudinal slots; (e) a first wall with a first end extending into the second slot, and a second, opposite end extending into the third slot; (f) a second wall with a first end extending into the fourth slot, and a second, opposite end extending into the fifth slot; (g) a third wall with a first end extending into the sixth slot, and a second, opposite end extending into the seventh slot; and (h) a fourth wall with a first end extending into the eighth slot, and a second, opposite end extending into the first slot.

7. The construction system in accordance with claim 6, further comprising a foraminous grid extending from attachment to at least one of the walls.

8. The construction system in accordance with claim 6, further comprising a foraminous grid extending from attachment to at least one of the posts.

9. The construction system in accordance with claim 6, wherein the first wall is made of at least first and second substantially parallel and co-planar planks, the first plank having a first groove formed in a lateral edge and the second plank having a second groove formed in a lateral edge that is adjacent the first groove, and further comprising a stiffener with members inserted in the first and second grooves.

10. A construction method comprising: (a) spacing an elongated first post from an elongated second post with a gap therebetween, wherein: (i) the first post has at least a longitudinal first slot formed in a side, the first slot defined by slot sidewalls spaced apart a first slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a first ridge gap, wherein the first slot width is greater than the first ridge gap; and (ii) the second post has at least a longitudinal second slot formed in a side, the second slot defined by slot sidewalls spaced apart a second slot width, and a pair of ridges extending toward one another from the slot sidewalls and terminating in ridge tips forming a second ridge gap, wherein the second slot width is greater than the second ridge gap; (b) extending a first end of a first wall into the first slot, the first end having a first leg portion, which is no wider than the first ridge gap, that is disposed between the ridge tips of the first slot, and a first foot portion, which is no narrower than the first ridge gap, that extends deeper into the first slot than the first leg portion; (c) extending a second, opposite end of the first wall into the second slot, the second end having a second leg portion, which is no wider than the second ridge gap, that is disposed between the ridge tips of the second slot, and a second foot portion, which is no narrower than the second ridge gap, that extends deeper into the second slot than the second leg portion; and (d) displacing the first and second ends of the first wall lengthwise along the first and second slots, respectively.

11. The method in accordance with claim 10, further comprising the step of mounting the first and second foot portions to the first and second ends, respectively, of the first wall.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0019] FIG. 1 is a top schematic view illustrating an embodiment of the present invention.

[0020] FIG. 2 is a side view illustrating the embodiment of FIG. 1.

[0021] FIG. 3 is a side view in section illustrating the embodiment of FIG. 2 through the line A-A with an enlarged portion.

[0022] FIG. 4 is a top view illustrating a corner of the embodiment of FIG. 1.

[0023] FIG. 5 is a top view illustrating an alternative post.

[0024] FIG. 6 is a top view illustrating an alternative post.

[0025] FIG. 7 is a top view illustrating an alternative post.

[0026] FIG. 8 is a top schematic view illustrating an alternative embodiment of the present invention.

[0027] FIG. 9 is a top view illustrating an alternative post.

[0028] FIG. 10 is a top view illustrating an alternative post.

[0029] FIG. 11 is a top view illustrating an alternative post.

[0030] FIG. 12 is a top view illustrating an alternative post combined with at least one wall.

[0031] FIG. 13 is a top view illustrating an alternative post combined with at least one wall.

[0032] FIG. 14 is a top view illustrating an alternative post combined with at least one wall.

[0033] FIG. 15 is a side view illustrating an alternative embodiment of the present invention.

[0034] FIG. 16 is a side view illustrating an alternative embodiment of the present invention.

[0035] In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or terms similar thereto are often used. They are not limited to direct connection, but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.

DETAILED DESCRIPTION OF THE INVENTION

[0036] U.S. provisional application Ser. No. 62/281,938 filed Jan. 22, 2016, which is the above claimed priority application, is incorporated herein by reference.

[0037] One example of the structure described herein is the surround 8 shown in FIGS. 1-4 with four substantially identical posts 10, 12, 14 and 16 disposed at four corners. Four sets of three horizontally mounted, vertically-stacked planks 20a-d, 22a-d and 24a-d are mounted at their opposing ends to respective pairs of the posts 10-16. The planks form walls and the posts retain the walls in position so the surround 8 can retain or screen items behind the walls. Between the posts 10 and 12 are the planks 20a, 22a and 24a. Between the posts 12 and 16 are the planks 20b, 22b and 24b. Between the posts 14 and 16 are the planks 20c, 22c and 24c. Between the posts 10 and 14 are the planks 20d, 22d and 24d. The orientation of some of the planks is shown in FIGS. 2 and 3, and the location of the planks 22b and 24b are the same as the location of planks 22d and 24d, but between the posts 12 and 16 rather than the posts 10 and 14.

[0038] The corner posts 10-16 may be vertically oriented as shown in FIGS. 1-4, such as by extending a lower end (not shown) into soil, concrete or any other substrate. Alternatively, the corner posts 10-16 may rest upon a patio 18 or other surface that is at ground level. The corner posts 10-16 have longitudinal slots and/or grooves into which the ends of the planks are inserted, as described in more detail below, to retain the planks solidly and until such time as the planks are deliberately removed therefrom.

[0039] The planks may be mounted at their ends to the posts and form walls, in the example shown and described, that may serve to contain items, such as toys or tools, within the surround 8, and/or may serve to screen from view one or more items within the walls, such as an air-conditioning unit or a pool pump. The posts maintain the vertical orientation of the planks, and the planks screen from view, or restrain, items within.

[0040] As shown in FIGS. 1 and 3, the posts 14 and 16 are spaced from the posts 10 and 12, and the planks 20c, 22c and 24c, which are parallel to the planks 20a-24a, extend between, and are attached to, the posts 14 and 16. Furthermore, the planks 20d, 22d and 24d extend between, and attach to, the posts 10 and 14, and they are parallel to the planks 20b, 22b and 24b that extend between, and attach to, the posts 12 and 16. The posts 10-16 may be positioned at corners of an imaginary rectangle, with predetermined distances between next adjacent posts, and with the planks of similar lengths mounted to and disposed between the posts forming the sides of the surround 8. In this manner, a containment system is formed that, when viewed from the top, is rectangular. This containment system may form a flower box or any other container.

[0041] A section view through the line A-A of FIG. 2 is shown in FIG. 3, in which the planks 20c-24c and the planks 20a-24a held in the posts 10 and 14 are sectioned. FIG. 3 shows a magnified view of an encircled portion. A stiffener 34 is placed between, and inserted into grooves 40a and 42a formed in, the edges of the adjacent planks 20a and 22a, respectively, to stiffen the entire wall made up of the planks 20a-24a. The stiffener 34 mechanically attaches the planks 20a and 22a that are adjacent to one another, thereby binding the planks 20a and 22a together so they reinforce one another. The stiffener 34 also stiffens the wall by having substantial thickness, thereby functioning as an I-beam that is added to the planks 20a and 22a. The stiffener 34 may be made of extruded aluminum, stainless steel, fiber-reinforced polymer composite or other strong material.

[0042] Other similar stiffeners are attached to, and stiffen, all adjacent pairs of planks. Thus, just as the planks 20a and 22a each receive a tongue 30a and 32a, respectively, of the stiffener 34 as shown in FIG. 2, all plank edges that are adjacent another plank edge may be slotted to receive a similar stiffener. The stiffeners stiffen the walls, and prevent soil and/or other particulate matter contained in the surround 8, so that particulate matter does not flow past the planks and stiffeners. The stiffeners prevent items hidden by the planks from being visible through cracks between adjacent planks. The stiffener 34 and its identical cousins shown herein are optional.

[0043] As shown in FIG. 4, the corner post 10 is shown from a top view with the planks 20a and 20d mounted at their ends to the post 10. A post cap may cover the top of the post 10 during normal use so the interior thereof is not visible or exposed to weather. The corner post 10 with attached planks is representative of the posts 12-16 and their respective attached planks, and therefore these other posts and planks are not described herein in detail.

[0044] The ends of each of the planks 20a and 20d may insert into longitudinal slots or channels 50a and 50d that are formed in adjacent sides, and along the entire length, of the post 10. The channels may be integrally formed in the post 10, such as during manufacture, and the post 10 may be made of aluminum extruded through a mold having a void cross section similar to the shape of the post 10 shown in FIG. 4. The channels 50a and 50d are defined by the post material having a cross-sectional shape shown in FIG. 4, which channels 50a and 50d receive the ends of the respective planks 20a and 20d. In this manner, the ends of the planks 20a and 20d may simply be retained in the channels 50a and 50d, respectively, by friction, such as between the opposing channel sidewalls.

[0045] Alternatively, each plank may have a fitting removably or integrally (such as by simultaneous molding during manufacture) mounted to each end thereof, with each fitting cooperating mechanically with structures that define the channels 50a and 50d. It is contemplated that two or more planks may be mounted to or within a single fitting, and the fitting mounted in a channel in a post.

[0046] In a preferred embodiment, the fittings 60a and 60d are mounted to the respective ends of the planks 20a and 20d, and similar fittings are mounted to all other plank ends that are retained within channels in the posts 10-16. The fittings 60a and 60d, which may be generally U-shaped in cross-section, mount to the ends of the planks 20 and 20a, respectively, by inserting the end of the plank into the void formed therein. A respective fastener, such as the screws 62a and 62d, extend through the fittings 60a and 60d into a respective end of each of the planks 20a and 20d. Any fastener is contemplated, but screws, adhesive and rivets are examples. The ridges 52a,d and 54a,d project inwardly from the respective channels 50a and 50d, defining pairs of ridges with tips spaced apart substantially equal to, or slightly greater than, the thickness of the planks 20a and 20d, but less than the width of the fittings 60a and 60d. The distance between a pair of tips is referred to as the ridge gap.

[0047] The fittings 60a and 60d are the same width or are narrower than the portions of the channels into which they are inserted in an operable position, but are at least as wide as the ridge gaps, which are the spaces between the tips of the ridges 52a,d and 54a,d. This relationship causes the fittings 60a and 60d to be retained in the channels 50a and 50d, respectively, on the opposite side of the ridges from the remainder of the planks. In the embodiment illustrated, the end of the plank may be considered a leg with the fitting considered a foot that forms an enlarged portion that prevents the wall from coming out of the channel along the plane of the wall, other than along the length of the channel. This configuration permits the fittings and their respective planks to be slid along the length of the channels 50a and 50d into place in the post 10 during installation and removal. Typically, this is a tight fitment that allows sliding along the length of the channels 50a and 50d under the force of average human strength, but prevents substantial movement of the planks relative to the posts in any direction except along the lengths of the channels. Once the planks are in position, they remain there due to the requirement for deliberate sliding along the channels for removal. Each wall end that is mounted in a post slot may have a fitting that provides a leg portion and a foot portion.

[0048] Thus, a method of constructing the surround 8 may include the positioning of each post 10-16, preferably spaced from one another, and each of the planks being placed with one end in one channel and an opposite end in a facing channel of another post. This process is repeated until the surround is complete. If desired, a fitting may be mounted to the end of each plank, and the insertion step carried out by inserting the leg portion and foot portion at a side of a slot or channel, and then forcing the wall along the slot's length with the foot portion deeper than the leg portion, until the wall is in the desired longitudinal position in the slot. In a contemplated method, the first, typically lowest, layer of planks is inserted into the channels of opposing posts, and a stiffener is placed on the exposed top edge of each plank, if needed. Then another plank is placed on top of the first (lowest) plank with its slot receiving the stiffener. This process is repeated for the entire second layer of planks. This process of inserting a stiffener is repeated by placing a stiffener in the slot on a top edge of the second layer of planks, and a third layer of planks is installed with slots in their lower edges receiving the top of the second stiffeners. This can continue for each desired layer. Top and bottom planks typically do not have a stiffener on top and bottom sides, respectively, but each plank that is adjacent two other planks may have a stiffener on both of its sides. A floor or cover may be mounted to one or more of the posts or planks, and such cover may be hinged. A clasp or other structure that permits locking of the surround 8 may also be used in a conventional manner.

[0049] It is contemplated that a single fitting may be mounted to two or more planks and one or more stiffeners. Thus, a method of constructing a surround may include the positioning of each post, preferably spaced from one another. Each of the planks is placed with one end in a first fitting and an opposite end in a second fitting. In a contemplated method, the first, typically lowest, plank is inserted into the fittings, and a stiffener, if needed, may be placed in a slot on the exposed top edge of the first plank. Then a second plank is placed on top of the first (lowest) plank with the second plank's slot receiving the stiffener. This process of inserting a stiffener is repeated by placing a stiffener in the slot on a top edge of the second plank, and a third plank is installed with the slot in its lower edge receiving the top of the second stiffener. Once the fitting is mounted to all the planks (and stiffeners, if desired), the fittings at opposite ends of the wall may be mounted in the post channels by inserting the first and second fittings at sides of slots or channels in the posts. The entire wall is then forced along the slots' lengths with the foot portion deeper than the leg portion, until the wall is in the desired longitudinal position in the slots.

[0050] If the span between corner posts is too long for the strength of the planks, even if stiffeners are used, one or more mid-posts, such as the mid-post 70 shown in FIG. 5, may be used. The mid-post 70 is substantially similar to the posts 10-16, except that it has structures on opposite sides that form opposing channels 70e and 70f. The planks described herein may mount to mid-posts 70, and all other posts described herein, in the same manner as described herein for the corner post 10. The ends of the planks are inserted into the channels 70e and 70f as described above for insertion into the channels of the corner posts 10-16. However, instead of the planks being oriented at about a 90 degree angle to one another, the planks are aligned in a single plane that intersects the mid-post 70. The mid-post 70 may be inserted into the ground or attached to another structure as with the corner posts 10-16.

[0051] The surround 8 is shown and described above in relation to FIGS. 1-4, a surround or container that is useful for any purpose may be readily constructed using four posts 10-16 and a plurality of planks 20-24a-d. In an even more basic embodiment, a fence may be constructed according to the invention, and such a fence may use a structure that resembles one side of the surround 8, such as that shown in FIG. 2 with two posts 14 and 16, and one wall. This fence may be used to screen from view an unsightly mechanical item, such as an air-conditioning unit. In this case, the fence is formed of two end posts and a wall, such as can be made up of three planks inserted in the posts. The corner posts 10-16, and the mid-post 70, all of which have two channels, would not be as attractive for such a purpose as posts that have only a single channel, such as the member 80 shown in FIG. 6. The member 80 has a single channel 80g that is substantially the same as the channels 50a and 50d formed in the post 10.

[0052] The member 80 may also be used as a top and/or bottom rail that extends horizontally between vertical posts, as shown in the fence 500 of FIG. 16. A wall may be made of one or more vertical planks 520 with lower ends that rest in the member 80 with its channel 80g upwardly oriented and serving as a bottom rail. Another member 510, which may be identical to the member 80, may serve as a top rail and is disposed with its channel downwardly oriented with the top ends of the vertical planks 520 inserted in the channel. Stiffeners 530 may be inserted into slots formed in the adjacent edges of the vertical planks 520 to eliminate any leaks in the wall. The top and bottom rails 510 and 80 are inserted at their ends into channels formed in the vertical posts 512 and 514, which channels are similar to the channels shown in FIG. 4. In the embodiment of FIG. 16, the wall is made up of the top and bottom rails 510 and 80, the planks 520 and the stiffeners 530, if stiffeners are used.

[0053] FIG. 7 shows a T-shaped post 90 that has structures defining the channels 90h,i,j that receive three walls at 90 degree angles to one another. Such a post 90 may be used as a mid-post in a structure in which perpendicular divider walls are desired. The T-shaped post 90 allows one to construct a container or surround with walls that divide the container into multiple sections, as shown in FIG. 8. Four posts 110, 112, 114 and 116 may be mounted at corners of an elongated rectangle, and two T-shaped posts 90 and 100 may be mounted midway along longer, opposing walls 120a, 120b, 120c, 120d, 120e and 120f between the corners. Thus, a surround 108 may be constructed having two or more chambers 92 and 94 with a wall 96 separating the chambers. The wall 96 inserts into the channels of the posts 90 and 110 in a manner described herein.

[0054] With regard to the embodiment shown in FIGS. 1-4, any number of planks can be oriented vertically along the height of the posts 10-16, and this variability illustrates the modularity of the system. One example of a plank is a 16 polymer deck board, with three such boards making the wall with a height of about 18 inches taking into consideration the stiffeners and the fact that a 16 board is nominally 5.5 inches wide. Any planks of any common dimension, such as 14, 26, etc., or any dimension that is not common, may be used with the posts 10-16 to construct a container or surround of virtually any size. A single sheet, such as plywood or glass, may be used as an alternative to the planks. Polymer decking planks are contemplated, as are virtually any material known to be suitable to outdoors use.

[0055] Alternative posts are shown in FIGS. 9-13. For example, a corner post 200 for use with a wall that has essentially the same thickness as the post 200 is shown in FIG. 9. A similar corner post 210 is shown in FIG. 10 having a larger radius of curvature on the corner facing away from the two channels. The post 220 of FIG. 11 is similar to the post of FIG. 9, but with a larger depth and thickness than the wall that inserts into the channels. The posts mid-post 300, corner post 310 and end post 320 shown in FIGS. 12, 13 and 14, respectively, match the corner posts 10-16 of FIGS. 1-4, and are shown with walls inserted therein.

[0056] Another alternative embodiment of the present invention is shown in FIG. 15. As noted above, the post and wall components can be combined to form a planter 410, and a foraminous or perforated grid 420 can be mounted to one side of the planter 410. Such a grid 420 may be screen or hardware cloth mounted within a rigid, rectangular frame that is mounted to the planter 410. The grid 420 allows climbing plants growing in soil held by the planter 410 to climb up the grid 420. This grid 420 may be mounted to the wall or the posts. In an example, posts that are similar to the post 220 shown in FIG. 11 are used in the planter 410, and the grid 420 is mounted by screwing the grid to the protuberance 222 on two of the adjacent posts of the planter 410.

[0057] This detailed description in connection with the drawings is intended principally as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and that various modifications may be adopted without departing from the invention or scope of the following claims.