Pre-fabricated outdoor column

Abstract

A pre-fabricated outdoor column assembly with an outer wall having the appearance of masonry. The pre-fabricated column assembly includes a tubular member with an insert disposed inside the tubular member. The insert has an opening for receiving a mounting post and is disposed in spaced apart relation to the ends of the tubular member such that a first space between the insert and the tubular member and a second space between the insert and the tubular member are formed.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Patent Application No. 60/592,083 filed on Jul. 28, 2004, entitled “Pre-fabricated Outdoor Column,” which is incorporated herein by reference.

FIELD OF INVENTION

The present invention relates to outdoor columns for use as free-standing landscape pillars, fencing columns, mailbox support columns and commercial sign support columns.

BACKGROUND OF THE INVENTION

Outdoor columns are typically constructed with masonry building materials such as concrete, cement mortar, reinforcing steel bar, clay, marble, brick, stone or stackable pre-cast concrete block of various shapes to achieve a column. Many of these materials are susceptible to cracking, scaling, effluorescence and hydro-freeze expansion. Also, these materials typically require a large foundation to support the weight of the building materials (typically 300-400 lbs.). These materials require extensive labor, packaging and heavy equipment to transport from suppliers to the installation site. Accordingly, there is a need for an outdoor column that provides a durable, decorative, versatile, relatively inexpensive, and easy to install design for use in exterior landscape, fencing and sign support applications.

SUMMARY OF THE INVENTION

The present invention meets the above-described need by providing a multi-purpose, outdoor engineered column system that is prefabricated for rapid installation in the field.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:

FIG. 1 is a perspective view of the core of the present invention;

FIG. 2 is a top perspective view of the core of the present invention;

FIG. 3 is a perspective view of a column of the present invention shown in a mailbox application;

FIG. 4 is a perspective view of a column of the present invention shown in a commercial sign application;

FIG. 5 is a perspective view of a column of the present invention with a light kit installed;

FIG. 6 is a perspective view of a column of the present invention having a simulated brick surface; and,

FIG. 7 is a perspective view of a mounting post attached to a concrete pad.

DETAILED DESCRIPTION

Referring to FIG. 1, a core 10 is typically rectangular with four side walls 12, 14, 16, and 18 joined at the corners to form a hollow structure with an inside cavity 19. The four walls 12, 14, 16, 18 may be joined at ninety degree keyed corners and bonded together by commercially available adhesives or the like as will be evident to those of ordinary skill in the art. The walls 12, 14, 16, and 18 may be molded from suitable plastic materials such as polystyrene, polyethylene, or polyurethane resins. The molding processes include, but are not limited to, injection molding and rotocasting (rotational molding). Molding provides for speed of manufacture, however, other methods of forming the walls may also be suitable. The outside surfaces 21 of the walls 12, 14, 16, and 18 are provided with surfaces textures that resemble traditional brick, paneled stucco, natural stone or the like. The outside surfaces 21 are provided with an exterior hard shell coating to provide the appropriate colors for the particular design and to provide a coating to provide protection for use in outdoor environments. By way of example only, the exterior coatings for the walls 12, 14, 16, 18 are a combination of commercially available polyurea base coating, acrylic bonding primer and an exterior insulation finishing system (EIFS) textured finish coating. The EIFS coating is a textured 100% acrylic polymer finish coat used in both residential and commercial construction. As an alternative, the walls and surface texture for some of the columns such as stone-type may be formed integrally in a rotocasting process where the textures and coloring would be inherent in the polyethylene or polyurethane resin compound.

In the example shown, the top 20 and bottom 22 are square-shaped and open. The inside cavity 19 is provided with an insert 24. The insert 24 may be rectangular shaped with outside dimensions matching the inside dimension of the cavity 19 such that the insert 24 may be disposed snugly inside the cavity 19. The insert 24 may be attached inside the cavity 19 by adhesives or the like as will be evident to those of ordinary skill in the art. The insert 24 has an opening 26 disposed along a central longitudinal axis. The opening 26 is sized to receive a standard 4″×4″ post. The opening 26 is also provided with at least one conduit raceway 28 defined along the edge of the opening 26 such that conduit(not shown) can be run along the outside of the post inside the insert 24. The electrical conduit/wire passageways or raceways 28 are designed to allow for electrical conduit or underground rated wire to be installed within the column 39 (FIG. 3) for supplying electrical power to an optional light fixture kit 40 (FIG. 3), electrical outlet kit, or illuminated house number kit.

As shown in FIG. 1, the insert 24 is spaced apart from the bottom 22 of the side walls 12, 14, 16, 18 such that a space 30 is formed below the insert 24. The space 30 provides for a degree of flexibility with. regard to the position of the conduit for applications such as lights or the like.

The core 10 is also provided with a space 33 extending to the top 20. The space 33 provides an area for a mailbox 31 (FIG. 3) to be inserted into the core 10 of the finished column 39 as shown in FIG. 3.

Turning to FIG. 2, wall 18 may be provided with an opening 36 in the shape of a mailbox. The opening 36 receives the mailbox 31 and newspaper box (not shown) which is disposed above the post when the column is installed. The conduit raceways 28 may be disposed on different sides of the opening 26 such that the conduit is not obstructed by the mailbox 31.

The structure described above for the core 10 provides the end user with the ability to rapidly install the finished product over a commonly available 4″×4″ wood, PVC, steel or aluminum post installed in the ground. The post may be initially installed into an 8″-10″ hole that is augured in the ground. The post is inserted into the hole to the appropriate depth depending on the local building codes with regard to the frost line. The post is secured by backfilling with commonly available pre-mixed concrete. The prefabricated column 39 is then mounted over the installed post and bonded to the post using commercially available exterior rated adhesives or the like. Using a 4″×4″ wood, PVC, aluminum or steel post provides a safe “break away” feature in the event that an moving vehicle comes into contact with the prefabricated column.

The columns are designed to accept various accessory devices that are field mounted to enhance the usefulness of the column such as a mailbox kit, a light fixture kit, a light fixture mounting base kit, a plant holder bracket and illuminated house number display.

In FIG. 3, a column 39 having a mailbox 31 and a lighting kit 40 is shown. The lighting kit 40 is mounted on a top cover 44 that engages with the top of the side walls 12, 14, 16, 18 to cover opening 20.

Turning to FIG. 4, a pillar 50 for supporting one side of a commercial sign (not shown) has an opening 53 on the side where the sign is inserted. Opening 53 extends through the core and insert of pillar 50 such that a bracket (not shown) can be inserted into the opening and attached to the post at one end and attached to the surface of the outdoor signage at the opposite end. Accordingly, the bracket and the post are load bearing and not the pillar 50. Except for the opening 53, the core and insert are similar to the core and insert shown in FIG. 1.

The pillar 50 is slid over a 4″×4″ aluminum or steel post set in concrete to the appropriate frost level to support the load of the sign. The bracket is bolted to the post once it is inserted into the opening 53 on the side of the pillar 50. The opposite end is bolted to the finished surface of the outdoor signage.

In FIGS. 5 and 6, alternate versions of the designs for the columns are shown. In FIG. 5, column 60 is a paneled stucco version having a top cover 44 with a light kit 40 installed therein. In FIG. 6 a brick column 70 is shown with a plain top cover 80.

As shown in FIG. 7, in addition to the post hole mounting, the column of the present invention may be field mounted to existing concrete footers, foundations, pads, sidewalks, patios, driveways, walkways, or asphalt parking lots by using optional pad mounting brackets 90 that are attached to the bottom of a mounting post 93. The brackets 90 are attached to a concrete pad 99 by commercially available masonry fasteners or the like as will be evident to those of ordinary skill in the art. Other shapes of brackets and mounting hole patterns including a single bracket may also be suitable.

While the invention has been described in connection with certain embodiments, it is not intended to limit the scope of the invention to the particular forms set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

Claims

1. A pre-fabricated outdoor column assembly, comprising:

an elongate tubular member having at least one inner wall, at least one outer wall, a first end and a second end disposed opposite the first end, the at least one outer wall having the appearance of masonry; and,

an insert having a first end and a second end, the insert disposed inside the tubular member, the insert disposed adjacent to the at least one inner wall of the tubular member, the insert disposed in spaced apart relation to the first and second ends of the tubular member such that a first space between the insert and the first end of the tubular member and a second space between the insert and the second end of the tubular member are formed, the insert having a opening sized to receive a mounting post

2. The pre-fabricated, outdoor column assembly of claim 1, wherein the tubular member further comprises an opening for receiving a mailbox into the first space in the tubular member.

3. The pre-fabricated, outdoor column assembly of claim 1, wherein the insert further comprises a raceway extending from the first end of the insert to the second end of the insert such that a conduit extending from the first space to the second space is capable of being disposed through the raceway.

4. The pre-fabricated, outdoor column assembly of claim 1, wherein the opening in the insert is defined by at least one first wall defining a first opening for receiving the post and at least one second wall forming a raceway disposed adjacent to the first wall such that conduit can be run inside the insert along an outside surface of the mounting post

5. The pre-fabricated, outdoor column assembly of claim 1, wherein the at least one outer wall of the tubular member is coated with an elastomeric hard shell coating.

6. The pre-fabricated, outdoor column assembly of claim 5, wherein the hard shell coating comprises a polyurea based coating.

7. The pre-fabricated, outdoor column assembly of claim 6, wherein the coating is applied by spraying.

8. The pre-fabricated, outdoor column assembly of claim 1, wherein the tubular member is formed by rotocasting.

9. The pre-fabricated, outdoor column assembly of claim 1, wherein the tubular member is formed by molding.

10. The pre-fabricated, outdoor column assembly of claim 1, further comprising a cap having a light fixture disposed therein, the cap capable of being attached to the column assembly at the first end of the tubular member.

11. The pre-fabricated, outdoor column assembly of claim 1, wherein the mounting post is an elongate vertical post disposed in the ground

12. The pre-fabricated, outdoor column assembly of claim 1, wherein the mounting post is an elongate vertical post attached to a concrete surface.

13. The pre-fabricated, outdoor column assembly of claim 1, wherein the column assembly has an elongate opening in the tubular member and has a corresponding opening in the insert such that one end of signage is capable of being attached to the mounting post.

14. The pre-fabricated, outdoor column assembly of claim 1, wherein the mounting post is a standard 4″×4″ post

15. The pre-fabricated, outdoor column assembly of claim 1, wherein the at least one outer wall has the appearance of brick.

16. The pre-fabricated, outdoor column assembly of claim 1, wherein the at least one outer wall has the appearance of paneled stucco.

17. The pre-fabricated, outdoor column assembly of claim 1, wherein the at least one outer wall has the appearance of stone.

18. The pre-fabricated, outdoor column assembly of claim 1, further comprising an illuminated house number display disposed in the column assembly.

19. The pre-fabricated, outdoor column assembly of claim 1, further comprising an electrical outlet disposed in the column assembly.

20. The pre-fabricated, outdoor column assembly of claim 1, wherein the tubular member is formed from four walls joined at ninety degree, keyed corners.

21. The pre-fabricated, outdoor column assembly of claim 1, wherein the tubular member further comprises an opening for receiving a newspaper box.

22. A pre-fabricated, outdoor column assembly, comprising:

an elongate tubular member having at least one inner wall, at least one outer wall, a first end, and a second end disposed opposite the first end, the at least one outer wall having the appearance of masonry, the at least one inner wall of the tubular member defining an opening extending from the first end to the second end of the tubular member;

an insert disposed inside the tubular member in spaced apart relation to the first and second ends of the tubular member such that a first space between the insert and the first end of the tubular member and a second space between the insert and the second end of the tubular member are formed, the insert having a first end and a second end, the insert having at least one first inner wall defining an opening extending from the first end to the second end, the opening sized to receive a mounting post, the insert having at least one second inner wall defining a raceway such that conduit may be disposed through the insert from the first space to the second space; and,

a cap sized to fit onto the first end of the tubular member.

23. The pre-fabricated, outdoor column assembly of claim 22, wherein the tubular member further comprises an opening for receiving a mailbox into the first space in the tubular member.

24. The pre-fabricated, outdoor column assembly of claim 23, wherein the mailbox is attached to the top surface of the mounting post.

25. The pre-fabricated, outdoor column assembly of claim 22, wherein the insert further comprises a raceway extending from the first end of the insert to the second end of the insert such that a conduit extending from the first space to the second space is capable of being disposed through the raceway.

26. The pre-fabricated, outdoor column assembly of claim 22, wherein the opening in the insert is defined by at least one first wall defining an opening for receiving the post and at least one second wall forming a raceway disposed adjacent to the first wall such that conduit can be run inside the insert along an outside surface of the mounting post.

27. The pre-fabricated, outdoor column assembly of claim 22, wherein the at least one outer wall of the tubular member is coated with an elastomeric hard shell coating

28. The pre-fabricated, outdoor column assembly of claim 27, wherein the hard shell coating comprises a polyurea based coating.

29. The pre-fabricated, outdoor column assembly of claim 28, wherein the coating is applied by spraying

30. The pre-fabricated, outdoor column assembly of claim 22, wherein the tubular member is formed by rotocasting.

31. The pre-fabricated, outdoor column assembly of claim 22, wherein the tubular member is formed by molding.

32. The pre-fabricated, outdoor column assembly of claim 22, further comprising a cap having a light fixture disposed therein.

33. The pre-fabricated, outdoor column assembly of claim 22, wherein the mounting post is an elongate vertical post disposed in the ground.

34. The pre-fabricated, outdoor column assembly of claim 22, wherein the mounting post is an elongate vertical post attached to a concrete surface.

35. The pre-fabricated, outdoor column assembly of claim 22, wherein the column assembly has an elongate opening in the tubular member and has a corresponding opening in the insert such that one end of signage is capable of being attached to the mounting post.

36. The pre-fabricated, outdoor column assembly of claim 22, wherein the mounting post is a standard 4″×4″ post.

37. The pre-fabricated, outdoor column assembly of claim 22, wherein the at least one outer wall has the appearance of brick.

38. The pre-fabricated, outdoor column assembly of claim 22, wherein the at least one outer wall has the appearance of paneled stucco.

39. The pre-fabricated, outdoor column assembly of claim 22, wherein the at least one outer wall has the appearance of stone

40. The pre-fabricated, outdoor column assembly of claim 22, further comprising an illuminated house number display disposed in the column assembly.

41. The pre-fabricated, outdoor column assembly of claim 22, further comprising an electrical outlet disposed in the column assembly.

42. The pre-fabricated, outdoor column assembly of claim 22, wherein the tubular member is formed from four walls joined at ninety degree keyed corners.

43. The pre-fabricated, outdoor column assembly of claim 22, wherein the tubular member further comprises an opening for receiving a newspaper box.

44. A method of constructing an outdoor column, comprising:

providing an elongate tubular member having at least one inner wall, at least one outer wall, a first end and a second end disposed opposite the first end, the at least one outer wall having the appearance of masonry;

providing an insert having a first end and a second end and at least one inner wall defining an opening extending from the first end to the second end;

attaching the insert inside the tubular member adjacent to the at least one inner wall of the tubular member, the insert disposed in spaced apart relation to the first and second ends of the tubular member such that a first space between the insert and the first end of the tubular member and a second space between the insert and the second end of the tubular member are formed, the tubular member and insert forming a prefabricated, outdoor column;

excavating a hole in the ground;

anchoring a vertical post to the hole;

placing the prefabricated, outdoor column over the post such that the post is received by the opening in the insert; and,

attaching the prefabricated, outdoor column to the post.

45. The method of claim 44, wherein the tubular member first comprises an opening for receiving a mailbox into the first space in the tubular member.

46. The method of claim 45, wherein the mailbox is attached to a top surface of the mounting post.

47. The method of claim 44, wherein the insert further comprises a raceway extending from the first end of the insert to the second end of the insert such that a conduit extending from the first space to the second space is capable of being disposed through the raceway.

48. The method of claim 44, wherein the opening in the insert is defined by at least one first wall defining an opening for receiving the post and at least one second wall forming a raceway disposed adjacent to the first wall such that conduit can be run inside the insert along an outside surface of the mounting post.

49. The method of claim 44, wherein the at least one outer wall of the tubular member is coated with an elastomeric hard shell coating.

50. The method of claim 49, wherein the hard shell coating comprises a polyurea based coating.

51. The method of claim 50, wherein the coating is applied by spraying.

52. The method of claim 44, wherein the tubular member is formed by rotocasting.

53. The method of claim 44, wherein the tubular member is formed by molding.

54. The method of claim 44, further comprising a cap having a light fixture disposed therein, the cap capable of being attached to the first end of the tubular member.

55. The method of claim 44, wherein the mounting post is an elongate vertical post disposed in the ground.

56. The method of claim 44, wherein the mounting post is an elongate vertical post attached to a concrete surface.

57. The method of claim 44, wherein the pre-fabricated column has an elongate opening in the tubular member and has a corresponding opening in the insert such that one end of signage is capable of being attached to the mounting post.

58. The method of claim 44, wherein the mounting post is a standard 4″×4″ post.

59. The method of claim 44, wherein the at least one outer wall has the appearance of brick.

60. The method of claim 44, wherein the at least one outer wall has the appearance of paneled stucco.

61. The method of claim 44, wherein the at least one outer wall has the appearance of stone.

62. The method of claim 44, further comprising an illuminated house number display disposed in the pre-fabricated outdoor column assembly.

63. The method of claim 44, further comprising an electrical outlet disposed in the pre-fabricated, outdoor column assembly.

64. The method of claim 44, wherein the tubular member is formed from four walls joined at ninety degree keyed corners.

65. The method of claim 44, wherein the tubular member further comprises an opening for receiving a newspaper box.

66. A prefabricated outdoor column assembly, comprising:

a hollow body having an outer wall, a top surface and a bottom surface, the outer wall having the appearance of masonry, the body having a first cavity disposed between the bottom and top surfaces, the first cavity having an opening associated with the bottom surface and sized to receive a mounting post, the body having a second cavity larger than the first cavity and disposed between the first cavity and the top surface, the body having a passageway in open communication between the outer wall mid the second cavity, the passageway capable of receiving a structure.