A post & rail assembly

Abstract

A post assembly comprising a base plate and a post member connected to the base plate and extending perpendicularly from it. The post member includes an at least partially hollow body having a top end and a bottom end connected to the base plate, with a front portion connected to a rear portion by two opposed side portions. Adjacent to the bottom end, the post member may include cutout portion.

Description

[0001] A POST & RAIL ASSEMBLY

[0002] TECHNICAL FIELD

[0003] [1] The present invention relates to a post and rail assembly for a barrier system, such as a guard rail system.

[0004] BACKGROUND

[0005] [2] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[0006] [3] Post and rail systems are widely used in various applications such as vehicle barriers, guardrails, and protective fencing. Traditional post assemblies are often constructed with rigid materials, such as steel, which, while strong in isolation, tend to introduce several challenges when integrated into larger systems. These challenges primarily arise from the interaction between the rigid posts and the anchoring structures, such as concrete slabs or ground surfaces.

[0007] [4] Rigid post systems typically transfer the majority of the impact forces to the anchor bolts securing the base plate to the underlying surface. This force transfer often results in high peak loads on the anchor bolts during impact events, increasing the likelihood of bolt pullout or structural damage to the support surface. To mitigate these effects, large base plates with widely spaced anchor bolts are sometimes employed. However, this approach introduces its own set of complications.

[0008] [5] An issue with traditional systems is their inability to dissipate impact energy effectively. The rigidity of the posts means that little to no energy is absorbed throughcontrolled deformation, leading to abrupt and damaging force transmission to the anchor system and surrounding structures.

[0009] [6] There is, therefore, a need for a post and rail system that addresses these challenges by providing a more efficient means of managing impact forces while minimizing the structural demands on the supporting surface.

[0010] SUMMARY OF INVENTION

[0011] [7] In an aspect, the invention provides a post assembly comprising:

[0012] a base plate; and

[0013] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0014] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; and

[0015] a cutout portion adjacent the bottom end.

[0016] [8] Preferably, the body is at least partially tapered from the rear portion toward the front portion and toward the top end.

[0017] [9] Preferably, the rear portion comprises two spaced apart members projecting perpendicularly from each of an opposed side portion. Preferably, the rear portion comprises a rear member extending between and connecting the two opposed side portions.

[0018]

[0010] Preferably, the front portion comprises a front member extending between an connecting the two opposed side portions.

[0019]

[0011] Preferably, the post member comprises a substantially hollow body.

[0012] In another aspect, the invention provides a post assembly comprising:

[0020] a base plate; and

[0021] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0022] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; and

[0023] a cutout portion adjacent the bottom end;

[0024] wherein:

[0025] the body is at least partially tapered from the rear portion toward the front portion and toward the top end; and

[0026] the rear portion comprises two spaced apart members projecting perpendicularly from each of an opposed side portion.

[0027]

[0013] Preferably, the base plate includes a forward end and a rearward end. Preferably, the post member is connected to the base plate adjacent the rearward end.

[0028]

[0014] Preferably, the front side is substantially straight or planar. More preferably, the front side is substantially straight or planar between the top end and the bottom end.

[0029]

[0015] Preferably, there is a cutout portion located in each of the opposed side portions.

[0030]

[0016] Preferably, the two spaced apart members projecting perpendicularly from each of an opposed side portion comprise a first rear side member projecting perpendicularly from a first side portion of the two opposed side portions, and asecond rear side member projecting perpendicularly from a second side portion of the two opposed side portions.

[0031]

[0017] Preferably, the post assembly includes one or more gussets connected to the base plate and the front portion of the post member.

[0032]

[0018] Preferably, the post assembly includes a lug connected to the post member. Preferably, the lug is connected to and extends from the front portion of the post member.

[0033]

[0019] Preferably, the post member includes an aperture (a first aperture) for receiving a fastener therethrough to connect the post member to a rail. Preferably, the aperture is located in the front portion. Preferably, the aperture is located adjacent the lug.

[0034]

[0020] Preferably, the post member includes an aperture (a second aperture) as a handhold. Preferably, the aperture is located in the front portion. Preferably, the aperture is located adjacent the top end of the post assembly. Preferably, the aperture is located between the top end and the first aperture.

[0035]

[0021] In another aspect, the invention provides a barrier system comprising:

[0036] a plurality of spaced apart post assemblies, each post assembly comprising: a base plate; and

[0037] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0038] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; and

[0039] a cutout portion adjacent the bottom end; anda rail connected to each of the plurality of spaced apart post assemblies and spanning between the plurality of spaced apart post assemblies to form a barrier.

[0040]

[0022] In another aspect, the invention provides a barrier system comprising:

[0041] a plurality of spaced apart post assemblies, each post assembly comprising: a base plate; and

[0042] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0043] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; and

[0044] a cutout portion adjacent the bottom end;

[0045] wherein:

[0046] the body is at least partially tapered from the rear portion toward the front portion and toward the top end; and

[0047] the rear portion comprises two spaced apart members projecting perpendicularly from each of an opposed side portion; and a rail connected to each of the plurality of spaced apart post assemblies and spanning between the plurality of spaced apart post assemblies to form a barrier.

[0048]

[0023] Preferably, the rail is connected to the front portion of each of the plurality of spaced apart post assemblies.

[0049]

[0024] In another aspect, the invention provides a post assembly comprising:

[0050] a base plate; and

[0051] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to two opposed side portions extending substantially perpendicularly therefrom; and

[0052] a cutout portion adjacent the bottom end.

[0053]

[0025] In another aspect, the invention provides a post assembly comprising:

[0054] a base plate; and

[0055] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0056] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions.

[0057]

[0026] In another aspect, the invention provides a post assembly comprising:

[0058] a base plate; and

[0059] a post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:

[0060] an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to two opposed side portions extending substantially perpendicularly therefrom.

[0061] BRIEF DESCRIPTION OF THE DRAWINGS

[0062]

[0027] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The DetailedDescription is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0063] Figure 1 illustrates a front perspective view of a first embodiment of a post assembly for a barrier system;

[0064] Figure 2 illustrates a rear perspective view of the post assembly of Figure 1; Figure 3 illustrates a rear view of the deformed post assembly of Figure 1 after being impacted;

[0065] Figure 4 illustrates a barrier system having a post assembly and rail;

[0066] Figure 5 illustrates a front perspective view of a second embodiment of a post assembly for a barrier system;

[0067] Figure 6 illustrates a side view of a second embodiment of a post assembly for a barrier system;

[0068] Figure 7 illustrates a rear perspective view of another embodiment of a post assembly; and

[0069] Figure 8 illustrates a rear perspective view of another embodiment of a post assembly.

[0070] DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0071]

[0028] Figures 1 to 4 illustrate a post assembly 100 that absorbs impact from a vehicle upon collision. The post assembly 100 comprises a base plate 1 and a post member 2, with the post member 2 extending perpendicularly from the base plate 1.The base plate 1 includes a forward end 1a and a rearward end 1b, and the post member 2 is connected at or adjacent the rearward end 1b. This configuration ensures the post member's connection to the base plate 1 provides stability while optimizing force distribution during impact.

[0072]

[0029] The base plate 1 is shown as being substantially rectangular but may be any suitable shape for connecting the post member 2 thereto.

[0073]

[0030] The post member 2 includes an at least partially hollow body with a top end 2a and a bottom end 2b that is connected to the base plate 1. The at least partially hollow body may include a hollow section at the bottom end 2b adjacent the base plate 1. In some embodiments, the post member 2 may be substantially or entirely hollow.

[0074]

[0031] The body is defined by a front portion 3 (having by a front member), a rear portion 4 (optionally including one or more rear members), and two opposed side portions 5 and 6 (defined by respective side members), and may be described as having a substantially rectangular cross-section. The ends of the body may be open. The one or more rear members of the rear portion 4 may extend from and, in some embodiments, connect the two opposed side portions 5, 6.

[0075]

[0032] In the illustrated embodiment, the front portion 3 is defined by a substantially straight or planar front member, extending from the top end 2b to the bottom end 2c. This provides a flat surface for a rail to be attached to.

[0076]

[0033] The body may be at least partially tapered from the rear portion 4 toward the front portion 3 and toward the top end 2a such that the rear portion 4 effectively tapers towards the front portion 3 at the top end 2a. This tapering reduces stress concentrations and facilitates the dissipation of forces along the length of the post member, ensuring a gradual and controlled response to impact events. The taperingalso acts as a yielding feature, limiting the transfer of force to the base plate 1 and reducing potential damage to the underlying support surface. From the side, the tapering may be understood by the shape of the members that define the opposed side portions 5 and 6, which include an angled portion 5a and 6a adjoining the rear portion 4 that is angled toward the front portion 3 from the bottom end 2b toward the top end 2a.

[0077]

[0034] The rear portion 4 of the post member 2 may be open or include one or more members.

[0078]

[0035] In some embodiments, the rear portion 4 includes two spaced-apart members projecting perpendicularly from the opposed side portions 5 and 6. As the members are spaced apart, the rear portion 4 of the post member 2 is partially open. These members may comprise a first rear side member 7 projecting from one side portion 5 and a second rear side member 8 projecting from the other side portion 6. This arrangement enhances the rigidity of the rear portion 4, ensuring that it maintains structural integrity during both normal operation and impact events. The spaced-apart configuration further supports the controlled collapse of the post member by directing forces along predefined paths, improving the overall reliability of the assembly.

[0079]

[0036] The spaced apart members may only extend partway along the rear portion 4 of the post member 2 such that a bottom or end of the spaced apart members are spaced apart from the base plate 1.

[0080]

[0037] The rear portion 4 may also be entirely or substantially open. That is, the post member includes an at least partially hollow body defined by a front portion 3 defined by the front member, two opposed side portions 5, 6 defined by the two opposedside members extending perpendicularly (or substantially perpendicularly) from the front member and a substantially open-faced rear portion 4.

[0081]

[0038] In some embodiments, the rear portion 4 may include a rear member 7a that extends between and connects the two opposed side portions 5,6. An example can be seen in Figure 7 showing post assembly 300 where rear member 7a connects the opposed side portions 5, 6 via spaced-apart side members 7, 8. However, in some embodiments, a rear member may be provided that connects to the opposed side portions 5,6 directly.

[0082]

[0039] Post assembly 300 may be substantially similar to post assembly 100 and post assembly 200 except for the inclusion of the rear member 7a and lack of cutout portions adjacent the base plate 1.

[0083]

[0040] The rear member 7a extends partially along the rear portion 4. That is, a bottom or end of the rear member 7a is spaced apart from the base plate 1. The rear member 7a may also not extend to the top end 2a.

[0084]

[0041] As shown, the rear member 7a does not extend to the bottom end 2b. Instead, the rear member 7a extends approximately halfway along the length of the body of the post member 2.

[0085]

[0042] In some embodiments, adjacent to the bottom end 2b of the post member, a cutout portion may be provided. The cutout portion may be located in the opposed side portions 5, 6 and rear portion 4 and are configured to provide controlled deformation of the post assembly 2 in an inwardly collapsing manner.

[0086]

[0043] In some embodiments, there may be no cutouts or cutout portion. An example of embodiments not including the cutouts or cutout portions can be seen in Figures 7 and 8. showing post assembly 300 and post assembly 400, respectively. Post assembly 400 may be substantially similar to post assembly 100, post assembly 200and post assembly 400 except for the lack of cutout portions adjacent the base plate 1 and a partially tapered body. Post assembly 400 can be seen to include the two spaced apart members 7,8 on the rear portion 4 the spaced apart members 7,8 extend to the top end 2a.

[0087]

[0044] The Inventor envisions that embodiments of the post may deform similarly with and without cutout portions at the bottom end.

[0088]

[0045] The cutout portion may include cutouts 9a ,9b located in each of the opposed side portions 5, 6. The cutouts 9a, 9b are substantially right-angled (or square-edged) cutouts located at corners of the body of the post member 2 where the bottom end 2b, rear portion 4, and one of the two side portions 5, 6 meet, adjacent to the rearward end 1b of the base plate 1. The cutouts 9a, 9b may also be described as being formed by a recessed portion or notched portion formed along an edge (or corner) of each side portion 5, 6 where the respective side portion 5, 6 meets the base plate 1 , and where the rear portion 4 does not extend to the base plate 1 such that the rear portion 4 is spaced apart from the base plate 1. In applicable embodiments, the cutouts 5, 6 are such that the bottom or end of the spaced-apart members of the rear portion 4 are also spaced apart from the base plate 1 vertically.

[0089]

[0046] These cutouts 9a, 9b are positioned to guide deformation and collapse during impact, enabling energy to be absorbed effectively while preventing uncontrolled structural failure. In particular, the cutout portions allow the body to collapse inwardly along lines X-X and Y-Y. In use, the cutouts function as yielding points, allowing the sidewalls of the post member to fold inwardly in a controlled manner during impact, thereby enhancing the assembly’s energy absorption capabilities. The design ensures that the collapse is predictable and confined to specific areas of the post member, reducing damage to the base plate 1 and the surrounding environment.Specifically, in combination with the spaced apart members described above, upon impact, the post member 2 collapses inwardly such that the bottom end 2b of the body collapses along lines X-X and Y-Y and the opposed side portions 5, 6 fold inwardly toward each other, driving the ends of the spaced-apart side members 7, 8 adjacent the respective cutout portions 9a, 9b toward each other and downward toward the base plate 1. This is best illustrated in Figure 3 which also shows that the ends of the spaced-apart side members 7, 8 distal to the cutout portions 9a, 9b are urged further apart such that the spaced-apart side members 7, 8 converge as they approach the base plate 1. As a result, these spaced-apart side members are urged inwardly and eventually impact the base plate 1, which acts as a stop mechanism to prevent complete failure of the post assembly. It will be understood that upon certain lesser impacts the spaced-apart side members may be forced towards each other but not fully converge and / or impact the base plate 1. Other embodiments that do not include the spaced-apart members will also deform in a similar manner.

[0090]

[0047] To enhance the connection between the base plate 1 and the post member 2, the post assembly may include a gusset 10. The gusset 10 is connected to the base plate 1 and the front portion 3 of the post member. This gusset 10 reinforces the assembly, preventing bending or distortion of the base plate 1 under heavy loads. By stabilizing the front portion 3, the gusset 10 may be useful in ensuring the post member 2 remains securely anchored to the base plate 1 , even under high-impact conditions. The gusset 10 allows for the sides of the post member 2 to fold inward rather than outward, contributing to predictable deformation and increasing the safety of the structure. In some embodiments, two or more gussets may be provided to further reinforce the assembly. Multiple gussets may be arranged side by side.

[0048] External welding, which may be provided in some embodiments in combination with the gusset or in other embodiments without the gusset, may be useful for controlling the collapse of the post member. Therefore, the body of the post member 2 and the base plate 1 may be welded together. In particular, the body of the post member 2 may be externally welded to the base plate 1. That is, only external-facing portions of the body of the post member 2 are welded to the base plate 1, and there is no internal or inside welding present. Put another way, only the outer perimeter of the post member 2 is welded to the base plate 1, rather than any internal walls of the body of the post member 2.

[0091]

[0049] The post member 2 may further include a lug 11 extending from the front portion 3 of the body. This lug 11 is configured to hold and support a rail 20 (see Figure 4) in place during installation, ensuring that the assembly can be installed with greater ease and precision. The inclusion of the lug 11 provides functional advantages by stabilizing the rail 20 during the assembly process, reducing the likelihood of misalignment and enhancing the system's efficiency during installation.

[0092]

[0050] In some embodiments, the post assembly 100 is configured to support a rail 20 in protective barrier systems. The rail 20 is mounted to the post member 2, which ensures stability and alignment during both installation and operation. The lug 11 on the post member 2 securely holds the rail 20 in place during installation, preventing misalignment and facilitating precise assembly. Once installed, the rail 20 spans multiple post assemblies, distributing impact forces along the structure. During an impact, the post assembly 100 absorbs and dissipates energy through controlled deformation, guided by the cutouts, tapered body, and gusset 10. This process helps maintain the rail’s height and alignment, ensuring that it continues to provide effective containment and protection. By combining structural integrity and energyabsorption, the post assembly and rail work together to form a reliable barrier system.

[0093]

[0051] The rail 20 may take the form of a corrugated steel beam guardrail.

[0094]

[0052] The rail 20 is preferably connected to the post member 2 using a suitable fastener 21 that extends through an aperture in the rail 20 aligned with an aperture 12 formed in the body of the post member 2. The aperture 12 of the body of the post member 2 is preferably located above the lug 11 (that is, towards the top end 2a on the front portion 3 but adjacent the lug 11) so that when the rail 20 rests on the lug 11, the aperture of the rail 20 is naturally aligned with the aperture 12 of the body of the post member 2.

[0095]

[0053] For installation, the base plate 1 also includes an aperture 13 through which an anchoring fastener 14 can be inserted to anchor the post assembly to a support surface 15, such as a road, for example.

[0096]

[0054] The post member 2 may also include a handhold aperture 16 located adjacent the top end 2a. The handhold aperture 16 may be elongate to accommodate the receipt of fingers and / or a palm therethrough to allow the post member 2 to be picked up and carrier comfortably.

[0097]

[0055] Figures 5 and 6 illustrate another embodiment of a post assembly 200 that absorbs impact from a vehicle upon collision. The post assembly of Figure 5 is substantially similar to the post assembly 100 illustrated in Figures 1 and 2 having the same features unless indicated otherwise herein. However, the post assembly 200 is taller (approximately 1.1m) than the post assembly 100 and does not include a handhold aperture. The post assembly 200 includes a second lug 11a and a second gusset 10a.

[0056] The second lug 11a is spaced apart from the first lug 11 vertically along the length of the front portion 3. The second lug 11a is useful for taller embodiments of the post assemblies where multiple rails 20 may be connected to the post assemblies in parallel.

[0098]

[0057] There is also a second aperture 12a located above the second leg 11a to help with securing a rail to the post assembly 200.

[0099]

[0058] Embodiments of the invention provide several advantages that address key shortcomings in the prior art.

[0100]

[0059] The tapered design of the post member reduces stress concentrations and directs deformation during impact, ensuring controlled energy absorption and minimizing damage to surrounding structures.

[0101]

[0060] The inclusion of a cutout portion at the bottom end in some embodiments allows for the controlled collapse, enhancing the post assembly's ability to dissipate impact forces.

[0102]

[0061] Embodiments of the rear portion, with spaced-apart members projecting perpendicularly from the opposed side portions, improve rigidity and guide the post's deformation path, ensuring predictable and reliable performance. Together with the base plate 1 , which anchors the assembly securely and resists deformation, these features provide a robust and efficient solution for absorbing and managing impact forces, offering enhanced safety and durability compared to traditional rigid systems.

[0103]

[0062] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0063] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0104]

[0064] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

CLAIMS1. A post assembly comprising:a base plate; anda post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; anda cutout portion adjacent the bottom end.

2. The post assembly according to claim 1, wherein the body is at least partially tapered from the rear portion toward the front portion and toward the top end.

3. The post assembly according to claim 1 or claim 2, wherein the rear portion comprises two spaced apart members projecting perpendicularly from each of an opposed side portion.

4. The post assembly according to any one of claims 1 to 3, wherein the post member comprises a substantially hollow body.

5. The post assembly according to any one of claims 1 to 4, wherein the base plate includes a forward end and a rearward end.

6. The post assembly according to claim 5, wherein the post member is connected to the base plate adjacent the rearward end.

7. The post assembly according to any one of claims 1 to 6, wherein the front portion is substantially straight or planar.

8. The post assembly according to claim 7, wherein the front side is substantially straight or planar between the top end and the bottom end.

9. The post assembly according to any one of claims 1 to 8, wherein there is a cutout portion located in each of the opposed side portions.

10. The post assembly according to any one of claims 1 to 9, wherein the two spaced apart members projecting perpendicularly from each of an opposed side portion comprise a first rear side member projecting perpendicularly from a first side portion of the two opposed side portions, and a second rear side member projecting perpendicularly from a second side portion of the two opposed side portions.

11. The post assembly according to any one of claims 1 to 10, wherein the post assembly includes a gusset connected to the base plate and the front portion of the post member.

12. The post assembly according to any one of claims 1 to 11, wherein the post assembly includes a lug connected to the post member.

13. The post assembly according to claim 12, wherein the lug is connected to and extends from the front portion of the post member.

14. The post assembly according to any one of claims 1 to 13, wherein the post member includes a first aperture for receiving a fastener therethrough to connect the post member to a rail.

15. The post assembly according to claim 14, wherein the first aperture is located in the front portion.

16. The post assembly according to claim 15, wherein the first aperture is located adjacent the lug.

17. The post assembly according to any one of claims 1 to 16, wherein the post member includes a second aperture as a handhold.

18. The post assembly according to claim 17, wherein the second aperture is located in the front portion.

19. The post assembly according to claim 18, wherein the second aperture is located adjacent the top end of the post assembly.

20. The post assembly according to claim 19, wherein the second aperture is located between the top end and the first aperture.

21. A barrier system comprising:a plurality of spaced apart post assemblies, each post assembly comprising: a base plate; anda post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to a rear portion by two opposed side portions; anda cutout portion adjacent the bottom end;wherein:the body is at least partially tapered from the rear portion toward the front portion and toward the top end; andthe rear portion comprises two spaced apart members projecting perpendicularly from each of an opposed side portion; and a rail connected to each of the plurality of spaced apart post assemblies and spanning between the plurality of spaced apart post assemblies to form a barrier.

22. The barrier system of claim 21, wherein the rail is connected to the front portion of each of the plurality of spaced apart post assemblies.

23. A post assembly comprising:a base plate; anda post member connected to the base plate and extending perpendicular to the base plate, the post member comprising:an at least partially hollow body having a top end and a bottom end connected to the base plate, and a front portion connected to two opposed side portions extending substantially perpendicularly therefrom.

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