Sports board apparatus and method

Abstract

A sports board apparatus, for use with a sports surface and boards, includes posts, a web, and an upper support, each constructed from a roll-formed metal material. Each post has lower and upper ends, and includes two post channels securely nested with one another. Each channel has back and side walls defining a C-shaped channel profile. The web securely engages two posts, and has back and side walls defining a C-shaped web profile. The upper support securely engages two posts adjacent to the upper ends thereof. The upper support, the web, and the posts are secured relative to the boards. The posts are secured relative to the sports surface, with the lower ends adjacent thereto. A method of forming the sports board apparatus includes a post channel roll-forming step, a web roll-forming step, and an upper support roll-forming step.

1 . A sports board apparatus for use with a sports surface and one or more substantially planar boards, said apparatus comprising: 
 a) a plurality of posts, each having a lower end portion and an upper end portion, with each of said posts comprising two elongate post channel members in securely nested relation with one another, with each of said post channel members extending longitudinally upward from said lower end portion to said upper end portion, and with each of said post channel members having a post back wall and two post side walls extending from said post back wall, with said post back wall and said two post side walls being together shaped to define a substantially C-shaped post channel profile;    b) at least one web member extending substantially between and securely engaging at least two of said posts, with said web member having a web back wall and two web side walls extending from said web back wall, with said web back wall and said two web side walls being together shaped to define a substantially C-shaped web profile; and    c) at least one upper support member securely engaging said at least two of said posts substantially adjacent to each said upper end portion of said at least two of said posts;    with each said upper support member, each said web member, and each of said post channel members being constructed from a roll-formed metal material;    wherein each said upper support member and each said web member is operatively securable relative to the boards; and    wherein each of said posts is operatively securable relative to the boards and to the sports surface, with said lower end portion of each of said posts operatively positioned substantially adjacent to the sports surface.    
   
   
       2 . An apparatus according to  claim 1 , wherein said metal material is a light gauge steel material.  
   
   
       3 . An apparatus according to  claim 2 , wherein each of said post channel members has a retention member extending inwardly from one of said post side walls, and wherein said post back wall of each of said post channel members is shaped so as to define a retention depression, such that in said securely nested relation, said retention depression of a first one of said two elongate post channel members receives therewithin a substantial extent of said retention member of a respective other one of said two elongate post channel members.  
   
   
       4 . An apparatus according to  claim 3 , wherein a first member and a second member are selected from a group consisting of each said upper support member, each said web member, and each of said post channel members, with each of said first member and said second member comprising one or more dimpled portions, with each of said dimpled portions of said first member being in said securely nested relation with a respective one of said dimpled portions of said second member, so as to form one or more nested pairs of said dimpled portions.  
   
   
       5 . An apparatus according to  claim 4 , further comprising a plurality of mechanical fasteners securely attaching said first member to said second member, with each of said mechanical fasteners extending substantially through a respective one of said nested pairs of said dimpled portions.  
   
   
       6 . An apparatus according to  claim 5 , wherein each of said mechanical fasteners comprises a head portion and a threaded portion, with each said threaded portion threadingly engaging a respective one of said nested pairs of said dimpled portions, and with a substantial extent of each said head portion being fully received within said respective one of said nested pairs of said dimpled portions.  
   
   
       7 . An apparatus according to  claim 3 , wherein each of said posts and said post channel members extends in a substantially upright direction.  
   
   
       8 . An apparatus according to  claim 7 , wherein each one of said web member and said upper support member extends substantially horizontally.  
   
   
       9 . An apparatus according to  claim 3 , wherein said web member has opposing web end portions and flanged web portions, with each of said flanged web portions extending from substantially adjacent to a respective one of said opposing web end portions, and securely engaging a respective one of said two of said posts.  
   
   
       10 . An apparatus according to  claim 9 , further comprising a plurality of mechanical fasteners securely attaching each of said flanged web portions to said respective one of said two of said posts.  
   
   
       11 . An apparatus according to  claim 3 , further comprising at least one web cover extending substantially between said two of said posts, with said web cover securely engaging said web member and being constructed from said roll-formed metal material.  
   
   
       12 . An apparatus according to  claim 11 , wherein said web cover has a cover back wall and two cover side walls extending from said cover back wall, with said cover back wall and said two cover side walls being together shaped to define a substantially C-shaped cover profile, and with each of said cover side walls having a web retention portion securely engaging said web member over a respective one of said web side walls.  
   
   
       13 . An apparatus according to  claim 3 , wherein said two of said posts comprise a first male end post and a first female end post, with said plurality of posts further comprising a second male end post matingly engaging said first female end post, and with said plurality of posts still further comprising a second female end post matingly engaging said first male end post.  
   
   
       14 . An apparatus according to  claim 13 , wherein one of said post channel members of each said male end post comprises a post mating protuberance, and wherein one of said post channel members of each said female end post comprises a post mating depression, with each said post mating protuberance matingly engaging a respective one said post mating depression in substantially aligned and close-fitting relation.  
   
   
       15 . An apparatus according to  claim 14 , further comprising post securing means for securely attaching said first male end post to said second female end post and for securely attaching said first female end post to said second male end post.  
   
   
       16 . An apparatus according to  claim 3 , wherein said web back wall has a notched web portion defining a web aperture therethrough, and wherein said web member securely engages at least three of said posts, with said three of said posts comprising two end posts and a middle post, with said web member extending substantially between said two end posts, and with said middle post being positioned between said two end posts and being securely received within said web aperture.  
   
   
       17 . An apparatus according to  claim 16 , wherein said upper support member has a notched beam portion defining a beam aperture, and wherein said upper support member securely engages said two end posts and said middle post, with said upper support member being mechanically fastened to said upper end portion of each of said two end posts, and with said middle post being securely received within said beam aperture.  
   
   
       18 . An apparatus according to  claim 3 , wherein said upper support member comprises a support channel member having a support back wall and two support side walls extending from said support back wall, with said support back wall and said two support side walls being together shaped to define a substantially C-shaped support channel profile, with said upper support member further comprising a first beam and a second beam in substantially parallel and spaced relation with said first beam, such that said first beam and said second beam define a beam opening therebetween, with each of said first beam and said second beam being positioned substantially between said two support side walls of said support channel member.  
   
   
       19 . An apparatus according to  claim 18 , wherein each of said first beam and said second beam has a beam back wall and two beam side walls extending from said beam back wall, with said beam back wall and said two beam side walls being together shaped to define a substantially C-shaped beam channel profile, with said beam back wall of said first beam substantially engaging a first one of said support side walls, and with said beam back wall of said second beam substantially engaging a second one of said support side walls.  
   
   
       20 . An apparatus according to  claim 18 , wherein said support back wall has a notched support portion defining a support aperture therethrough, wherein each of said first beam and said second beam has a beam back wall and two beam side walls extending from said beam back wall, wherein each of said beam side walls of each of said first beam and said second beam has a notched beam portion defining a beam aperture, and wherein said upper support member engages at least three of said posts, with said three of said posts comprising two end posts and a middle post positioned between said two end posts, with each of said first beam and said second beam being mechanically fastened to said upper end portion of each of said two end posts, with said support channel member extending substantially between said two end posts, and with said middle post being securely received within said support aperture and within each said beam aperture.  
   
   
       21 . An apparatus according to  claim 20 , wherein each one of said first beam and said second beam has two flanged beam portions, with each of said flanged beam portions extending from a first wall that is selected from the group consisting of said beam back wall and said beam side walls, and with each of said flanged beam portions being mechanically fastened to said upper end portion of a respective one of said two end posts.  
   
   
       22 . An apparatus according to  claim 18 , wherein said support back wall is shaped so as to define two or more pole openings therethrough, with said apparatus further comprising two or more poles and a substantially transparent and substantially planar sheet supported between said poles, with said each of said poles extending through the beam opening and through a respective one of said pole openings, and wherein each of said poles has a pole base that is securely attached relative to said web member.  
   
   
       23 . An apparatus according to  claim 22 , further comprising at least one web cover extending substantially between said two of said posts, with said web cover securely engaging said web member and being constructed from said roll-formed metal material, with said pole base securely attached to said web cover.  
   
   
       24 . An apparatus according to  claim 22 , further comprising at least one substantially planar top cover securely engaging said upper support member in substantially overlying relation substantially adjacent to each said upper end portion of said at least two of said posts, with said poles extending through apertures shaped in said top cover.  
   
   
       25 . An apparatus according to  claim 3 , further comprising at least one bottom channel member extending substantially between and securely engaging each said lower end portion of said at least two of said posts, with said bottom channel member having a bottom channel back wall and two bottom channel side walls extending from said bottom channel back wall, with said bottom channel back wall and said two bottom channel side walls being together shaped to define a substantially C-shaped bottom channel profile, with said bottom channel member being constructed from said roll-formed metal material, and with said bottom channel member being operatively positioned substantially adjacent to the sports surface and being operatively securable relative to the boards and to the sports surface.  
   
   
       26 . An apparatus according to  claim 25 , wherein said bottom channel member extends substantially horizontally.  
   
   
       27 . An apparatus according to  claim 25 , wherein said bottom channel member and at least one of said post channel members of each of said at least two of said posts each comprises one or more dimpled portions, with each of said dimpled portions of said bottom channel member being in securely nested relation with a respective one of said dimpled portions of said at least one of said post channel members of each of said at least two of said posts, so as to form at least two nested pairs of said dimpled portions.  
   
   
       28 . An apparatus according to  claim 25 , further comprising at least one bottom cover having a bottom cover back wall and two bottom cover side walls extending from said bottom cover back wall, with said bottom cover back wall and said two bottom cover side walls being together shaped to define a substantially C-shaped bottom cover profile, and with each of said bottom cover side walls having a bottom channel retention portion securely engaging said bottom channel member over a respective one of said bottom channel side walls, wherein said bottom cover back wall has a notched bottom cover portion defining a bottom cover aperture therethrough, wherein said bottom cover extends substantially between said lower end portion of said two of said posts and is constructed from said roll-formed metal material, and wherein said plurality of posts further comprises a middle post positioned between said two of said posts, with said middle post being securely received within said bottom cover aperture.  
   
   
       29 . A method of forming a sports board apparatus for use with a sports surface and one or more substantially planar boards, said method comprising the steps of: 
 a post channel forming step of roll-forming at least four post channel members by passing first elongate sheets of light gauge steel material through a series of roll-forming post channel tool sets, with passage of said first elongate sheets through each successive one of the post channel tool sets progressively forming said post channel members, such that each of said post channel members has a post back wall and two post side walls extending from said post back wall, with said post back wall and said two post side walls being together shaped to define a substantially C-shaped post channel profile;    a web forming step of roll-forming one or more web members by passing second elongate sheets of light gauge steel material through a series of roll-forming web tool sets, with passage of said second elongate sheets through each successive one of the web tool sets progressively forming said web members, such that each of said web members has a web back wall and two web side walls extending from said web back wall, with said web back wall and said two web side walls being together shaped to define a substantially C-shaped web profile;    an upper support forming step of rbll-forming a plurality of beams by passing a plurality of third elongate sheets of light gauge steel material through a series of roll-forming beam tool sets, with passage of said third elongate sheets through each successive one of the beam tool sets progressively forming said beams;    wherein each of said post channel members is adapted to be in operative securely nested relation with another one of said post channel members to form at least two posts, with each of said posts having a lower end portion and an upper end portion, and with each of said post channel members extending longitudinally upward from said lower end portion to said upper end portion;    wherein each of said web members and each of said beams is adapted to operatively extend substantially between and securely engage said two posts, with each of said beams engaging said two posts substantially adjacent to each said upper end portion of said two posts; and    wherein each of said beams and each of said web members is operatively securable relative to the boards; and    wherein each of said posts is operatively securable relative to the boards and to the sports surface, with said lower end portion of each of said posts operatively positioned substantially adjacent to the sports surface.    
   
   
       30 . A method according to  claim 29 , wherein in said post channel forming step, a retention member and a retention depression are roll-formed on each of said post channel members, with passage of said first elongate sheets through each successive one of said post channel tool sets progressively forming said retention member and said retention depression, such that said retention member extends inwardly from one of said post side walls, and said retention depression is formed in said post back wall, such that in said operative securely nested relation, said retention depression of said each of said post channel members receives therewithin a substantial extent of said retention member of said another one of said post channel members.  
   
   
       31 . A method according to  claim 30 , further comprising a mechanical fastening step of securely attaching a first member to a second member using a mechanical fastener extending substantially therethrough, with each of said first member and said second member being selected from a group consisting of said post channel members, said web members, and said beams.  
   
   
       32 . A method according to  claim 31 , further comprising: 
 a dimpling step, before said mechanical fastening step, of forming one or more dimpled portions in each of said first member and said second member; and    a nesting step, after said dimpling step and before said mechanical fastening step, of securely nesting each of said dimpled portions of said first member in said operative securely nested relation with a respective one of said dimpled portions of said second member, so as to form one or more nested pairs of said dimpled portions;    wherein in said mechanical fastening step, each of said mechanical fasteners extending substantially through a respective one of said nested pairs of said dimpled portions, such that a substantial extent of said each of said mechanical fasteners is fully received within said respective one of said nested pairs of said dimpled portions.