U.S. patent application number 14/708384 was filed with the patent office on 2016-11-17 for interlocking, self-aligning and torque transmitting coupler assembly.
The applicant listed for this patent is PIER TECH SYSTEMS, LLC. Invention is credited to Kevin Kaufman, Michael D. Wilkis.
Application Number | 20160333540 14/708384 |
Document ID | / |
Family ID | 57249477 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160333540 |
Kind Code |
A1 |
Kaufman; Kevin ; et
al. |
November 17, 2016 |
INTERLOCKING, SELF-ALIGNING AND TORQUE TRANSMITTING COUPLER
ASSEMBLY
Abstract
A self-aligning and torque transmitting coupler assembly
includes an outer coupler coupled to a first shaft of and an inner
coupler coupled to a second shaft. The outer coupler comprises an
inner surface having primary and secondary alignment and torque
transmitting features, and the inner coupler comprises an outer
surface having primary and secondary alignment features. The
primary and secondary alignment features are configured to
interlock and facilitate alignment of the first and second shafts
along a common axis in an exemplary application of a foundation
support system.
Inventors: |
Kaufman; Kevin; (Des Peres,
MO) ; Wilkis; Michael D.; (Ellisville, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PIER TECH SYSTEMS, LLC |
Chesterfield |
MO |
US |
|
|
Family ID: |
57249477 |
Appl. No.: |
14/708384 |
Filed: |
May 11, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04G 23/065 20130101;
E02D 7/22 20130101; Y10T 403/7035 20150115; E02D 27/48 20130101;
E02D 5/56 20130101; E02D 27/12 20130101; E02D 5/24 20130101; Y10T
403/7033 20150115; E04G 23/04 20130101; E21B 17/04 20130101; E02D
5/28 20130101; E02D 35/005 20130101; E02D 5/526 20130101; E21B
17/046 20130101 |
International
Class: |
E02D 5/52 20060101
E02D005/52; E02D 5/56 20060101 E02D005/56; E04G 23/06 20060101
E04G023/06; E02D 27/12 20060101 E02D027/12; E02D 27/48 20060101
E02D027/48; E02D 5/24 20060101 E02D005/24; E02D 7/22 20060101
E02D007/22 |
Claims
1. A coupler assembly for connecting a first shaft to a second
shaft, the coupler assembly comprising: an outer coupler configured
to be coupled to the first shaft, the outer coupler comprising an
inner surface formed with at least one primary alignment feature
and at least one secondary alignment feature; and an inner coupler
configured to be coupled to the second shaft, the inner coupler
comprising an outer surface formed with at least one primary
alignment feature and at least one secondary alignment feature;
wherein the primary and secondary alignment features of the outer
coupler are respectively configured to engage the primary and
secondary alignment features of the inner coupler when the outer
surface of the inner coupler and the inner surface of the outer
coupler are assembled and engaged, wherein when the inner coupler
and outer coupler are engaged, an interlocking torque transmission
structure is established between the inner and outer coupler,
wherein each of the primary and secondary alignment features of the
inner coupler and the outer coupler comprises one of a projection
and a recess, wherein the at least one primary alignment feature of
each of the inner coupler and outer coupler is circumferentially
offset from at least one secondary alignment feature in each of the
inner coupler and the outer coupler.
2. (canceled)
3. The coupler assembly in accordance with claim 1, wherein the at
least one secondary alignment feature of the outer coupler
comprises a circumferential projection, and wherein the at least
one secondary alignment feature of the inner coupler comprises at
least one circumferential recess that is configured to receive the
at least one circumferential projection when the outer coupler and
the inner coupler are assembled and engaged.
4. (canceled)
5. The coupler assembly in accordance with claim 1, wherein the
inner coupler comprises a collar comprising a lip surface, and
wherein the outer coupler comprises an end surface configured to
contact the lip surface such that the collar is positioned adjacent
the end surface.
6. The coupler assembly in accordance with claim 5, wherein the
inner coupler comprises a first seating surface extending obliquely
between the outer surface and the collar, and wherein the outer
coupler comprises a second seating surface extending obliquely
between the inner surface and the end surface that is configured to
mate with the first seating surface.
7. The coupler assembly in accordance with claim 1, wherein the at
least one primary alignment feature includes a pair of elongated
ribs in one of the inner coupler and the outer coupler, and wherein
the at least one primary alignment feature comprises a pair of
elongated grooves in the other one of the inner coupler and the
outer coupler.
8. The coupler assembly in accordance with claim 1, wherein the
outer coupler comprises an outer surface including at least one
wing formed thereon, wherein the at least one wing is positioned
proximate the at least one primary alignment feature.
9. The coupler assembly in accordance with claim 1, wherein the
inner coupler includes a pair of first transverse openings and the
outer coupler includes a pair of second transverse openings,
wherein the pair of first transverse openings is aligned with the
pair of second transverse openings when the primary and secondary
alignment features of the inner coupler and the outer coupler are
mated and wherein the pairs of transverse openings in the inner
coupler and the outer coupler respectively facilitate a cross-bolt
connection of the first shaft and the second shaft.
10. (canceled)
11. (canceled)
12. The coupler assembly in accordance with claim 1, wherein the at
least one primary alignment feature extends axially on at least one
of the inner coupler and the outer coupler, and wherein the at
least one secondary alignment feature extends circumferentially on
the other one of the inner coupler and the outer coupler.
13. The coupler assembly in accordance with claim 1, in combination
with the first shaft and the second shaft, wherein at least one of
the first shaft and the second shaft is one of a primary pile and
an extension piece of a foundation support system.
14-27. (canceled)
28. A coupler assembly for connecting a first shaft to a second
shaft, the coupler assembly comprising: an outer coupler configured
to be coupled to the first shaft, the outer coupler comprising an
inner surface formed with at least one primary alignment feature
and at least one secondary alignment feature; and an inner coupler
configured to be coupled to the second shaft, the inner coupler
comprising an outer surface formed with at least one primary
alignment feature and at least one secondary alignment feature;
wherein the primary and secondary alignment features of the outer
coupler are respectively configured to engage the primary and
secondary alignment features of the inner coupler when the outer
surface of the inner coupler and the inner surface of the outer
coupler are assembled and engaged, wherein when the inner coupler
and outer coupler are engaged, an interlocking torque transmission
structure is established between the inner and outer coupler,
wherein each of the primary and secondary alignment features of the
inner coupler and the outer coupler comprises one of a projection
and a recess, and wherein the at least one secondary alignment
feature of the outer coupler comprises a circumferential
projection, and wherein the at least one secondary alignment
feature of the inner coupler comprises at least one circumferential
recess that is configured to receive the at least one
circumferential projection when the outer coupler and the inner
coupler are assembled and engaged.
29. The coupler assembly in accordance with claim 28, wherein the
at least one primary alignment feature of each of the inner coupler
and outer coupler is circumferentially offset from at least one
secondary alignment feature in each of the inner coupler and the
outer coupler.
30. The coupler assembly in accordance with claim 28, wherein the
inner coupler comprises a collar comprising a lip surface, and
wherein the outer coupler comprises an end surface configured to
contact the lip surface such that the collar is positioned adjacent
the end surface.
31. The coupler assembly in accordance with claim 30, wherein the
inner coupler comprises a first seating surface extending obliquely
between the outer surface and the collar, and wherein the outer
coupler comprises a second seating surface extending obliquely
between the inner surface and the end surface that is configured to
mate with the first seating surface.
32. The coupler assembly in accordance with claim 28, wherein the
at least one primary alignment feature includes a pair of elongated
ribs in one of the inner coupler and the outer coupler, and wherein
the at least one primary alignment feature comprises a pair of
elongated grooves in the other one of the inner coupler and the
outer coupler.
33. The coupler assembly in accordance with claim 28, wherein the
outer coupler comprises an outer surface including at least one
wing formed thereon, wherein the at least one wing is positioned
proximate the at least one primary alignment feature.
34. The coupler assembly in accordance with claim 28, wherein the
inner coupler includes a pair of first transverse openings and the
outer coupler includes a pair of second transverse openings,
wherein the pair of first transverse openings is aligned with the
pair of second transverse openings when the primary and secondary
alignment features of the inner coupler and the outer coupler are
mated and wherein the pairs of transverse openings in the inner
coupler and the outer coupler respectively facilitate a cross-bolt
connection of the first shaft and the second shaft.
35. The coupler assembly in accordance with claim 28, wherein the
at least one primary alignment feature extends axially on at least
one of the inner coupler and the outer coupler.
36. The coupler assembly in accordance with claim 28, in
combination with the first shaft and the second shaft, wherein at
least one of the first shaft and the second shaft is one of a
primary pile and an extension piece of a foundation support
system.
37. A coupler assembly for connecting a first shaft to a second
shaft, the coupler assembly comprising: an outer coupler configured
to be coupled to the first shaft, the outer coupler comprising an
inner surface formed with at least one primary alignment feature
and at least one secondary alignment feature; and an inner coupler
configured to be coupled to the second shaft, the inner coupler
comprising an outer surface formed with at least one primary
alignment feature and at least one secondary alignment feature;
wherein the primary and secondary alignment features of the outer
coupler are respectively configured to engage the primary and
secondary alignment features of the inner coupler when the outer
surface of the inner coupler and the inner surface of the outer
coupler are assembled and engaged, wherein when the inner coupler
and outer coupler are engaged, an interlocking torque transmission
structure is established between the inner and outer coupler, and
wherein each of the primary and secondary alignment features of the
inner coupler and the outer coupler comprises one of a projection
and a recess, wherein the inner coupler comprises a collar
comprising a lip surface, and wherein the outer coupler comprises
an end surface configured to contact the lip surface such that the
collar is positioned adjacent the end surface, wherein the inner
coupler comprises a first seating surface extending obliquely
between the outer surface and the collar, and wherein the outer
coupler comprises a second seating surface extending obliquely
between the inner surface and the end surface that is configured to
mate with the first seating surface.
38. The coupler assembly in accordance with claim 37, wherein the
at least one secondary alignment feature of the outer coupler
comprises a circumferential projection, and wherein the at least
one secondary alignment feature of the inner coupler comprises at
least one circumferential recess that is configured to receive the
at least one circumferential projection when the outer coupler and
the inner coupler are assembled and engaged.
39. The coupler assembly in accordance with claim 37, wherein the
at least one primary alignment feature of each of the inner coupler
and outer coupler is circumferentially offset from at least one
secondary alignment feature in each of the inner coupler and the
outer coupler.
40. The coupler assembly in accordance with claim 37, wherein the
at least one primary alignment feature includes a pair of elongated
ribs in one of the inner coupler and the outer coupler, and wherein
the at least one primary alignment feature comprises a pair of
elongated grooves in the other one of the inner coupler and the
outer coupler.
41. The coupler assembly in accordance with claim 37, wherein the
outer coupler comprises an outer surface including at least one
wing formed thereon, wherein the at least one wing is positioned
proximate the at least one primary alignment feature.
42. The coupler assembly in accordance with claim 37, wherein the
inner coupler includes a pair of first transverse openings and the
outer coupler includes a pair of second transverse openings,
wherein the pair of first transverse openings is aligned with the
pair of second transverse openings when the primary and secondary
alignment features of the inner coupler and the outer coupler are
mated and wherein the pairs of transverse openings in the inner
coupler and the outer coupler respectively facilitate a cross-bolt
connection of the first shaft and the second shaft.
43. The coupler assembly in accordance with claim 37, wherein each
of the inner coupler and the outer coupler includes a hollow round
body.
44. The coupler assembly in accordance with claim 37, wherein the
at least one primary alignment feature extends axially on at least
one of the inner coupler and the outer coupler, and wherein the at
least one secondary alignment feature extends circumferentially on
the other one of the inner coupler and the outer coupler.
45. The coupler assembly in accordance with claim 37, in
combination with the first shaft and the second shaft, wherein at
least one of the first shaft and the second shaft is one of a
primary pile and an extension piece of a foundation support system.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to coupler
assemblies for connecting first and second structural elements, and
more specifically to an interlocking, self-aligning and torque
transmitting coupler assembly for connecting foundation elements in
building structure foundation support systems and related methods
for assembling and installing foundation support systems.
[0002] Foundation support stability issues are of concern in both
new building construction and in maintenance of existing buildings.
While much attention is typically paid to the fabrication of a
foundation in new construction to adequately support a building
structure, on occasion foundation support systems are desired to
accomplish the desired stability and prevent the foundation from
moving in a way that may negatively affect the structure. As
buildings age and settle there is sometimes a shifting of the
foundation that can cause damage to the building structure,
presenting a need for lifting or jacking the foundation to restore
it to a level position where repairs to the structure can be made
and further damage to the building structure is prevented. Numerous
foundation support systems and methods exist that may capably
provide the desired foundation stability and/or may capably lift
building foundations to another elevation where they may be
optimally supported. Existing foundation support systems and
methods typically include a pier or piling driven into the ground
proximate a building foundation, leaving a piling projecting
upwards on which a support element or lifting element may be
attached.
[0003] Existing foundation support systems and methods are,
however, disadvantaged in some aspects. For example, it is
sometimes necessary to extend the length of a piling by connection
an extension piece when conditions are such that a pier is driven
deeply into the ground to provide the desired amount of support.
Attaching the piling an extension piece in some existing support
systems involves a coupler having fastener holes that is attachable
to both the piling and the extension piece.
[0004] Because the extension pieces may be many feet long and tend
to be relatively heavy it is often quite difficult to complete the
desired connections with the proper alignment of the fastener holes
in the coupler and the fastener holes in the extension piece so
that the connection can be completed by installing a fastener
through the aligned holes. If the connections are not properly
aligned to make the connection, the integrity of the support system
to provide the proper level of support can be compromised and
system reliability issues can be presented. Accordingly, the needs
of the marketplace have not been completely met with existing
building foundation support systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Non-limiting and non-exhaustive embodiments are described
with reference to the following Figures, wherein like reference
numerals refer to like parts throughout the various drawings unless
otherwise specified.
[0006] FIG. 1 illustrates a perspective view of one embodiment of a
foundation support system interacting with a building
structure.
[0007] FIG. 2 shows a cross-sectional view of a piling assembly for
the system shown in FIG. 1 including a coupler assembly according
to an embodiment of the present invention and including an inner
coupler and an outer coupler.
[0008] FIG. 3 illustrates a perspective view of an inner coupler of
the coupling assembly shown in FIG. 2.
[0009] FIG. 4 illustrates a side view of the inner coupler shown in
FIG. 3.
[0010] FIG. 5 illustrates a bottom view of the inner coupler shown
in FIG. 3.
[0011] FIG. 6 illustrates a cross-sectional view of the inner
coupler taken along line 6-6 in FIG. 4.
[0012] FIG. 7 illustrates a perspective view of the outer coupler
shown in FIG. 2.
[0013] FIG. 8 illustrates a cross-sectional view of the outer
coupler shown in FIG. 7.
[0014] FIG. 9 illustrates a cross-sectional view of the outer
coupler taken along line 9-9 in FIG. 8.
[0015] FIG. 10 illustrates a cross-sectional view of the outer
coupler taken along line 10-10 in FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Exemplary embodiments of interlocking, self-aligning coupler
assemblies to connect structural elements such as foundation
elements of a foundation support system and related methods of
assembling, connecting installing and supporting building
foundation elements are described that address certain problems and
disadvantages in the art. As described below, an interlocking
self-aligning and torque transmitting coupler assembly of the
present invention facilitates a simplified alignment and connection
between, for example, a piling and an extension piece during
assembly of a building foundation support system, while ensuring
that an adequate lifting strength and support is reliably
established by avoiding installation issues that can otherwise be
problematic when subjected to torque to drive the pilings deeper
into the ground. Foundation support elements may therefore be
assembled more quickly and more reliably while reducing labor costs
and simultaneously improving system reliability by avoiding
problematic torque-related issues that can otherwise cause elements
of a foundation support system to deform and negatively impact the
stability of the system and its load bearing capacity.
[0017] More specifically, the support system described herein
includes an interlocking, self-aligning, torque transmitting
coupler assembly that includes first and second couplers and a
plurality of mating alignment and torque transmission features
provided in each coupler that assist in attaching first and second
structural elements to each other with relative ease while ensuring
proper alignment of the connections made, including but not limited
to connections between foundation elements in a foundation support
system. Multiple and different features are provided in each
coupler in the coupler assembly that serve dual purposes of
facilitating alignment and reliable connection of foundation
elements in the field, as well as to more effectively transmit
torque between the foundation elements after the aligned
connections are established.
[0018] In a contemplated embodiment, the inventive coupler assembly
includes a first or inner coupler attached to a first foundation
element including a first shaft and an outer coupler attached to a
second foundation element including a second shaft. The inner
coupler includes a pair of primary alignment and torque
transmitting ribs formed on a round outer surface thereof that are
configured to be slidably inserted into a respective pair of
primary alignment and torque transmitting grooves formed in a round
inner surface of the outer coupler. As such, when the first and
second foundation elements are desired to be attached, the inner
coupler is inserted partly into the outer coupler and rotated about
its center axis until the primary alignment and torque transmitting
ribs of the inner coupler align and mate with the primary alignment
and torque transmitting grooves of the outer coupler where complete
mating engagement of the inner and outer couplers may occur. Only
when the alignment and torque transmitting features are fully mated
can the inner coupler be completely received in the outer coupler
to complete a connection between the first and second shafts while
also effectively mechanically isolating any fasteners provided from
torque as a foundation support system is installed. By virtue of
the inventive coupler assembly, torsional force applied to one of
the foundation elements is transmitted to the other by the
engagement of the torque transmission features formed in the inner
and outer couplers.
[0019] In another contemplated embodiment, a fastened connection of
the inner and outer couplers may include a cross-bolt connection
wherein first and second bolts respectively extend through pairs of
fastener holes or fastener openings formed in the respective inner
and outer coupler. The fastener holes are self-aligning when the
inner and outer couplers are completely engaged and the first and
second bolts extend in mutually perpendicular directions through
the fastener holes. The first and second bolts also extend at
offset elevations to one another in the coupler assembly.
Advantageously, no fastener holes in the pile and extension piece
are needed to make the cross-bolt connection via the inner and
outer coupler. Alignment difficulties associated with fastener
holes in the pile and extension piece are completely avoided.
[0020] In other contemplated embodiments, however, a single
fastener may be utilized to complete a connection between the first
and second shafts through the coupler assembly and as such a single
pair of fastener holes may be provided in each of the inner and
outer couplers that are self-aligning when the inner and outer
couplers are engaged.
[0021] In still another contemplated embodiment the mechanical
connection between the shafts may be completed without using any
fasteners via the interlocking alignment and torque transmitting
features formed in the inner and outer couplers.
[0022] As described in further detail below, an exemplary
embodiment of a coupler assembly is self-aligning and self-locking
in a manner that enables quick and easy coupling of first and
second shafts, and in some cases accommodates a sturdy and easily
accomplished cross-bolt fastening connection between the first and
second shafts in a desirable manner. Any torque imparted onto the
coupled shafts via twisting of the upper shaft is contained within
interlocking features of the coupler assembly as opposed to being
transferred through bolted connections between the s shafts in
conventional support systems. Method aspects of the inventive
concepts will be in part apparent and in part explicitly discussed
in the following description.
[0023] FIG. 1 illustrates a perspective view of an exemplary
embodiment of a foundation support system 100 interacting with a
building foundation 102 of a structure. The foundation support
assembly 100 may interact with new foundation upon which a
structure is to be built, or may alternatively interact with a
foundation supporting an existing structure. That is, the
foundation support system 100 may be applied to new building
construction projects as well as to existing structures for
maintenance and repair purposes. Of course, the support system 100
may alternatively be used to support an object other than a
building foundation as desired.
[0024] After determining, according to known engineering
methodology and analysis, how the foundation 102 or other structure
needs to be supported, primary piles or pipes (hereinafter
collectively referred to as a "pile" or "piles") 104 of appropriate
size and dimension may be selected and may be driven into the
ground or earth at a location proximate or near the foundation 102
using known methods and techniques. The primary piles 104 typically
consist of a long shaft 106 driven into the ground, upon which a
support element such as a plate or bracket (not shown) or a lifting
element such as the lifting assembly 108 is assembled. The shaft
106 of the primary pile 104 may include one or more lateral
projections such as a helical auger 110. The piles 104 may be, for
example, helical steel piles available from Pier Tech Systems
(www.piertech.com) of St. Louis, Mo., although other suitable piles
available from other providers may likewise be utilized in other
embodiments.
[0025] The helical auger 110 may in some embodiments be separately
provided from the piling 104 and attached to the piling 104 by
welding to a sleeve 112 including the auger 110 provided as a
modular element fitting. As such, the sleeve 112 of the modular
fitting is slidably inserted over an end of the shaft 106 of the
piling shaft 104 and secured into place, for example with fasteners
such as the bolts as shown in FIG. 1. In such an embodiment, the
sleeve 112 includes one or more pairs of fastener holes or openings
for attachment to the piling shaft 106 with the fasteners shown. In
the embodiment illustrated there are two pairs of fastener holes
formed in the sleeve 112, which are aligned with corresponding
fastener holes in the shaft 106 to accept orthogonally-oriented
fasteners and establish a cross-bolt connection between the shaft
106 and the sleeve 112. To make a primary pile 104 with a
particular length one merely slides the sleeve 112 onto a piling
shaft 106 of the desired length and affixes the sleeve 112 in
place. In the illustrated embodiment, the end of the piling shaft
106 is provided with a beveled tip 114 to better penetrate the
ground during installation of the pile 104. In different
embodiments, the tapered tip 114 may be provided on the shaft 106
of the piling 104, or alternatively, the tip 114 may be a feature
of the modular fitting including the sleeve 112 and the auger
110.
[0026] The lifting assembly 108 may be attached to an upper end of
the primary pile 104 after being driven into the ground. If the
primary pile 104 is not sufficiently long enough to be driven far
enough into the ground to provide the necessary support to the
foundation 102, one or more extension piles 116 can be added to the
primary pile 104 to extend its length in the assembly, as described
in further detail below. The lifting assembly 108 may then be
attached to one of the extension piles 116.
[0027] As shown in FIG. 1, the lifting assembly 108 interacts with
the foundation 102 to support and lift the building foundation 102.
In a contemplated embodiment, the lifting assembly 108 may include
a bracket body 118, one or more bracket clamps 120 and accompanying
fasteners, a slider block 122, and one or more supporting bolts 124
(comprising allthread rods, for example) and accompanying hardware.
In another suitable embodiment the lifting assembly 108 may also
include a jack 126 and a jacking block 128. Suitable lifting
assemblies may correspond to those available from Pier Tech Systems
(www.piertech.com) of St. Louis, Mo., including for example only
the TRU-LIFT.RTM. bracket of Pier Tech Systems, although other
lifting assemblies, lift brackets, and lift components from other
providers may likewise be utilized in other embodiments.
[0028] The bracket body 118 in the example shown includes a
generally flat lift plate 130, one or more optional gussets 132,
and a generally cylindrical housing 134. The lift plate 130 is
inserted under and interacts with the foundation or other structure
102 that is to be lifted or supported. The lift plate 130 includes
an opening, with which the cylindrical housing 134 is aligned and
to accommodate one of the primary pile 104 or an extension pile
116. The housing 134 is generally perpendicular to the surface of
lift plate 110 and extends above and below the plane of lift plate
130.
[0029] In the exemplary embodiment shown, one or more gussets 132
are attached to the bottom surface of the lift plate 130 as well as
to the lower portion of the housing 134 to increase the holding
strength of the lift plate 130. In one embodiment, the gussets 132
are attached to the housing 134 by welding, although other secure
means of attachment are encompassed within this invention.
[0030] In the exemplary embodiment, the bracket clamps 120 include
a generally .OMEGA.-shaped piece having a center hole at the apex
of the ".OMEGA." to accommodate a fastener. The .OMEGA.-shaped
bracket clamp 120 includes ends 136, extending laterally, that
include openings to accommodate fasteners. The fasteners extending
through the openings in the ends 136 are attached to the foundation
102, while the fastener extending through the center opening at the
apex of the ".OMEGA." extends into an opening in the housing 134.
In one embodiment the fastener extending through the center opening
in the bracket clamp 120 and into the housing 134 further extends
through one of the primary pile 104 or the extension pile 116 and
into an opening on the opposite side of the housing 134, and then
anchors into the foundation 102. In such cases, however, the
fastener is not inserted through one of the primary pile 104 or the
extension pile 116 until jacking or lifting has been completed,
since bracket body 118 must be able to move relative to pile 104 or
116 in order to effect lifting of the foundation 102.
[0031] In one embodiment, the bracket body 118 is raised by
tightening a pair of nuts 138 attached to the top ends of the
supporting bolts 124. The nuts 138 may be tightened simultaneously,
or alternately, in succession in small increments with each step,
so that the tension on the bolts 124 is kept roughly equal
throughout the lifting process. In another suitable embodiment, the
jack 126 is used to lift the bracket body 118. In this embodiment,
longer support bolts 124 are provided and are configured to extend
high enough above the slider block 122 to accommodate the jack 126
resting on the slider block 122, the jacking block 128, and the
nuts 138.
[0032] When all of the components are in place as shown and
sufficiently tightened, the jack 126 (of any type, although a
hydraulic jack is preferred) is activated so as to lift the jacking
plate 128. As the jacking plate 128 is lifted, force is transferred
from the jacking plate 128 to the support bolts 124 and in turn to
the lift plate 130 of the bracket body 118. When the foundation 102
has been lifted to the desired elevation, the nuts immediately
above the slider block 122 (which are raised along with support
bolts 124 during jacking) are tightened down, with approximately
equal tension placed on each nut. At this point, the jack 126 can
then be lowered while the bracket body 118 will be held at the
correct elevation by the tightened nuts on the slider block 122.
The jacking block 128 can then be removed and reused. The extra
support bolt material above the nuts at the slider block 122 can be
removed as well, using conventional cutting techniques.
[0033] The lifting assembly 108 and related methodology is not
required in all implementations of the foundation support system
100. In certain installations, the foundation 102 is desirably
supported and held in place but not moved or lifted, and in such
installations the lifting assembly shown and described may be
replaced by a support plate, support bracket or other element known
in the art to hold the foundation 102 in place without lifting it
first. Support plates, support brackets, support caps, and or other
support components to hold a foundation in place are available from
Pier Tech Systems (www.piertech.com) of St. Louis, Mo. and other
providers, any of which may be utilized in other embodiments of the
foundation support system.
[0034] As shown in FIG. 1, the exemplary foundation support system
100 includes a coupler assembly 200 according to an embodiment of
the present invention that establishes a mechanical connection
between the shaft 106 of the primary pile 104 and the shaft of the
extension pile 116. It is appreciated, however, that more than one
coupler assembly 200 may be utilized to connect another extension
pile 116 to the extension pile 116 shown 200 or to mechanically
connect other ones of the foundation elements 112, 134 to the
respective piles 104 and 116 shown and described above. Further, it
should be appreciated that the coupler assembly 200 may be utilized
in a foundation support system 100 that does not include an
extension pile 116. For example, the coupler assembly 200 could
establish a connection between the pile 104 and the housing 134, or
between the pile 104 and the sleeve 112 of the modular fitting. The
connector assembly 200 may accordingly facilitate a modular
assembly of the foundation elements shown and described in various
combinations.
[0035] FIG. 2 shows the coupler assembly 200 in cross-sectional
view wherein the coupler assembly 200 is seen to include an inner
coupler 202 attached to a shaft of a first piling 300 and an outer
coupler 204 attached to a shaft of a second piling 302. In one
embodiment, pilings 300 and 302 include a length of pipe fabricated
from a metal such as steel. The couplers 202, 204 may likewise be
integrally formed from a metal material such as steel according to
known techniques to include the features described. The first
piling 300 may be of the same dimension in terms of its inner and
outer diameter and correspond in cross sectional shape to the
second piling 302, to which it is attached. Alternatively stated,
the pilings 300, 302 being connected via the coupler assembly 200
are constructed to be the same, albeit with possibly different
lengths, although this not necessarily required in all embodiments.
The cross-sectional shape of the pilings 300, 302 can be circular,
square, hexagonal, or another shape as desired. The pilings 300,
302 can be made to different lengths, however, as the application
requires, and the pilings 300, 302 can be hollow or filled with a
substance such as concrete or another known suitable substance
familiar to those in the art.
[0036] In the exemplary embodiment shown, the first piling 300 may
correspond to an extension piling, such as the extension piling 116
shown in FIG. 1, and the second piling 302 may correspond to a
primary piling, such as the primary piling 104 shown in FIG. 1. As
noted above, the coupler assembly 200, however, may alternatively
be used to connect other shafts of other foundation elements in the
foundation support system 100 previously described, or still
further may be utilized to connect other structural shaft elements
in another application apart from foundation support. In the
exemplary embodiment shown, the shaft of the first piling 300
includes a distal end 304, to which is coupled the inner coupler
202, and the shaft of the second piling 302 includes a distal end
306, to which is coupled the outer coupler 204. The distal ends 304
and 306 are positioned adjacent each other such that the inner
coupler 202 is configured to be at least partially inserted into
the outer coupler 204, as described in further detail below.
[0037] FIGS. 3, 4 and 5 respectively illustrate a perspective view,
bottom view and rear cross-sectional of the inner coupler 202 of
the coupling assembly 200 that will be described collectively in
the following discussion.
[0038] In the exemplary embodiment illustrated, the inner coupler
202 includes a first end 206, a second end 208, and a hollow round
body portion 210 extending therebetween. The inner coupler 202
accordingly includes a generally round opening 212 extending
therethrough between the ends 206, 208. The first end 206 includes
a collar portion 214 including a counter bore 216 configured to
receive the distal end 304 of the shaft of the first piling 300. In
the exemplary embodiment shown, the counter bore 216 includes an
inner diameter or circumference that is sized, shaped and
dimensioned to be large enough to accommodate the outer diameter of
the shaft of the piling end 300 (FIG. 2) such that when the piling
end 304 is inserted into the counter bore 216 the end of the shaft
is received in the counter bore 216. In an alternative embodiment,
the outer diameter of the collar 214 may be selected to be small
enough to fit within the inner diameter of the shaft of the piling
end 300. Regardless, the shaft of the first piling 300 is fixedly
attached to the inner coupler 202 by any known means, such as, but
not limited to, welding. As previously mentioned, the shaft may
include a round cross-section, a square cross-section, or another
cross-sectional shape, and accordingly the end 206 of the inner
coupler 202 has a complementary round shape, square shape or other
shape to facilitate the connection of the shaft end to the counter
bore 216.
[0039] As further seen in the figures, the body portion 210 of the
inner coupler 202 is attached to the collar 214 via a seating
surface 218. More specifically, the seating surface 218 obliquely
extends between an outer surface 220 of the body portion 210 and a
lip surface 222 of the collar 214.
[0040] The inner coupler 202 also includes a pair of axially
extending ribs 224 that project or extend radially outward from the
round outer surface 220 of the body portion 210. In the exemplary
embodiment, the axially extending ribs 224 are positioned opposite
each other on the round body 210 of the inner coupler 202. That is,
the ribs 224 are extended about 180.degree. from one another on an
outer surface of the round body 210, and extend lengthwise or in a
direction parallel to a longitudinal axis of the shafts that are
connected with the coupler assembly.
[0041] In another suitable embodiment, the ribs 224 are positioned
at any point on the round body 210 that facilitates operation of
the coupler assembly 200 as described herein. Each rib 224 includes
a pair of side surfaces 226 and a seating surface 228 that each
extends obliquely from round outer surface 220 of the body 210. The
ribs 224 serve as a primary alignment feature to align the inner
coupler 202 with the outer coupler 204 to enable connecting the
first piling 300 to the second piling 302 as well as a primary
torque transmitting feature when the inner coupler 202 is mated to
the outer coupler 204. More specifically, the pair of ribs 224 are
configured to cooperatively engage a pair of grooves defined in the
outer coupler 204 to accomplish alignment and torque transmission,
as described in further detail below. While a pair of ribs 224 are
shown, it is understood that greater or fewer number of ribs may
likewise be provided in further and/or alternative embodiments.
[0042] In the exemplary embodiment shown, the inner coupler 202
also includes a secondary alignment and torque transmission feature
that includes a pair of circumferentially extending recesses 230
defined in the round body 210 proximate the second end 208 of the
inner coupler 202. Specifically, the circumferential recesses 230
extend from an end surface 232 of the inner coupler second end 208
partly around the circumference of the body 210. Similar to the
ribs 224, the recesses 230 are configured to engage a pair of
projections defined in the outer coupler 204, as described in
further detail below. Further, the recesses 230 are
circumferentially offset from the ribs 224, such that the recesses
230 and the ribs 224 are not aligned with one another. In another
suitable embodiment, the recesses 230 may be circumferentially
aligned with the ribs 224 if desired. While a pair of
circumferential recesses 230 are shown, it is understood that
greater or fewer number circumferential recesses 230 may likewise
be provided in further and/or alternative embodiments. As best seen
in FIG. 5, at the locations of the circumferential recesses 230,
the inner surface of the coupler 202 includes flat regions that
maintain a desired wall thickness in the coupler body 210. As such,
inner surface of the coupler 202 in cross-section seen in FIG. 5
includes two rounded curve portions separated by straight or linear
portions at the locations of the recesses 230 whereas the inner
surface of the coupler 202 is otherwise uniformly round and
circular in cross section at other locations in the body 210 as
shown in the figures.
[0043] The inner coupler body portion 210 in the example
illustrated also is formed with one or more pairs of fastener holes
or openings 234, 236 defined therethrough to allow for fastening of
the inner coupler 202 and the outer coupler 204. The two openings
234 are shown on opposite sides or locations in the round body
portion 210 such that a fastener such a bolt extending through the
openings 234 will be generally perpendicular to the longitudinal
axis and will enter and leave the body portion 210 approximately
normal to the round outer surface 220. In a further embodiment, the
body portion 210 includes the first pair of openings 234 proximate
the first end 206 and a second pair of openings 236 located
proximate the second end 208. The pairs of openings 234 and 236 are
angularly offset from one another by 90.degree. such that fasteners
inserted into the openings 234 and 236 are mutually perpendicular
to one another when received through the respective openings 234,
236. This particular configuration is sometimes referred to as a
cross-bolt connection and is shown in FIG. 1 wherein the coupler
assembly 200 connects the shafts 106 and 116.
[0044] FIG. 7 illustrates a perspective view of the outer coupler
204 of the coupling assembly 200 that may be used with the
foundation support system 100 shown in FIG. 1 and the inner coupler
202 shown in FIGS. 3-6. FIG. 8 illustrates a cross-sectional view
of the outer coupler 204. FIG. 9 illustrates a cross-sectional view
of the outer coupler 204 taken along line 9-9 in FIG. 8. FIG. 10
illustrates a cross-sectional view of the outer coupler 204 taken
along line 10-10 in FIG. 8. The following discussion shall
collectively refer to FIGS. 7-10.
[0045] In the exemplary embodiment shown, the outer coupler 204
includes a first end 238, a second end 240, and a hollow round body
portion 242 extending therebetween. The outer coupler 204
accordingly includes an opening 244 extending between ends 238 and
240. As shown in FIG. 8, the second end 240 includes a flange 246
extending from an inner surface 248 of the round body 242. The
flange 246 defines a cavity 250 at the second end 240 that
configured to receive the distal end 306 of the shaft of the second
piling 302. In the exemplary embodiment, the cavity 250 includes an
inner diameter that is large enough to accommodate the outer
diameter of the shaft at the piling end 306 such that the shaft of
the piling end 306 is inserted in to the cavity 250 to join the
outer coupler 204 with the second piling 302. In another suitable
embodiment, at least a portion of the outer diameter of the second
coupler body 242 is small enough to fit within the inner diameter
of shaft of the piling end 306. The shaft of the second piling 302
is fixedly attached to the second end 240 of the outer coupler 204
by any known means, such as, but not limited to, welding. As
previously mentioned, the shaft of the second piling 302 may
include a round cross-section, a square cross-section, or another
cross-sectional shape, and accordingly the end 240 of the outer
coupler 204 has a complementary round shape, square shape or other
shape to facilitate the connection of the shaft end to the coupler
204. It should also be noted here that the couplers 202, 204 may be
configured to receive and connect to shafts having different cross
sectional shapes as desired in further and/or alternative
embodiments.
[0046] The outer coupler 204 also includes a pair of axially
extending grooves 252 that are formed in the round inner surface
248 and extend from a first end surface 254 toward the second end
240. In the exemplary embodiment, the grooves 252 are positioned
opposite each other on the body 242 of the outer coupler 204. In
another suitable embodiment, the grooves 252 are positioned at any
point on the body 242 that facilitates operation of the coupler
assembly 200 as described herein. The grooves 252 are configured to
receive the pair of ribs 224 of the inner coupler 202 as a primary
alignment feature with the inner coupler 202 to more easily connect
the shaft of first piling 300 to the shaft of the second piling
302, as well as transmit torque in a manner contained within the
coupler assembly. Each groove 252 includes a seating surface 256
proximate the second end 240 that is configured to mate with the
seating surface 228 on a rib 224 of the inner coupler 202, as
described in further detail below.
[0047] In the exemplary embodiment, the outer coupler 204 also
includes a pair of wings or flares 258 that extend outward from a
round outer surface 260 of the outer coupler body 242. Each wing or
flare 258 is positioned approximate the respective groove 252 such
that the wings or flares 258 facilitate a substantially constant
thickness of the outer coupler body 242. Each wing or flare 258
extends from the end surface 254 toward the second end 240 and
terminates at approximately the same axial position at the groove
252. The wings or flares 258 impart a rounded outer surface having
a discontinuous outer diameter in the outer surface of the outer
coupler 204. As seen in the cross sections of FIGS. 9 and 10, the
outer coupler has an eccentric, complex curvature and elliptical
shape where the rings or flares 258 reside.
[0048] The outer coupler 204 also includes a secondary alignment
and torque transmission feature that includes a pair of
circumferential projections in the form of tabs 262 extending
outwardly from the round body portion 242 proximate the second end
240. Specifically, the circumferential projections 262 extend
radially inward from the inner surface 248 proximate the flange
246. The circumferential projections 262 are configured to engage
the pair of circumferential recesses 230 defined in the inner
coupler 202 when the coupler assembly 200 is assembled. Further,
the circumferential projections 262 are circumferentially offset
from the grooves 252 in the outer coupler, such that the
projections 262 and the grooves 252 are not aligned. In another
suitable embodiment, the projections 262 may be circumferentially
aligned with the grooves 252.
[0049] Additionally, the outer coupler body portion 242 may be
formed with one or more pairs of fastener holes or openings 264,
266 defined therethrough to allow for joining of the outer coupler
204 to the inner coupler 202. Two openings 264 may be formed on
opposite sides of the body portion 242 such that a fastener
extending through openings 264 will be generally perpendicular to
the longitudinal axis and will enter and leave the body portion 242
approximately normal to the surface 260. In a preferred embodiment,
the body portion 242 includes the first pair of openings 264
proximate the first end 238 and a second pair of openings 266
located proximate the second end 240. The pairs of openings 264 and
266 are preferably rotationally offset from one another by
90.degree. such that fasteners inserted into the openings 264 and
266 are perpendicular to one another when coupler assembly 200 is
viewed in cross-section. This orientation of fastener holes
facilitates a cross-bolt connection as described above.
[0050] As mentioned above, however, the cross-bolt connection is
not required in all embodiments, however, and instead one fastener
may be employed to complete a connection with the coupler assembly
200 in another embodiment. Still further, a mechanical connection
may be completed without a fastener at all in certain applications
as explained further below.
[0051] Although the inner coupler 202 is shown and described herein
as including ribs 224 and outer coupler 204 is described herein as
having grooves 252, it is contemplated that this arrangement of
features may be reversed and/or combined in another embodiment.
That is, in an alternative embodiment the inner coupler 202 may
include grooves instead of or in addition to ribs 224, and the
outer coupler 204 may likewise include ribs instead of or in
addition to grooves 252. Further, the inner coupler 202 may include
at least one of each a rib and a groove, while outer coupler may
include a corresponding rib and a corresponding groove. Similarly,
although the inner coupler 202 is described herein as including the
circumferential recess 230 and the outer coupler 204 is described
herein as having the circumferential projection 262, it is
contemplated that the inner coupler 202 may include a
circumferential projection instead of or in addition to the
circumferential recess 230, and that the outer coupler 204 may
include a circumferential recess instead of or in addition to
projection 262. Generally, the inner coupler 202 includes at least
one alignment and torque transmission feature that is configured to
engage with a corresponding alignment and torque transmission
feature of the outer coupler 204 to facilitate alignment of the
couplers 202 and 204 to couple shafts of different foundation
elements in the foundation support system.
[0052] Further, although ribs 224 and grooves 262 are shown as
substantially linear, axially extending features oriented in
parallel with the longitudinal axis of the shafts of the piles to
which they are coupled, it is contemplated that the ribs 224 and
grooves 262 may be in a non-parallel orientation with respect to
the longitudinal axis of the shafts of the piles, such as
obliquely-oriented. Additionally, it is contemplated that ribs 224
and grooves 262 may be non-linear in nature and form a curved shape
such as, but not limited to, a spiral shape about their outer and
inner surfaces of the respective couplers 202 and 204.
[0053] Referring again to FIG. 2, the coupler assembly 200
facilitates connecting the shaft of the first piling 300 with the
shaft of the second piling 302. As described above, the first
piling 300 may be an extension piling 116 (shown in FIG. 1). The
second piling 302 may be one of the primary piling 104 (shown in
FIG. 1) or an extension piling 116.
[0054] In another suitable embodiment, the coupler assembly 200 may
be utilized to connect any two structural shaft components and is
not restricted to use within a foundation support system 100, as
described herein. That is, the shafts being connected with the
coupler assembly 200 need not be shafts of piles or piers or any of
the components shown and described in the foundation support system
described above, but instead other structural elements for other
purposes. Provided that the ends of the structural elements being
connected are shaped to fit the counter bores in the inner and
outer couplers 202, 204, the structural elements need not even be
shafts.
[0055] In operation, the inner coupler 202 is fixedly attached to
the end 304 of the shaft of the first piling 300 and the outer
coupler 204 is fixedly attached to the end 306 of the shaft of the
second piling 302. The second end 208 of the inner coupler 202 is
then partly inserted into the first end 238 of the outer coupler
204 such that at least a portion of the inner coupler 202 is
received within the opening 244. The diameter of the inner coupler
202 at the location of the ribs 244 is larger than the inner
diameter of the outer coupler inner surface 248 such that the inner
coupler 202 can only be inserted into the outer coupler 204 in a
predetermined orientation. More specifically, the diameter of the
outer coupler 204 at the location of the grooves 254 is large
enough to accommodate the diameter of the inner coupler 202 at the
location of the ribs 244. As such, the ribs 224 of the inner
coupler 202 must be aligned with the grooves 254 of the outer
coupler 204 to assemble the coupler assembly 200. Once the second
end 208 of the inner coupler 202 is partially inserted, simple
rotation of the first piling 300 causes automatic alignment of the
couplers 202 and 204. Because the pile 300 is relatively heavy, the
inner coupler 202 once aligned will fall into place via
gravitational force as the piling 300 is rotated to the point of
alignment. Therefore, the ribs 224 and the grooves 254 serve as a
self-alignment feature that makes it easier to connect the pilings
300 and 302 to each other.
[0056] Once the ribs 224 are aligned with the grooves 254, the
inner coupler 202 may then be removably inserted into the outer
coupler 204. Insertion terminates when the lip surface 222 and the
seating surface 218 of the inner coupler 202 mate, respectively,
with the end surface 254 and a seating surface 268 at the first end
238 of the outer coupler 204. As such, in the exemplary embodiment,
the collar portion 214 of the inner coupler 202 remains exposed and
is not inserted into the opening 244 of the outer coupler 204. In
another suitable embodiment, the inner coupler 202 is fully
inserted into the outer coupler 204.
[0057] Referring to the second ends 208 and 240, when the ribs 224
are fully inserted into the grooves 254, the seating surface 228 on
the ribs 224 is in contact with the seating surface 256 on the
grooves 254. Additionally, the end surface 232 on the inner coupler
202 contacts the flange 246 on the outer coupler 204. As such,
seating surfaces 218, 268, 228, and 256, end surface 232, and
flanges 246 are configured to ensure that the inner coupler 202 is
properly positioned within the outer coupler 204 with respect to
depth.
[0058] Furthermore, each circumferential recess 230 in the second
end 208 of the inner coupler 202 receives a circumferential
projection tab 262 in the second end 240 of the outer coupler 204
to further ensure proper alignment of the couplers 202 and 204 as
well as torque transmission. Over time and through continued usage,
it is possible that friction may erode away small portions of the
ribs 224. However, the circumferential recesses 230 and projections
262 serve as a secondary alignment and torque transmission feature
to facilitate assembly of the coupler assembly 200.
[0059] When the combination of alignment features have properly
seated and aligned the couplers 202 and 204, the first piling 300
is spaced from the second piling 302 by a distance equal to the
distance between the counter bore 216 in the inner coupler 202 and
the flange 246 in the outer coupler 204. As such, the pilings 300
and 302 are not directly connected to the same component of the
coupler assembly 200 and no component of the coupler assembly 200
overlaps both pilings 300 and 302. In such a configuration, any
torque imparted onto the support system 100 is contained within the
coupler assembly 200 instead of being transferred between the
pilings 300 and 302 using fasteners such as bolts extending through
fastener holes in the pilings 300 and 302. Advantageously, by
virtue of the couplers 202 and 204, the connections can be
established between the pilings 300 and 302 without fastener holes
and fasteners extending through the pilings 300, 302. As clearly
seen in the Figures, the fasteners, when provided extend only
through the couplers 202, 204. As such, torque related issues
associated with deformation of fastener holes in the pilings 300,
302 that may occur in conventional systems are eliminated by the
coupler assembly 200.
[0060] More specifically, if the first piling 300 were to be
rotated while the inner coupler 202 is positioned within and
engaged with the outer coupler 204 to drive the pilings 300, 302
deeper into the ground, the torque is distributed in the coupler
assembly 200 between the ribs 224 and the grooves 254, between the
circumferential recesses 230 and the circumferential projections
262. Further, because the primary alignment and secondary alignment
features described are differently sized and proportions, as well
as being offset and spaced apart from one another in the coupler
assembly 200, any applied torque is distributed across multiple
locations in the coupler assembly 200 where the alignment and
torque transmitting features are engaged. Because some of the
alignment and torque transmitting features are axially oriented
while others are circumferential, a particularly strong and sturdy
connection is realized that facilitates torque transfer without
deformation of either coupler 202, 204 or the connecting shafts of
the piles 300, 302. Finally, because the couplers 202 are each
fabricated from high strength steel in a contemplated embodiment,
they are capable of withstanding high torsional forces to install a
foundation support system by driving piles into the ground. Simpler
and easier connections of foundation elements such as piles are
therefore realized with improved reliability that likewise
facilitates simpler and easier installation of a foundation support
system with improved reliability.
[0061] Further, in such a configuration, the first pair of fastener
holes or openings 234 on the inner coupler 202 is automatically
aligned with the first pair of fastener holes or openings 264 on
the outer coupler 204 when the couplers 202, 204 are mated.
Similarly, the second pair of fastener holes or openings 236 on the
inner coupler 202 is automatically aligned with the second pair of
fastener holes or openings 266 on the outer coupler 204. As such, a
technician can easily insert a first fastener through openings 234
and 264 and a second fastener through openings 236 and 266 to
secure the inner 202 to the outer coupler 204 and establish a
cross-bolt connection. As such, the coupler assembly 200 configured
as shown in the Figures is sometimes referred to as a cross-bolt
and cross-lock coupler.
[0062] As mentioned above, a single fastener may also be utilized
in another embodiment. In such a scenario, one of the pairs of
fastener holes may be omitted in the construction of the couplers
202, 204 or only one of the pairs of fastener holes may be utilized
to receive a fastener.
[0063] In still another embodiment no fasteners may be utilized and
the couplers 202, 204 could either be formed without fastener holes
at all or the fastener holes provided may simply not be utilized
with fasteners. Because the pilings in the example of the
foundation support system are driven and loaded with compression
force in use, the fastened connection may not be strictly necessary
because of the interlocking engagement of the alignment and torque
transmission features that may transmit torsional force in the
absence of any fasteners. The configuration of the couplers 202,
204 further facilitates direct and distributed transmission of
compressive forces by the seating surfaces described on each
coupler that mate with one another when the couplers 202, 204 are
engaged. The flush engagement of the mating ends when the coupler
assembly 200 is fully assembled, in combination with the seating
surfaces described, provides a high strength connection in the
assembly.
[0064] Such a configuration of coupler assembly 200 and shafts of
the piles 300 and 302 reduces, and substantially eliminates the
stress in the assembly that may otherwise result because of the
difficulties in aligning relatively long and heavy pieces in the
assembly. If fasteners are intentionally or unintentionally forced
through openings that are not completely aligned in adjacent shafts
in the assembly the joint between adjacent shafts may be subject to
a significant amount of mechanical stress that in conventional
systems may lead to deformation of the fastener holes and weakening
of the shafts. Because the coupler assembly 200 is self-aligning,
however, such issues are avoided.
[0065] Additionally, deformation of the fastener holes via
unintentional misalignment of piles in conventional support systems
may result in some relative movement, sometimes referred to as
play, in the coupled connection that can also adversely affect the
load bearing capacity of the system. Also, increased stress caused
by misalignment of adjacent components may cause a reduction in the
effective service life of the piles, thus requiring more frequent
replacement. By virtue of the self-aligning and self-locking
coupler assembly and system described, these problems are
substantially minimized, if not completely eliminated, in most
cases where the coupler assembly 200 is properly used. The
inter-engagement of the coupler features described, and in
particular the alignment and torque transmission features of each
coupler 202 and 204, mechanically isolates the fasteners, when
provided, from torsional force.
[0066] The fasteners, when utilized with fully engaged couplers
202, 204, are further mechanically isolated from compression forces
in the coupler assembly 200 when the pilings are driven further
into the ground via application of torsional force on and end of an
above ground piling. The seating surfaces described in the coupler
assembly 200 that bear upon and inter-engage with one another when
the coupler assembly 200 is fully engaged, provide direct
transmission of compression forces through the couplers 202,
204.
[0067] The fasteners provided may, however, realize tension force
depending on how the support system is configured and applied More
specifically, the fasteners may experience a tensile load from a
loading of a pile with a uplift force, or if the pile should need
to be removed the fasteners when provided ensure that the
connection maintains engagement.
[0068] The benefits and advantages of the inventive concepts
described herein are now believed to have been amply illustrated in
relation to the exemplary embodiments disclosed.
[0069] An embodiment of a coupler assembly for connecting a first
shaft to a second shaft has been disclosed. The coupler assembly
includes: an outer coupler configured to be coupled to the first
shaft, the outer coupler comprising an inner surface formed with at
least one primary alignment feature and at least one secondary
alignment feature; and an inner coupler configured to be coupled to
the second shaft, the inner coupler comprising an outer surface
formed with at least one primary alignment feature and at least one
secondary alignment feature; wherein the primary and secondary
alignment features of the outer coupler are respectively configured
to engage the alignment features of the inner coupler when the
outer surface of the inner coupler and the inner surface of the
outer coupler are assembled and engaged, wherein when the inner
coupler and outer coupler are engaged, an interlocking torque
transmission structure is established between the inner and outer
coupler, and wherein each of the primary and secondary alignment
features of the inner coupler and the outer coupler comprises one
of a projection and a recess.
[0070] Optionally, the primary alignment feature of the inner
coupler comprises at least one rib and the primary alignment
feature of the outer coupler comprises at least one groove for
mating with the at least one rib. The at least one secondary
alignment feature of the outer coupler may optionally include a
circumferential projection, and the at least one secondary
alignment feature of the inner coupler may include at least one
circumferential recess that is configured to receive the at least
one circumferential projection when the outer coupler and the inner
coupler are assembled and engaged. The at least one primary
alignment feature of each of the inner coupler and outer coupler
may be circumferentially offset from at least one secondary
alignment feature in each of the inner coupler and the outer
coupler.
[0071] The inner coupler may optionally include a collar defining a
lip surface, wherein the outer coupler comprises an end surface
configured to contact the lip surface such that the collar is
positioned adjacent the end surface. The inner coupler may also
include a first seating surface extending obliquely between the
outer surface and the collar, and the outer coupler may include a
second seating surface extending obliquely between the inner
surface and the end surface that is configured to mate with the
first seating surface.
[0072] The at least one primary alignment feature may include a
pair of elongated ribs in one of the inner coupler and the outer
coupler, and the at least one primary alignment feature may include
a pair of elongated grooves in the other one of the inner coupler
and the outer coupler. The outer coupler may also include an outer
surface including at least one wing formed thereon, wherein the at
least one wing is positioned proximate the at least one primary
alignment feature.
[0073] The inner coupler may include a pair of first transverse
openings and the outer coupler may include a pair of second
transverse openings, wherein the pair of first transverse openings
are aligned with the pair of second transverse openings when the
first and second alignment features are mated and wherein the pairs
of transverse openings in the inner coupler and the outer couple
respectively facilitate a cross-bolt connection of the first and
second shafts.
[0074] The at least one primary alignment feature and the at least
one secondary alignment feature may be differently sized and shaped
in each of the inner coupler and the outer coupler. Each of the
inner coupler and the outer coupler may include a hollow round
body. The at least one primary alignment feature may extend axially
on at least one of the inner coupler and the outer coupler, and the
at least one secondary alignment feature may extend
circumferentially on the other one of the inner coupler and the
outer coupler. The coupler assembly may be in combination with the
first shaft and the second shaft, wherein at least one of the first
shaft and the second shaft is one of a primary pile and an
extension piece of a foundation support system.
[0075] An embodiment of a shaft assembly has been disclosed
including: a first shaft comprising a first distal end; a second
shaft comprising a second distal end; an outer coupler extending on
the first distal end, the outer coupler formed with at least a
first alignment feature comprising a projection or a groove; and an
inner coupler extending on the second distal end, the inner coupler
comprising at least a second alignment feature that is configured
to engage the at least one first alignment feature; wherein when
the inner coupler and the outer coupler are partly mated and one of
the inner coupler and outer coupler is rotated relative to the
other of the inner coupler and the outer coupler, the first
alignment feature is self-aligning with the second alignment
feature; and wherein the first alignment feature and the second
alignment feature are aligned and mated, the inner coupler and the
outer coupler are rotationally interlocked with one another to
facilitate torque transmission from the first shaft to the second
shaft without utilizing a fastener hole in either of the first
shaft or the second shaft.
[0076] Optionally, the first axial alignment feature comprises at
least one groove defined on a round inner surface of the outer
coupler, and wherein the second axial alignment feature comprises
at least one rib extending from a round outer surface of the inner
coupler. The first alignment features and the second alignment
features may each extend axially on the inner coupler and the outer
coupler. The first axial alignment feature may include a pair of
linearly extending grooves located on an inner surface of the outer
coupler and opposing one another, and the second alignment feature
may include a pair of linearly extending ribs located on an outer
surface of the inner coupler. The inner coupler may include a
counter bore configured to receive the second distal end of the
second shaft, and the outer coupler may include a flange, wherein
the flange at least partially defines a cavity configured to
receive the first distal end of the first shaft. The inner coupler
may include at least one pair of first fastener openings and the
outer coupler includes at least one pair of second fastener
openings, wherein the pair of first fastener openings are
self-aligned with the pair of second fastener openings when the
first and second alignment features are mated. The inner coupler
may include a first pair and a second pair of fastener holes and
the outer coupler includes a first pair and a second pair of
fastener holes, the first and second pairs of fastener holes in the
outer coupler being self-aligning with the first and second pairs
of fastener holes in the inner coupler and facilitating cross-bolt
connection of the inner coupler and outer coupler when the inner
coupler and outer coupler are fully engaged. At least one of the
first shaft and the second shaft may be one of a primary pile and
an extension piece of a foundation support system.
[0077] An embodiment of a foundation support system has been
disclosed comprising: a first foundation element comprising a first
shaft having a first distal end and a second end configured to be
driven into the ground proximate a building foundation; a second
foundation element comprising a second shaft having a second distal
end; an outer coupler coupled to one of the first and second distal
ends, the outer coupler comprising an inner surface having at least
one first alignment feature formed with the inner surface; an inner
coupler coupled to the other of the first and second distal ends,
the inner coupler comprising an outer surface having at least one
second alignment feature, the at least one second alignment feature
formed with the outer surface; wherein the outer coupler and the
inner coupler are configured to engage in a self-aligning manner
via the first alignment feature and the at least one second
alignment feature, wherein one of the first alignment feature and
the secondary alignment feature comprises a projection and the
other of the first alignment feature and the secondary alignment
feature comprises a groove.
[0078] Optionally, the at least one first alignment feature may
include at least one of an axially extending rib and a
circumferentially extending groove, and wherein the at least one
second alignment feature includes at least one of an axially
extending groove and a circumferentially extending tab. The outer
coupler may include a body defining a round inner surface including
at least one projection and at least one recess angularly offset
from one another, wherein the inner coupler comprises a round outer
surface including at least one projection and at least one recess
angularly offset from one another. Each of the inner coupler and
the outer coupler may be configured to facilitate a cross-bolt
connection of the inner coupler and the outer coupler. The second
foundation element may be an extension piling.
[0079] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *