Patent Application
20240026626
Embodiments of the design provided herein generally relate to a foundation pile system. In an embodiment, a pile cap is applied to improve the foundation pile system.
An existing foundation pile can include several components welded to the pile. However, on the one hand, welding is inherently a dangerous process. On the other hand, after the welding process is performed, the welder is required to inspect the welded regions and parts to find any bad welding. Frequently, the bad-welding regions and parts have to be rewelded. As a result, the welding process becomes a time-consuming and, thus, expensive process.
Methods and apparatus for a multiple-part pile cap are disclosed. In an embodiment, a multiple-part pile cap can include a top portion and a bottom portion that are configured to supply a mechanical interface between a first foundation pile providing a foundation for a structure and a frame of a structure itself. The multiple-part pile cap can be installed onto the first foundation pile of a set of foundation piles driven into the ground to provide the foundation for the structure using the multiple-part pile cap as the mechanical interface between the first foundation pile and the frame of the structure being secured to the first foundation pile. The bottom portion of the multiple-part pile cap can be i) matched in width to a width of a webbing of the first foundation pile and ii) has one or more holes in a first flange of the multiple-part pile cap to be bolted to the webbing of the first foundation pile. These and other features are discussed further herein.
The drawings refer to some embodiments of the design provided herein.
While the design is subject to various modifications, equivalents, and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will now be described in detail. It should be understood that the design is not limited to the particular embodiments disclosed, but—on the contrary—the intention is to cover all modifications, equivalents, and alternative forms using the specific embodiments.
Note, a multiple-part pile cap 100 is configured to be installed onto the foundation pile of a set of foundation piles driven into a ground to provide the foundation for the structure using the multiple-part pile cap 100 as the mechanical interface between the foundation pile and the frame of the structure being secured to the foundation pile. For example, see
On the right-hand side,
Next, the upward flange of the angle bracket of the bottom portion of the multiple-part pile cap 100 mates to a flange of the top part of the multiple-part pile cap 100 with one or more bolts and nuts. Thus, the flange of the angle bracket of the bottom portion of the multiple-part pile cap 100 receives a bolt coming from the angle bracket of the top portion of the multiple-part pile cap 100 in order to mechanically secure the top and bottom portions of the multiple-part pile cap 100 together. Note, also not shown are, in this example, one or more bolts going through the flange of the angle bracket making up the top portion of the multiple-part pile cap 100 into the frame of the structure that is going to be secured to the foundation pile.
Referring to
Thus, the multiple-part pile cap 100 is configured to be installed on the foundation pile. One or more foundation piles of the set of foundation piles are driven into the ground and have been cut relative the other foundation piles in the set of foundation piles so that the portions of the foundation piles in the set of foundation piles extending above ground level form a substantially level plane (e.g. + or −0.5 inches) for the frame of the structure being secured to a set of multiple-part pile caps corresponding to the set of foundation piles so that the frame of the structure will be level when mechanically secured to the set of foundation piles. For example, see
Again, the multiple-part pile cap 100 can be bolted onto the webbing of the foundation pile, such as a wide flange I beam, and the equipment. For example, a structure such as an electrical inverter skid for solar power can have 10 support foundation piles each. Four foundation piles, each with its own multiple-part pile cap 100 are shown in
Note, as discussed later, the top portion of the multiple-part cap pile can be adaptable/adjustable to match a size and/or shape of a frame of the structure/platform that the pile foundation is attaching to. The bottom portion of the multiple-part pile cap 100 can connect to the foundation pile (e.g., an I beam or an H beam). The bottom portion of the multiple-part pile cap 100 can be bolted to the foundation pile. The multiple-part pile cap 100 can be connected to a frame of structures for any pile-mounted equipment, such as an inverter structure, a battery structure, etc.
The multiple-part pile cap 100 can include an angle bracket such as an L-shaped bracket. The L-shaped bracket can include a horizontal surface and a vertical surface connected on one side. The horizontal surface and the vertical surface can be substantially perpendicular to each other. Further, the vertical surface and the horizontal surface can include holes. A set of bolts can attach the vertical surface to the foundation pile (e.g., an I beam) via a first set of holes. Another set of bolts can attach the horizontal surface to an angle bracket via a second set of holes. The angle bracket can be part of the equipment that is being installed on the foundation pile.
The first and second sets of holes can be formed by punching through the vertical surface and the horizontal surface of the multiple-part pile cap 100.
Thus, a first flange of an angle bracket in the bottom portion of the multiple-part pile cap 100 can be mated to the webbing in the foundation pile. The first flange of the angle bracket is i) matched in width to a width of the webbing and ii) has one or more holes in the first flange to be bolted to the webbing of its corresponding foundation pile. A second flange of an angle bracket in the bottom portion of the multiple-part pile cap 100 can be bolted to a first flange of another angle bracket in the top portion of the multiple-part pile cap 100. One or more holes in the second flange of the angle bracket in the bottom portion are matched in location with one or more holes in the first flange of the other angle bracket in the top portion when mated together. Thus, the bottom portion of the multiple-part pile cap 100 is bolted to the top portion of the multiple-part pile cap 100. The two brackets are mated together with bolts, nuts, and washers. The top angle bracket can be shimmed as needed to ensure a solid connection between the top of the foundation pile and the frame of the structure. The equipment connections can be i) slotted or ii) have bolt holes to match the type of structure they are being installed on. The bolt size can change accordingly to adjust size variations of different equipment and different manufacturers. One or more washers, such as lock washers, can be used to fill gaps between the bolts and the brackets of the multiple-part pile cap 100.
The bottom portion of the multiple-part pile cap 100 can be a first angle bracket. The top portion of the multiple-part pile cap 100 can be a second angle bracket. The first angle bracket in the bottom portion and the second angle bracket in the top portion of the multiple-part pile cap 100 are attached together in opposite rotations. The angle bracket in the bottom portion and the angle bracket in the top portion of the multiple-part pile cap 100 can be seen as two 90-degree brackets that are attached together in opposite rotations. That is, if the L-shaped bracket is a right angle bracket, the angle bracket is a left angle bracket that is attached to the horizontal surface of the L-shaped bracket.
The bottom portion of the multiple-part pile cap 100 is configured to be bolted to the top portion of the multiple-part pile cap 100, and then, the top portion of the multiple-part pile cap 100 is mechanically secured to the frame of the structure. The flange of the second angle bracket in the top portion of the multiple-part pile cap 100 can be bolted to the frame of the structure. Thus, when the frame of the structure that is going to be secured to the foundation pile has a flat portion on its side that the angle bracket can mate up to, then the flange of the second angle bracket in the top portion of the multiple-part pile cap 100 is bolted to holes in that flat portion of the frame. The angle bracket of the top portion of the multiple-part pile cap 100 is rotated relative to the bottom angle bracket and connects through bolt connections the bottom portion of the multiple-part pile cap 100 and the frame of the structure being secured to the foundational pile. Lastly, any bolted connections are configured to be torqued to be seismically safe.
Again, once all the foundation piles are installed on the ground, the multiple-part pile caps 100 can be installed on the foundation piles. The multiple-part pile caps 100 create an overall surface, i.e., a platform, for the equipment to be installed on. The foundation pile, i.e., a W6 pile, can be inserted into the ground in such a way that at least portions of the foundation pile are located above the ground. The pile-mounted equipment then can be attached to the pile foundation via the multiple-part pile cap 100. The multiple-part pile cap 100 can then be used to connect the foundation piles to the equipment via the angle brackets. The pile foundation and the multiple-part pile cap 100 can form a raised platform above the ground. In cases where the angle brackets do not exactly fit on the multiple-part pile cap 100 and gaps are formed, washers can be used to fill the gap. That is, the washers can be used to compensate for height variations. Additionally, if there are no preexisting holes on the foundation piles, then holes can be created by using a mag drill, and the brackets can be bolted to the foundation piles.
In cases where the angle bracket includes pre-made holes, using washers and/or clamps can compensate for any possible height variations. The holes on the vertical surface or the horizontal surface can be pre-made or during the installation. By bolting the L-shaped brackets to the foundation pile and the equipment, extensive welding can be avoided, which can save time and operational expenses.
In an embodiment, the angle bracket can have a first flange/horizontal surface and ii) the vertical surface/a second flange that are used to connect the multiple-part pile cap 100 to the equipment. Each of i) the horizontal surface and ii) the vertical surface can include one hole or two or more holes.
The horizontal surface can be a cold rolled steel L-bracket, mounted in the W6 web of the pile on both sides. The bolts on the horizontal surface can fasten the surface to the foundation pile whether it be an H beam or an I beam. The angle bracket can be ½ inch to ⅜ inch thick steel and the bolts can be ¾ inch hex head coarse thread bolts.
Each bracket and flange can be hot dipped into galvanized finish to resist weather and rusting. The flange can be a protruded ridge, a lip, or a rim. Alternatively, the flange can be either external or internal, and serve to increase strength, make attachment/transfer of contact force with another object easier, or stabilize and guide the movements of a machine or its parts.
The cross-section of the horizontal surface can be uniform throughout its length. In such embodiments, the horizontal surface is “inserted” into the I beam. That is, the flanges of the I beam are positioned on, i.e., the cover, both sides of the horizontal surface. In such embodiments, the horizontal surface can include only one hole. Alternatively, comparing 8A to 2A, the cross-section of the horizontal surface can change throughout its length. For example, while the horizontal surface is “inserted” into the I beam closer to the vertical surface, once the flange ends, the cross-section of the horizontal surface enlarges, in such a way that the largest width of the horizontal surface can substantially match the width of the flange. In such embodiments, the horizontal surface can include two holes. The holes of the horizontal surface can be formed closer to the side of the horizontal surface that is farther from the vertical surface.
Note, the bolted connections will be torqued to be seismically safe.
Other frames come with a part that can be bolted into (pre-existing holes in the frame) and then the angle bracket forming the top portion of the multiple-part bracket will bolt into that part of the frame that can be bolted into. When the top portion of the multiple-part pile cap 100 is a clamp then the clamp will have a bolt run through the clamp into the bottom portion of the angle bracket and will be torqued. A slot is in the clamp version.
The angle bracket has two holes on the bottom portion's angle bracket that connects to the webbing of the foundation pile. One slot is in the other flange of the bottom angle bracket for the clamp. The clamping can facilitate installing equipment that needs elbow connections, e.g., side-connection. The clamps, e.g., rocking washer, lindapeter clamps, etc. can include noses and tails. Each clamp can be so arranged on the vertical surface that the nose of the clamp is positioned above the hole. The bolt can be inserted via a hole in the nose of the clamp into the hole of the vertical surface. If necessary, the height can be adjusted by a washer. A further washer can be used above the clamp to further adjust the clamp on the vertical surface and improve the stability of the multiple-part pile cap 100.
Note, the required amount of foundation piles needed for the structure being secured to the foundation piles is typically dictated by the weight of the structure itself and this can dictate whether the amount of bolt holes used in each flange.
While the foregoing design and embodiments thereof have been provided in considerable detail, it is not the intention of the applicant(s) for the design and embodiments provided herein to be limiting. Additional adaptations and/or modifications are possible, and, in broader aspects, these adaptations and/or modifications are also encompassed.
Further, the terms “or” and “and/or” as used herein are to be interpreted as inclusive or meaning any one or any combination. As an example, “A, B or C” or “A, B and/or C” mean “any of the following: A; B; C; A and B; A and C; B and C; A, B and C.” An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive. As this invention is susceptible to embodiments of many different forms, it is intended that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described.
This non-provisional application claims priority to under 35 USC 119 and the benefit of U.S. provisional patent application titled “MULTIPART PILE CAP FOR A FOUNDATION PILE,” filed Jul. 20, 2022, application No. 63/390,721, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63390721 | Jul 2022 | US |
