The present invention relates to various flat-plate foundation supports that provide a foundation anchor for various ground supported structures.
The present invention relates to a foundation apparatus, a method of providing structural support, and method of making, using, and installing the foundation apparatus for structural support. For background consider U.S. Pat. No. 4,882,891, which is incorporated herein by reference, which relates to an apparatus and method for installing a structural anchor or foundation in an earthen hole wherein the foundation includes radial vanes for resisting turning moments. For further similar background see U.S. Pat. No. 4,974,997, this is also incorporated herein by reference, and which discloses a hydraulic setting tool assembly that is particularly useful for installing a structural anchor or foundation in an earthen hole.
U.S. Pat. Pub. No. 2003-0085394, which is incorporated herein by reference, discloses a metal foundation or support post for a guardrail system having a plurality of the vertical support posts supporting a plurality of guardrail beams. Each post includes a pair of flanges having free edge portions with edge folds defining tubular beads on the free edge portions to provide reinforcement and desired to utilize a minimum amount of material usage for the posts.
U.S. Pat. Pub. Nos. 2014-0008594, 2012-0205603, and 2011-0186795, are incorporated herein by reference, disclose a metal foundation or highway guardrail post which comprises an elongated one-piece roll-formed metal body including a front wall defining an attachment face, a pair of opposing side walls orthogonal to the front wall, a first pair of inverted corners respectively connecting the pair of side walls to the front wall, and a second pair of inverted corners respectively extending from the pair of side walls and terminating in a pair of spaced rear edges to define a rear access opening opposite the front wall. The guardrail posts may be manufactured by roll-forming a metal sheet or coil and cutting the roll-formed metal sheet or coil into lengths.
There remains a need in the art for cost effective easy to install foundations. The foundations of the present invention reduces or eliminates the need for specialized installation equipment such as is the case for drilled foundations. The foundations of the present invention also substantially eliminate the expenses associated with the handling and disposal of excavation spoils, placing of concrete reinforcing rods, trucking and placement of concrete, and time delay associated with concrete curing before the foundation can be put in service.
This invention is directed to a flat-plate foundation support which includes a lower portion extending longitudinally along a central longitudinal axis of the support and adapted for insertion into a ground surface. The lower portion has a plurality of flat plates that are mutually connected along the central longitudinal axis of the support and extend laterally or radially from the central longitudinal axis. The flat plates are beveled and have a sharpened leading edge at a lower end of the lower portion. An upper portion of the support is attached to a top end of the lower portion. The upper portion of the support is attached to a ground supported apparatus to anchor the apparatus to the ground.
According to an embodiment of the present invention, the upper portion is a cylindrical pipe disposed over the top end of the lower portion and having an inner surface attached to the individual flat plates, which extend above the ground surface.
According to another embodiment of the present invention, the upper portion is a top plate that is disposed on the top end of the lower portion such that the plate extends across the top edges flat plates of the lower portion, which are disposed flush with the ground surface such that the top plate is disposed on the ground surface.
According to another embodiment of the present invention, the lower portion of the support includes an elongated plate having a center portion that is beveled, with respect to the longitudinal axis of the lower portion, and a bottom portion that is beveled more sharply, with respect to the longitudinal axis. The leading edge of both the center and bottom portions of the elongated plate are sharpened. The lower portion also includes a pair of side plates disposed on either side of the elongated plate and connected to the elongated plate along the central longitudinal axis. The lower end of the side plates is beveled and includes a sharpened leading edge. The length of the side plates along the central longitudinal axis is shorter than the length of the elongated plate such that the side plates are buried in the ground surface while the top end of the elongated plate extends above the ground surface. The upper portion of the support includes a pair of support plates disposed on top of opposing lateral ends of the elongated plate. The support plates may additionally be supported by one or more triangular gussets extending between the elongated plate and the support plate. One structure, such as an A-frame structure, or plural ground supported structures may be anchored according this embodiment.
According to another embodiment of the invention a one-piece, Z shaped steel plate foundation comprises a main plate body extending the longitudinal length of the foundation from a top to a bottom of the foundation, a single rear flange extending perpendicular to the main plate body in a first direction at a rear edge of the main plate body, wherein the single rear flange does not extend past the main plate body in the direction opposite the first direction, a single front flange extending perpendicular to the main plate body in the direction opposite the first direction at a front edge of the main plate body, wherein the single front flange does not extend past the main plate body in the first direction; and a plurality of mounting holes at the top of the one-piece metal plate foundation configured for attachment to the structure to be supported.
According to another embodiment of the invention a method of forming a one-piece metal plate foundation comprising the steps of: Providing a single flat steel plate wherein a central portion of the single flat plat forms a main plate body extending the longitudinal length of the foundation from a top to a bottom of the foundation; Bending a single rear flange extending at an angle from the main plate body in a first direction at a rear edge of the main plate body; and Bending a single front flange extending at an angle from the main plate body in the direction opposite the first direction at a front edge of the main plate body.
The features that characterize the present invention are pointed out with particularity in the claims which are part of this disclosure. These and other features of the invention, its operating advantages and the specific objects obtained by its use will be more fully understood from the following detailed description in connection with the attached figures.
For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific devices illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting.
As shown in
As shown in
With further reference to
It is to be appreciated that the foundation support 10 may be of any longitudinal length and the upper and lower portions may be of varying relative longitudinal lengths depending on the conditions of use. Additionally, the flat plates 14 and 16 may also be of varying thickness and lateral lengths extending from the central longitudinal axis and the diameter of the cylindrical pipe of the upper portion may be of a corresponding diameter depending on the conditions of use.
It is also to be appreciated that individual foundation supports may be pre-assembled and then shipped to a construction site for installation. In particular, the individual foundation supports 10 may be inserted into the ground surface individually by using a vibrator or push-it machine to apply vibration to the lower portion of the foundation support 10 while pushing downward on the top end in order to insert the foundation support into the ground 12 beginning with the beveled lower end. It is also to be appreciated that, depending on the application and conditions of the ground surface 12, the foundation support 10 may be inserted into the ground surface 12 without the necessity of pre-drilling a hole in the ground surface 12. Alternatively, the foundation support 10 may be installed in a pre-drilled hole depending on the conditions of the ground surface 12. Additionally, use of the foundation support 10 according to this embodiment substantially eliminates the need for backfilling of soil and/or concrete to complete the foundation, thus saving substantial construction time and costs. A ground supported structure may then be attached to the top of the cylindrical pipe. In operation, one or more foundation supports 10 may be provided to support a single structure.
The upper portion is distinct and comprises a top plate 32 that is disposed on the top end of the lower portion such that the top plate 32 extends across the top edges of the flat plates 14 and 16 of the lower portion, which are disposed flush with the ground surface 12 such that the top plate 32 is disposed on or near the ground surface 12. A ground supported structure is then attached to the top plate. Typically, the ground supported structure will include a mounting plate 34 having a corresponding structure to the top plate 32 of the support foundation 30. The two plates 32 and 34 may then be connected by known methods, such as bolt fasteners 36, as best shown in
The lower portion of the foundation support 50 also includes a pair of side plates 60, or side fins 60, disposed on opposing sides of the elongated plate 54 and connected to the elongated plate 54 along the central longitudinal axis by a known method, such as welding of the plates 60 along the central longitudinal axis. The lower ends of the side plates 60 are also beveled and include sharpened leading edges. It is to be appreciated that the beveled portions and sharpened edges are provided to facilitate the installation of the lower portion of the foundation support 50 without the necessity of pre-drilling or digging of a hole in the ground surface. The length of the side plates 60 along the central longitudinal axis is shorter than the length of the elongated plate 54, such that the side plates 60 are buried in the ground surface 12, while the top end of the elongated plate 54 extends above the ground surface 12.
As shown in
It is to be appreciated that the foundation support 50 shown in
It is also to be appreciated that individual foundation supports 50 may be pre-assembled and then shipped to a construction site for installation. In particular, the individual foundation supports 50 may be inserted into the ground surface individually by using a vibrator or push-it machine to apply vibration to the foundation support 50 while pushing downward on the top end in order to insert the foundation support 50 into the ground 12 beginning with the beveled lower end 58. It is also to be appreciated that, depending on the application and conditions of the ground surface 12, the foundation support 50 may be inserted into the ground surface 12 without the necessity of pre-drilling a hole in the ground surface 12. Alternatively, the foundation support 50 may be installed in a pre-drilled hole depending on the conditions of the ground surface. Additionally, use of the foundation support 50 according to this embodiment eliminates the need for backfilling of soil and/or concrete to complete the foundation, thus saving substantial construction time and costs. A ground supported structure, such as 70, may then be attached to the top plates 62 at the lateral ends of the elongated plate 54, as discussed above.
The foundation 80 includes a single rear flange 84 extending at an angle, preferably perpendicular, to the main plate body 82 in a first direction at a rear edge of the main plate body 82, wherein the single rear flange 84 does not extend past the main plate body 82 in the direction opposite the first direction.
The foundation 80 includes a single front flange 86 extending at an angle, preferably perpendicular, to the main plate body 82 in the direction opposite the first direction at a front edge of the main plate body 82, wherein the single front flange 86 does not extend past the main plate body 82 in the first direction.
The foundation 80 includes a plurality of mounting holes 88 at the top of the one-piece metal plate foundation 80 configured for attachment to the structure 100 to be supported. A pair of elongated oval shaped mounting holes in the main body 82 extending at an angle relative to elongated mounting holes on the associated structure 100 give adjustment in two directions for the coupling of the foundation 80 to the structure 100 (i.e horizontal adjustment along mounting holes 88 and vertical adjustment along mounting holes in the structure 100).
In the one one-piece metal plate foundation 80 according to
The one-piece metal plate foundation 80 according to
It is to be appreciated that the above-described embodiments of a flat plate foundation supports 10, 30 and 50 may be manufactured according to any technique known to be suitable to those having ordinary skill in the art and may be made from any material known to be suitable to those having ordinary skill in the art. According to one embodiment of the present invention, the flat plate foundation supports 10, 30 and/or 50 are made from steel and individual steel pieces of the foundation support are connected by welding and are pre-assembled and shipped to a construction site ready for installation.
A preferred method of forming the one-piece Z-shaped steel plate foundation 80 of
According to another embodiment of the present invention, the flat plate foundation supports 10, 30, 50 and/or 80 may be installed by a metal foundation push-it and installation apparatus of the type disclosed in U.S. Pat. Nos. 5,660,504, 5,733,068, and 5,944,452, all of which are incorporated herein by reference.
While several embodiments of a flat plate foundation support were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims and all changes to the invention that fall within the meaning and the range of equivalency of the claims are embraced within their scope.
This application is a divisional of U.S. patent application Ser. No. 15/242,723 filed Aug. 22, 2016 entitled “ONE-PIECE Z-SHAPED FLAT PLATE FOUNDATIONS AND METHOD OF FORMING SAME” and which published as U.S. Publication US 2017-0009419 A1 on Jan. 12, 2017, and which publication is incorporated herein by reference in its entirety. U.S. patent application Ser. No. 15/242,723 is a divisional of U.S. patent application Ser. No. 14/708,608 filed May 11, 2015 entitled “Flat Plate Foundation Supports” and which published as U.S. Publication US 2016-0024740 A1 on Jan. 28, 2016, and issued Aug. 23, 2016 as U.S. Pat. No. 9,422,687 and which publication and Patent are incorporated herein by reference in its entirety. U.S. patent application Ser. No. 14/708,608 is a divisional of U.S. patent application Ser. No. 14/346,656 filed Mar. 21, 2014 entitled “Foundation Apparatus and Method” and which published as U.S. Publication US 2014-0237913 A1 on Aug. 28, 2014 and which publication is incorporated herein by reference in its entirety. U.S. patent application Ser. No. 14/346,656 is a national stage of International Patent Application Serial Number PCT/US12/56699 filed Sep. 21, 2012 entitled “Foundation Apparatus and Method” and which published as International Publication WO 2013/044125 on Mar. 28, 2014 and which publication is incorporated herein by reference in its entirety. International Patent Application Serial Number 14/346,656 claims the benefit of provisional Patent Application Ser. Nos. 61/671,469 and 61/671,488 both filed Jul. 13, 2012 and both entitled “Foundation Apparatus and Method.” International Patent Application Serial Number 14/346,656 claims the benefit of provisional Patent Application Ser. No. 61/537,803 filed Sep. 22, 2011 entitled “Flat Plate Foundation Supports.”
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