Patent Application
20220081861
In many applications, elongate tubes or pipes, also known as piles, are used to support various structures. For example, piles may be driven into the ground to support large structures that are being built on varying ground types, and generally add increased stability for the structure being built. In some installations, it may be useful to use multiple piles that are inserted into the ground and placed upon one another in series. That is, the piles may need to reach a depth beyond a length of a single pile, so a second pile may be attached to the first pile in series, which may be followed by, e.g., a third pile, a fourth pile, a fifth pile, etc.
Some embodiments of the present disclosure provide a pile system for supporting structures comprising a first pile and a second pile, the first pile being configured to be coupled with the second pile. Each of the first pile and the second pile includes a first end having a first distal edge, a second end having a second distal edge, an elongate body, a transition region, and an annular seating shoulder. The elongate body can extend from the first end toward the second end and define an internal cavity with a longitudinal axis, the elongate body having a primary outer diameter and a primary inner diameter along at least 80% of a length of the elongate body. The transition region can be disposed between the elongate body and the second end, the transition region defining a secondary outer diameter. The primary outer diameter can be disposed proximate the first end, and the secondary outer diameter can be disposed proximate the second end, the secondary outer diameter being greater than the primary outer diameter.
The annular seating shoulder can be defined by an inner surface of the cylindrical elongate body. Further, the annular seating shoulder can define a step increase from the primary inner diameter to a secondary inner diameter, the secondary inner diameter being greater than the primary inner diameter. The transition region can include a convex surface and a concave surface that tangentially connect an outer surface of the second end and an outer surface of the elongate body. Further, the annular seating shoulder can include a cylindrical wall that extends circumferentially along the inner surface of the pile and an annular contact surface that is positioned perpendicular to the cylindrical wall. Moreover, the first end of the first pile can be configured to insert into the second end of the second pile until the first distal edge of the first pile contacts the annular contact surface of the second pile.
Some embodiments of the disclosure provide a pile that includes a first end, a second end, and a cylindrical, elongate body extending from the first end toward the second end. The elongate body can have a primary outer diameter and a primary inner diameter along at least 50% of a length of the elongate body. The pile can further include an internal seating shoulder disposed on an inner surface of the pile. Further, the pile can include a transition region disposed between the elongate body and the second end, the pile increasing from the primary outer diameter to a secondary outer diameter in the transition region, the pile having the primary outer diameter on a side of the transition region proximate the first end, and the pile having the secondary outer diameter on a side of the transition region proximate the second end. The secondary outer diameter can be greater than the primary outer diameter. The transition region can be configured such that the pile gradually increases from the primary outer diameter to the secondary outer diameter and an outer surface of the pile is a smooth, continuous curve within the transition region. Further, a diameter of the pile can increase within the transition region from the primary inner diameter to a secondary inner diameter, the transition region being configured such that the pile transitions from the primary inner diameter to the secondary inner diameter, and the internal seating shoulder is configured to receive the first end of a second pile.
Some embodiments of the disclosure provide a pile system for supporting structures on top of a ground surface. The pile system can be configured to extend into the ground to support the structures. Further, the pile system can include at least two piles being configured to couple to each other. The at least two piles each include a first end, a second end, and a cylindrical, elongate body extending from the first end toward the second end and defining an internal cavity with a longitudinal axis. The elongate body can have a primary outer diameter and a primary inner diameter, and the first end can have a first end outer diameter and a first end inner diameter that is equal to the primary outer diameter. The at least one pile can further include a transition region disposed between the elongate body and the second end, the pile increasing from the primary outer diameter to a secondary outer diameter in the transition region. Further, the pile can have the primary outer diameter on a side of the transition region proximate the first end, and the secondary outer diameter on a side of the transition region proximate the second end, the secondary outer diameter being greater than the primary outer diameter. The transition region can be configured such that the pile gradually increases from the primary outer diameter to the secondary outer diameter and an outer surface of the pile is a smooth, continuous curve within the transition region. Further, in the transition region, the pile can increase from the primary inner diameter to a secondary inner diameter, the transition region being configured such that the pile transitions from the primary inner diameter to the secondary inner diameter adjacent an internal shoulder disposed on an inner surface of the pile. The second end of a first pile of the at least two piles can be configured to receive the first end of a second pile of the at least two piles.
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of embodiments of the disclosure:
Before any embodiments of the disclosure are explained in detail, it is to be understood that the embodiments disclosed herein are not limited in application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The various embodiments disclosed herein are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
Also as used herein, unless otherwise specified or limited, directional terms are presented only with regard to the particular embodiment and perspective described. For example, reference to features or directions as “horizontal,” “vertical,” “front,” “rear,” “left,” “right,” and so on are generally made with reference to a particular figure or example and are not necessarily indicative of an absolute orientation or direction. However, relative directional terms for a particular embodiment may generally apply to alternative orientations of that embodiment. For example, “front” and “rear” directions or features (or “right” and “left” directions or features, and so on) may be generally understood to indicate relatively opposite directions or features.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the disclosure. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the disclosure. Thus, embodiments of the disclosure are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the disclosure. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the disclosure.
The terms “about” and “approximately,” as used herein, refer to variations in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for elongate tubes or pipes or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in manufacturing processes; through differences in the manufacture, source, or materials used to make the articles; and the like. Throughout the disclosure, the terms “about” and “approximately” may refer to a range of values±5% of the numeric value that the term precedes.
Piles are well known for use in a wide variety of applications, including, e.g., supporting building foundations, signs and posts, and retention walls, because of their ability to provide relatively strong resistance to axial forces with minimal disturbance to the soil and very little material. Commonly, piles include helical blades for cutting into the ground as the pile is rotationally drilled into place. More specifically, a pile generally includes an elongated shaft in the form of a solid rod or hollow tube that includes one or more helical blades mounted to an end thereof. Rotation of the shaft, such as by application of a torque motor driver or hydraulic auger, results in driving the shaft into the ground via the helical blades. In many installations, the pile may be required to reach a particular depth, e.g., to reach bedrock. In some instances, the depth of the bedrock is beyond a length of the pile. To that end, the pile may be required to be driven into the ground to a depth that is deeper than the length of the shaft supporting the blade or blades. In such installations, a secondary shaft, or extension shaft, may be attached at the primary shaft's trailing end. Successive extension shafts may be used in series until the desired or required depth is reached.
Generally, securing a secondary shaft to a primary shaft is accomplished in the field by aligning a socket or collar that is mounted to the end of one of the shafts with a corresponding or mating end of the other shaft such that mounting holes thereof align to receive fasteners therethough. Because this procedure is typically done on-site, is frequently conducted repeatedly during a single construction project, and requires sufficient precision, it can be time consuming. For example, aligning the holes of the shafts commonly requires incremental adjustments before the holes are sufficiently aligned for receiving a fastener therethrough. Therefore, a need exists for a pile system that facilitates precise alignment of the shafts during installation in the field, thereby enhancing installation efficiency and ease.
Referring now to
Still referring to
In the example of
Due to the design of the ends of the tube 54, proper alignment of the tubes, e.g., the first tube 58 and the second tube 62, can be tedious and difficult. For example, because the elongate shaft body 66 gradually transitions into the second end 74 via the transition region 78 along an inner surface thereof, over-inserting the first end 70 into the second end 74 is likely to occur, which could result in misalignment of the openings 82, 86. Similarly, in an effort to avoid over-insertion of the first tube 58 into the second tube 62, the first tube 58 may be cautiously or conservatively inserted, which may result in under-insertion thereof. Attempts to correct under-insertion and/or over-insertion may result in the opposite issue, i.e., over-insertion and under-insertion, respectively, which ultimately results in a tedious and inefficient installation process.
Embodiments of the present disclosure can help alleviate this issue, and others. For example, embodiments of the disclosure may provide a pile system that includes features that can be used to repeatedly couple pipes in series with enhanced precision. In this way, installation and assembly of pile systems that incorporate aspects of the present disclosure may require less time than existing systems, resulting in significant cost savings. Further, installation and assembly of systems incorporating aspects of the present disclosure may enhance other aspects of installation and assembly, thereby enhancing the systems.
The embodiments described below are presented in the context of piles and extension tubes or pipes intended for use in construction applications or related applications. Although these configurations can be particularly useful in construction applications, in part due to the frequency of installation, construction site conditions, and necessity for efficiency during construction projections, other configurations are possible. For example, the principles disclosed herein can be used with pipes and tubes intended for use in a variety of applications, such as, e.g., ceiling and/or wall structures, plumbing, HVAC, automobile frames and components, nautical vessels and accessories, light fixtures, and so on. Further, while embodiments of the disclosure are presented in the context of cylindrical pipes, embodiments of the disclosure may be used with pipes and articles having different shapes. For example, the present disclosure may be particularly useful with pipes having square, rectangular, or oval cross-sections.
Referring to
For the sake of clarity and brevity, opposing ends of the first tube 128 and the second tube 132 are shown in
Still referring to
With continued reference to
As discussed above, the first end 112 of the first tube 128 may be configured to couple to a mating component.
More specifically, the elongate shaft body 108 transitions into the second end 116 at a transition region 156, the transition region 156 being a region through which an inner diameter and an outer diameter of the second tube 132 changes. In the illustrated embodiment, the transition region 156 comprises an annular seating shoulder 160, also referred to as a positive stop, disposed on an internal surface 164 of the tube 132 at the transition region 156. As best illustrated in
Still referring to
In the illustrated embodiment, the tube 132 gradually transitions from the inner diameter d3 of the elongate shaft body 108 to the inner diameter d2 of the cylindrical wall portion 168. More specifically, and referring to
While the embodiment illustrated has the connecting angled surface 188 disposed between and connecting the cylindrical wall surface 180 and the inner surface 184 of the elongate shaft body 108, some embodiments may include a cylindrical wall surface that is even with an inner surface of the elongate shaft. That is, in some embodiments, an inner diameter of the cylindrical wall may be substantially equal to an inner diameter of the elongate shaft body such that the inner surfaces thereof of are continuous and smooth, i.e., substantially without curves, ridges, bumps, and/or steps along the axial direction. Furthermore, the cylindrical wall portion and the elongate shaft body may be connected by different structures. For example, in some embodiments, the inner surface of the elongate shaft portion may transition to the inner surface of the cylindrical wall portion via a step. The step may be abrupt or sharp in some embodiments, whereas the step may be filleted or gradual in other embodiments. Moreover, in some embodiments, an inner diameter of cylindrical wall portion may be greater than the inner diameter of the elongate shaft body. The transitioning features discussed above, e.g., angled surfaces, steps, filleted edges, etc., may also be used in such embodiments.
Still referring to
As shown in the cross-sectional view of
With continued reference to
Because the inner surface 196 and the annular contact surface 172 are substantially perpendicular in the present embodiment, and because the internal transition edge 192 is tangentially joined to both the inner surface 196 and the annular contact surface 172, the internal transition edge 192 may generally define a 90 degree curve. As illustrated in
An outer surface 200 of each pile 100, i.e., outer surfaces of the first tube 128 and the second tube 132, may generally exhibit a smooth transition between the elongate shaft body 108 and the second end 116. Referring to
Still referring to
Referring now to
While exemplary dimensions are provided herein, it should be understood that aspects of the present disclosure may be incorporated into tubes having a variety of shapes and sizes. Generally, embodiments of the present disclosure, such as the embodiment shown in
The wall thickness of a tube may depend on the tube's diameter. More specifically, a tube having a larger diameter (inner or outer) may have a larger wall thickness than a tube having a smaller diameter. For example, one common pile configuration has an outer diameter of 3.50 in. The outer diameter of 3.50 in. is associated with the first end outer diameter, i.e., the outer diameter D1 of the first end 112 (see
Furthermore, aspects of the present disclosure may be incorporated into tubes of a variety of lengths. For purposes of discussion, a length of the tube may be measured from a first distal end to a second distal end, i.e., the first distal edge 136 of the first end 112 to the second distal edge 152 of the second end 116. Some common lengths may include 5 feet (“ft.”), 7 ft., 8 ft., 10 ft., and 12 ft., for example. Tubes of varying lengths may be used in series to reach a required depth when being installed into the ground. For example, if tubes according to embodiment of the present disclosure are being used to support a structure that is being installed at a site having bedrock located approximately 50 ft. below a ground surface, a combination of varying tube lengths may be used in series to reach the bedrock.
Returning now to
Each of the first end 112 and the second end 116 include the plurality of openings 144, 148, respectively, that may be configured to be aligned with one another and receive fasteners, such as threaded bolts, rods, or studs, therethrough. Each opening 144, 148 is generally a hole that extends entirely through one of the first and second ends 112, 116. More specifically, each of the openings 144 on the first end 112 is an opening that extends into the first end 112 through a side wall thereof and out of the first end 112 through the side wall on an opposing side thereof. Generally, the openings 144 may be aligned such that an opening center axis 228 intersects and is perpendicular to the longitudinal axis of the tube. The aforementioned general characteristics may also apply to the openings 148 of the second end 116.
As shown in
A distance L2 represents a distance between the first distal edge 136 and a center point of an opening 144a of the plurality of openings 144 that is positioned closest to the first distal edge 136 taken along the longitudinal axis 124. Similarly, a distance L3 is the distance between the annular contact surface 172 and a center point of an opening 148a of the plurality of openings 148 this is positioned closest to the annular contact surface 172 taken along the longitudinal axis 124. Preferably, because alignment of the openings 144, 148 should be a result of the first distal edge 136 contacting the annular contact surface 172, the distance L2 and the distance L3 should be substantially similar. The distance L2 may be less than about 3.0 in., about 2.5 in., or about 2 in. Preferably, the distance L2 is between about 1.25 in. and about 1.75 in., or about 1.5 in. Correspondingly, the distance L3 may be less than about 3.0 in., about 2.5 in., or about 2 in. Preferably, the distance L3 is between about 1.25 in. and about 1.75 in. In the illustrated embodiment, the distance L3 is about 1.525 in. Thus, in some embodiments, such as the illustrated one, the distances L2 and L3 may vary slightly to account for tolerances. Preferably, a difference between the distance L2 and the distance L3 is less than about 0.1 in. Even more preferable, the difference between the distance L2 and the distance L3 is less than about 0.05 in. Furthermore, it should be understood that the distances L2 and L3 may have a variety of different values. For example, the distance L2 and/or the distance L3 may be greater than 2.0 in., 3.0 in., 5.0 in., or 10 in.
Moreover, each of the plurality of openings 144 on the first end 112 is spaced from each other by the distance L4, and each of the plurality of openings on the second end 116 is spaced from each other by a distance L5. Because each of the openings 144 on the first end 112 must generally align with the openings 148 on the second end 116 when assembled, the distance L4 and the distance L5 are preferably substantially equal. In some embodiments, the distance L4 is less than about 4.0 in., about 3.0 in., or about 2.0 in. In some embodiments, the distance L4 may be between about 1.25 in. and about 1.75 in. In some embodiments, the distance L4 may be between about 1.4 in. and about 1.6 in. or between about 2.8 in. and about 3.2 in. Similarly, the distance L5 may be less than about 4 in., about 3 in., or about 2 in. In some embodiments, the distance L5 may be between about 1.25 in. and about 1.75 in. In some embodiments, the distance L5 may be between about 1.4 in. and about 1.6 in. or between about 2.8 in. and about 3.2 in. In the illustrated embodiment, the distances L4 and L5 are about 1.50 in.
However, in some embodiments, the distances L4 and L5 may differ as a result of manufacturing tolerances. Preferably, a difference between the distances L4 and L5 is no greater than about 0.1 in. Even more preferable, the difference between the distances L4 and L5 is less than about 0.05 in. Furthermore, while each of the openings 144 on the first end 112 are evenly distributed in the illustrated embodiment, one or more openings may be unevenly distributed on the first end in alternative embodiments. Similarly, while each of the openings 148 on the second end 116 are evenly distributed in the illustrated embodiment, one or more openings on the second end may be unevenly distributed in alternative embodiments.
Still referring to
Referring again to
Further, the first tube 128 and the second tube 132 of the illustrated embodiment are designed so that the openings 144, 148 align when the first tube 128 is substantially or completely received by the second tube 132, i.e., the coupled configuration shown in
Therefore, embodiments of the present disclosure may provide a critical benefit of consistent and precise axial alignment during coupling. However, alternative embodiments may incorporate additional features for circumferential alignment as well. For example, by modifying first and second ends of a plurality of piles to have an oval cross-section, circumferential alignment can be ensured. That is, by having oval cross-sections, the first end may only be inserted into the second end in two positions, a first position and a second position, the second position being 180 degrees from the first position. In this way, alignment of the openings can be consistent circumferentially in addition to radially, thereby further easing and expediting an installation process.
Tubes, or piles, according to embodiments of the present disclosure may be fabricated according to a variety of methods. For example, a tube according to an embodiment of the present disclosure may be made of a high strength material such as steel, or any other high strength metal alloy, or non-metal composite. The tube may be a unitary homogenous structure created by processes such as forging, extruding, casting, and other known manufacturing techniques. In some embodiments, the tube is a forged steel cylinder, and the mounting holes are machined or pierced. Alternatively, the sleeve may be a fabrication of two or more parts that are assembled and consolidated into a unitary structure by known processes such as welding, brazing, or autoclave bonding. Generally, however, fabricating a pile that includes aspects taught herein with welding may be costly and difficult. Therefore, a preferred method of fabrication is forging. For example, a straight tube may be forged to create the widened second end having the positive stop, i.e., the seating shoulder 160 as shown in
Thus, embodiments of the disclosure can provide improved pile systems for accurately and efficiently coupling tubes. In some embodiments, for example, an improved pile according to the disclosure may include a seating shoulder on an internal surface thereof for created a stop, also referred to as a positive stop, which may limit an axial insertion of a mating pile. Thus, for example, align mating openings on a pair of piles in the field may be a simple procedure, thereby expediting an installation process.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the same. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
