SUPPORT FOOTING AND ANCHORING SYSTEM AND METHOD OF USE

Abstract

A support system and method to support structures in a substrate such as the ground. The system generally comprises a tubular hollow body with a conical head, and a number of smaller hollow tubes positioned inside. Each of the smaller tubes having a bend and an opening adapted to communicate with a corresponding opening in the hollow body head. In use, the assembly is driven into the substrate to the desired depth, and rods are driven down each of the smaller tubes so that they at least partially extend out from the head and into the surrounding substrate. The support system may also include a screw structure at the head to aid in driving the support system into the ground, and guards to protect the smaller tubes from damage during installation.

Description

BACKGROUND OF THE INVENTION

The present invention relates to support systems. More specifically, a support footing and anchoring system designed to be driven into a support substrate, such as the ground, and preferably below the frost line, and to provide support for various load bearing structures and constructions, such as piers, decks, buildings, foundations, signs, and the like.

Typical support systems for use in the construction industry make use of concrete footings reinforced with rebar to support foundations in construction projects and other load bearing applications. However, these and other concrete based support systems have inherent limitations. For example, such systems may take days before the concrete is cured enough to be worked on, and weeks to fully cure for use. Moreover, typical concrete support footings are susceptible to shifting and moving from their initial position, known as settling. Further, known concrete support systems require numerous installers having specialized skills and equipment for proper installation. Thus, there is a need for an improved support system.

The present invention provides a support system having several advantages as compared to the typical concrete and rebar based foundation support systems in use today. For example, since the present invention does not use concrete, it does not require curing and therefore is immediately ready to support loads after installation. Further, the unique tree root-inspired design provides an added support surface area than known systems making it much less susceptible to moving and shifting after installation. Moreover, the present system may be installed without the use of specialized personnel. The present invention achieves all of the above advantages all while needing less equipment and fewer specialized skillset personnel for installation.

SUMMARY OF THE INVENTION

The present invention is directed to a support system and method of use for support of various load bearing structures and constructions in the ground or other selected substrate.

The support system of the present invention includes an elongated, tubular hollow body having a longitudinal axis. The hollow body includes a first end, and an oppositely disposed second end, the first end including an opening for access to the hollow body interior. The elongated hollow body further comprises a head member attached to the second end. The head member includes a tip portion and at least one head opening, preferably a series of head openings, as will be discussed.

The support system further preferably includes an array of relatively smaller, interior hollow tubes, each one of the individual tubes being positionable in the hollow body interior and running substantially parallel to the longitudinal axis of the elongated hollow body. Each one of the interior hollow tubes preferably includes a relatively straight portion and a bend portion, the bend portion located at a distal end. The bend portion preferably deviates from the straight portion and longitudinal axis between 0 and 180 degrees. Each one of the interior hollow tubes being a through bore having an opening at a proximal end and an opening positioned at the distal end of the bend portion. The opening of each interior hollow tube distal end is arranged for communication with a corresponding head opening such that each head opening interfaces with a respective interior hollow tube distal end opening.

The support structure further comprises at least one rod member adapted to be positioned within a selected interior hollow tube, and arranged to protrude outwardly through the selected interior hollow tube distal end opening and corresponding head opening upon installation. Preferably the support structure includes a plurality of individual rod members, with each individual rod member positioned within a respective interior hollow tube, extending through the respective interior hollow tube and its tube opening. Each rod member being arranged to move in a longitudinal direction within a respective hollow tube during installation, such that once the support structure is located within the selected substrate, each rod member is moved through the respective hollow tube until at least a portion of the rod member protrudes from a respective head opening.

In another embodiment of the present invention, a top portion of the head member may include a threaded screw portion. The threaded screw portion assists the user during installation of the support system by providing enhanced means to drive the support structure into the soil.

Another embodiment of the present invention may include a series of guard members. The guard members are each preferably positioned on the head member and adjacent a corresponding head opening and toward the tip of each of the tube openings. The guard members are arranged to correspond to each of the interior hollow tube distal openings and to protect the hollow tubes and their respective openings from damage when the support system is being driven into the ground.

In yet another embodiment, the first end of the body may also include a post adapter. The post adaptor allows the body to be adaptable to various mechanical mating mechanisms, such as a foundation, a guywire, a pier, or the like.

The present invention further provides a method including the steps of:

providing an elongated, tubular hollow body having a longitudinal axis, the hollow body including a first end, an oppositely disposed second end, the first end including an opening for access to the hollow body interior, the elongated hollow body including a head member attached to the second end wherein the head member includes a tip portion and at least one head opening:

providing at least one, preferably an array, of relatively smaller, interior hollow tubes, each one of the hollow tubes being positionable inside the hollow body and running substantially parallel to the longitudinal axis of the elongated hollow body; each one of the hollow tubes having a relatively straight portion and a bend portion, the bend portion located at a distal end, each one of the hollow tubes being a through bore having an opening at a proximal end and an opening positioned at the distal end of the bend portion, and wherein the opening of each hollow tube distal end is arranged for communication with a corresponding head opening, such that each head opening interfaces with a respective interior tube opening;

providing at least one individual rod member positioned within a selected individual hollow tube, and arranged to protrude outwardly through the tube opening and corresponding head opening upon installation;

positioning at least one interior hollow tube inside the hollow body interior such that the distal end opening is in alignment with a head opening;

positioning the tubular hollow body with the head member pointed toward a support substrate, such as the ground;

driving the hollow body into a support substrate until it has reached a predetermined depth;

inserting the at least one rod member into a selected hollow tube; and

moving the at least one rod member through the selected hollow tube until at least a portion of the at least one rod member partially protrudes from the tube opening and corresponding head opening and into the support substrate.

A method according to the present invention may further include the steps of providing the hollow tube bend portion with a predetermined bend of between 0 degrees and 180 degrees measured from the longitudinal axis, and providing a tube opening positioned after the bend portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a support system according to the present invention.

FIG. 2 is an exploded view of the support system shown in FIG. 1.

FIG. 3A is a side view of the support system shown in FIGS. 1 and 2 being driven into a support substrate, such as the ground.

FIG. 3B is a view similar to that of FIG. 3A, but showing a further step of a rod member being inserted in a hollow tube.

FIG. 3C is a view similar to that of FIGS. 3A and 3B, but showing a further step of a rod member driven through a hollow tube, through a respective head opening, and into the support substrate.

FIG. 3D is a view similar to that of FIGS. 3A, 3B and 3C, but showing the support system in installed condition, with a plurality of rod members each extending from a respective hollow tube and into the support substrate.

FIG. 3E is an enlarged view of a portion of FIG. 3D.

FIG. 4 is a cross section of the support system shown in FIGS. 1-3D and taken along lines 4-4 of FIG. 3D.

FIG. 5 is a cross section view of the support system shown in FIGS. 1-4 and taken along line 5-5 of FIG. 4.

FIG. 6 is a fragmentary view of the support system and showing the first end of the body having a post adapter.

FIG. 7 is a fragmentary view of the support system and showing the head member having a threaded screw and a series of guard members.

FIG. 8 is a view of the support system but showing multiple rod members extending from the head member and body.

FIG. 9 is a view similar to that of FIG. 3D, but showing the first end of the body having flattened rods extending therefrom and engaging a support substrate.

FIG. 9A is a view similar to that of FIG. 9, but showing hollow tubes located on the outside of the body.

FIG. 10 is a view similar to that of FIG. 9, but showing multiple support systems arranged in an array.

FIG. 11 is a view similar to that of FIG. 3D but showing first end of the body having a post adapter and supporting a deck structure.

FIG. 12 is a view similar to that of FIG. 11 but showing first end of the body having a post adapter and supporting a pier structure.

FIG. 13 is a view similar to that of FIGS. 11 and 12 but showing first end of the body having a post adapter and supporting a sign.

FIG. 14 is a view similar to that of FIGS. 11-13 but showing first end of the body having a post adapter and supporting a guy wire connector.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

With reference to FIGS. 1 and 2, the support system 100 may be seen in its assembled and exploded condition. As seen, particularly in FIG. 2, the support system 100 preferably includes an elongated, tubular hollow body 102 having a longitudinal axis 104. The hollow body 102 includes a first end 106, and an oppositely disposed second end 108, the first end 106 including an opening 110 for access to the hollow body interior 112 (see FIGS. 4 and 5). The elongated hollow body 102 further preferably includes a head member 114 attached to the second end 105 of the body 102. As shown, the head member 114 includes a tip portion 116 and at least one head opening 112, preferably a series of head openings 118, as will be discussed in further detail.

With further reference co FIGS. 1 and 2, the support system 100 may be seen to include an array 120 of relatively smaller, interior hollow tubes 122, each one of the individual hollow tubes 122 being positionable in the tubular body interior 112 (see FIG. 4), and running substantially parallel to the longitudinal axis 104 of the elongated hollow body 102.

With particular attention to FIG. 2, each one of the hollow tubes 122 preferably includes a relatively straight portion 124 and a curved, bend portion 126, the bend portion 126 being located at a distal end 128. The bend portion 126 preferably deviates from the straight portion 124 between 0 and 180 degrees. Each one of the individual hollow tubes 122 being a through bore having an opening 130A at a proximal end 132 and an opening 130B positioned at the distal end 128 of the bend portion 126. The opening 130B of each interior tube 122 distal end 128 is arranged for communication with a corresponding head opening 118 such that each head opening 118 interfaces with a respective interior tube 122 opening 130B.

The support structure 100 further includes at least one rod member 134 positioned within a selected hollow tube 122, and arranged to protrude outwardly through the selected tube distal end opening 130B and corresponding head opening 118 upon installation. As previously mentioned, the head member 114 is preferably provided with series of head openings 118 corresponding to the number of individual hollow tubes 122, and respectively positioned to interface with each of the distal end tube openings 130B. As is shown, the support structure 100 preferably includes a plurality of individual rod members 134, with each individual rod member 134 being positioned within a respective hollow tube 122, extending through the respective hollow tube 122, and extending through the respective tube opening 130B.

In an embodiment, the elongated hollow body 102 takes the form of a tube having a wall 132. As may be seen particularly in FIG. 4, the cross section of the hollow body 102 is substantially circular and having an inner diameter D1 and outer diameter D2, the diameters D1, D2 defining hollow body wall thickness T1. As mentioned, the elongated hollow body 102 includes a longitudinal axis 104 that extends along the longest dimension of elongated hollow body 102. The two diameters, D1, D2 of the elongated hollow body 102 may vary depending on the application but the thickness of elongated hollow body wall 133 must be sufficient to maintain its shape without undue distortion when the system 100 driven into the ground or other substrate 136 (see for example FIGS. 3A-3D). Moreover, the inner diameter D1 is preferably of a dimension large enough to accommodate an array 120 of hollow tubes 122 as may be required for a specific installation. The elongated hollow body 102 may be fabricated from a repurposed oil drilling pipe, or other like structure that is manufactured of high carbon steel or aluminum alloys and designed to be rigid and strong enough to maintain shape when being driven into a selected substrate 136, such as the ground, lake bed, or the like. As mentioned, the elongated hollow body 102 includes an opening 110 on a first end 106 to allow access to the interior 112. An array 120 of interior hollow tubes 122 is positioned inside the elongated hollow body 102 and perpendicular to the longitudinal axis 104.

As previously mentioned, the support system 100 further includes an array 120 of individual hollow tubes 122. The hollow tubes 122 are preferably manufactured of a rigid material similar to that of the elongated hollow body 102, such as high carbon steel or other acceptable rigid metal alloy. As is shown in the Figures, the individual hollow tubes 122 are preferably arranged in a compact and space efficient manner, for example, they may be arranged in such a way as to allow the maximum number of individual hollow tubes 122 of a selected outer diameter within the elongated hollow body 102. The individual hollow tubes 122 may be arranged symmetrically, in an asymmetrical pattern, or the system 100 may include fewer individual hollow tubes 122. Another embodiment, such as that shown in FIG. 9A, may include an array 120 of tubes 122 arranged along the exterior of the elongated hollow body 102. Such variations in hollow tube 122 arrangement are within the scope of the present invention, and may be desired in various installation placements such as, for example, if the selected substrate 136 does not have uniform structural integrity, such as during installation along a clay or sand deposit, or other specific applications.

With particular attention to Figure it may be seen that each of the individual hollow tubes 122 primarily includes two portions. A first, substantially straight portion 124 is positioned generally parallel to the longitudinal axis 104 of the elongated hollow body 102. A second, curved bend portion 126 is located at a distal end 128 of the inner hollow tube 122. The curved bend portion 126 preferably deviates between zero and 180 degrees from the longitudinal axis 104. As mentioned, each tube 122 also includes two openings 130A, 130B located opposite each other, opening 130A being located at the proximal end 132, and opening 130B located after the bend portion 126 at an oppositely disposed distal end 128.

Again referring to FIG. 1, the support system 100 may be seen to include a head member 114 located at the second end 108 of the hollow elongated body 102 and opposite the first end 106. The head member 114 includes a tip portion 116 that is shaped to aid the support system 100 to penetrate the selected substrate 136 during installation. As is shown, the head member 114 is of a generally conical shape and may be manufactured as a separate component or integrally formed with the body 102. The head member 114 may be manufactured of rigid metal alloys similar to that of the hollow elongated body 102 and the individual hollow tubes 122. The head member 114 may be bolted, welded, or otherwise mechanically affixed to the second end 108 of the hollow elongated body 102. Alternatively, the head 114 could take other shapes and forms including simply cutting the second end 108 of the hollow elongated body 102 at an oblique angle (not shown).

With attention to FIGS. 2 and 5, the head member 114 may be seen to include at least one, and preferably a series, of head openings 118. Each head opening 118 is arranged to interface with a respective hollow tube 122 opening 130B. While the Figures depict the hollow tubes 122 as flush with outer surface of the head member 114, it is to be understood that other arrangements are within the scope of the present invention, including, but not limited to, the hollow tubes 122 extending outward at least partially from the head member 114. Moreover, while the Figures illustrate the head openings 118 as being symmetrically arranged about the head member 114, similarly to the hollow tubes 122, they may be arranged in asymmetric patterns, depending on the application.

With specific attention to FIG. 7, an embodiment of the head member 114 may be seen in more detail. As shown, at least one, and preferably a series of guard members 140 may be installed adjacent respective head openings 118. The guard members 140 are arranged to shield and protect the head openings 118 during installation and to deflect rocks or other debris encountered during installation. As is illustrated, each guard member 140 is preferably located proximate a respective individual head opening 118. With continued attention to FIG. 7, it may be seen that other features may optionally be included proximate the tip portion 116 of the head member 114 to aid the support system 100 during installation and being driven into a selected substrate 136 (see FIGS. 3A-3D). For example, the head member 114 may include a threaded portion 142. In this embodiment, the threaded portion 142 aids the support structure 100 as it is torqued about the longitudinal axis 104 while being driven into the selected substrate 136, such as the ground (see FIGS. 3A-3D).

With attention now to FIGS. 2-3D, the support structure 100 may be seen to include a plurality of rod members 134. Each rod member 134 is adapted to be positioned within a respective hollow tube 122. The rod members 134 are preferably fabricated of a metal alloy that is softer and more malleable than the alloy used to manufacture the hollow tubes 122 and tubular body 102 to assist in deformation during installation, as will be discussed. For example, in an embodiment, the rod members 134 may be constructed of common steel rebar. During installation of the support system 100, each rod member 134 is driven into a respective opening 130A of a selected hollow tube 122. Each rod member 134 is moved in a longitudinal direction along the axis 104 and through the selected hollow tube 122 straight portion 124. When the rod member 134 reaches the bend portion 126 of the hollow tube 122, the curvature of the bend portion 126 will deform and bend the rod member 134 towards the tube opening 130B. Each rod member 134 is further driven into each selected hollow tube 122 and into the bend portion 126 until each one protrudes, at least partially, out of the tube opening 130B and corresponding head opening 113, and outwardly into the selected substrate 136. The distal end 156 of the rod member 134 may be tapered or pointed, as is shown in FIG. 3E, for ease in installation. Moreover, and as may be seen in FIG. 3D, upon installation the rod members 134 fan out from the tip portion 116 to produce a structure similar to the roots of a tree.

It is to be understood that the number of rod members 134 used and the distance they protrude outwardly from the tip portion 116 and into the surrounding substrate 136 depends on the specific application, but generally the support system 100 is more stable when the rod members 134 are driven further into the surrounding substrate 136 and when used in greater numbers. In this way, the support system 100 of the present invention is scalable for use in a variety of applications.

Although not shown in the Figures, the present invention may include the use of multiple rod members 134 within each individual hollow tube 120. Moreover, it is within the scope of the present invention to utilize hollow tubes 122 of varying diameter or material. Further, and as shown in FIG. 10, the present invention may be scaled to utilize more than one support system 100 installed in close proximity to one another. In yet another embodiment, and as seen in FIG. 9, at least one rod member 134 may extend outwardly from the opening 130A of the proximal end 132 of a respective hollow tube 122. In this arrangement, the extending rod member 134A may be bent perpendicular to the longitudinal axis 104 to provide further stability of the system 100. Moreover, a concrete foundation 144 or like structure, may be poured over the support system 100, and interface directly with rod members 134A.

With attention now to FIG. 6, the first end 106 of the tubular body 102 is shown in greater detail. As shown, an embodiment of the system 100 may include a post adapter 146. A post adaptor 146 may be utilized to adapt the system 100 to support a variety of devices. For example, and as shown in FIGS. 11-14, the post adaptor 146 allows the tubular body 102 to secure devices such as, by non-limiting example, a deck support 146 (see FIG. 11), a dock support 150 (see FIG. 12), signpost 152 (see FIG. 13), a guywire mooring 154 (see FIG. 14), or any number of uses that require a stable and secure foundation in the ground.

The present invention further includes a method of use. A method according to the present invention may be seen particularly in the views of FIGS. 3A-3C. A method includes the steps of:

providing an elongated, tubular hollow body 102, the tubular hollow body 102 having a longitudinal axis 104 a first end 106, and an oppositely disposed second end 108. The first end 106 including an opening 110 for access to the hollow body interior 112. The elongated hollow body 102 including a head member 114 attached to the second end 108 wherein the head member 114 includes a tip portion 116 and at least one head opening 118;

providing at least one, preferably an array 120 of relatively smaller, hollow tubes 122, each one of the hollow tubes 122 being a through bore and having a proximal end 132, a distal end 128, a relatively straight portion 124 and a bend portion 126, the bend portion 126 located at the distal end 128, an opening 130A at the proximal end 132 and an opening 130B at the distal end 128;

providing at least one rod member 134;

positioning the at least one hollow tube 122 inside the hollow body interior 112

aligning the distal end 129 opening 130B with a selected head opening 118;

positioning the tubular body 102 with the head member 114 pointed toward a support substrate 136;

driving the tubular body 102 into a support substrate 136 in a longitudinal direction and in the direction of arrow A until it has reached a predetermined depth;

moving at least one rod member 134 into a hollow tube 122 in the direction of arrow B;

moving at least one rod member 134 into a hollow tube 122 in the direction of arrow C of such that the rod member 134 at least partially protrudes from the tube opening 130B and into the support substrate 136.

A method according to the present invention may include the further steps of providing the interior tube bend portion 126 with a predetermined bend of between 0 degrees and 180 degrees, measured as a deviation from the longitudinal axis 104, and positioning the tube opening 130B after the bend portion 126. The method may also include the step of providing a plurality of hollow tubes 122 and a plurality of rod members 134.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Claims

1. A support system comprising: an elongated hollow body having a longitudinal axis, a first body end having a body opening, and an oppositely disposed second end;at least one hollow tube, said at least one hollow tube being positioned inside the body and being parallel to said longitudinal axis; said at least one hollow tube including a straight section, and a bend between 0 degrees and 180 degrees measured from the longitudinal axis; a tube opening positioned after the bend;a head member attached to the second end of the elongated hollow body, including, a series of head openings corresponding to each of the number of individual hollow tubes and respectively positioned to interface with each of the tube openings, the head member further including a tip portion; andan array of rods comprising a number of individual rods positioned within at least some of the individual hollow tubes and protruding outward from each of the respective head openings.

2. The support system of claim 1, wherein the head further comprising a screw portion positioned at the tip portion.

3. The support system of claim 1, wherein the head member further includes a plurality of guards corresponding to each of the number of individual hollow tubes and respectively positioned toward the tip portion of each of the tube openings.

4. The support system of claim I further comprising a post adapter positioned at the first end of the elongated body.

5. A method for installing a support system including the steps of: providing a support system including an elongated hollow body having a longitudinal axis, a first end having body opening, an oppositely disposed second end; an array of interior hollow tubes positioned inside the body and running parallel to the longitudinal axis, the array including a predetermined number of individual hollow tubes, each individual hollow tube comprising a straight portion, and a bend portion, the bend portion having a predetermined bend of between 0 degrees and 180 degrees, measured from the longitudinal axis; a tube opening positioned after the bend portion; a head member attached to the second end of the elongated hollow body, the head member including a series of head openings corresponding to each of the number of individual hollow tubes and respectively positioned to interface with each of the tube openings;positioning the support system with the head pointed toward a selected substrate;driving the support system into the ground until it has reached a desired depth;forcing rods down at least some of the hollow tubes such that that they at least partially protrude from the tube opening and corresponding head opening into the substrate.

6. A support system comprising: an elongated, tubular hollow body, said hollow body having a longitudinal axis, a hollow body interior, a first end having an opening, and an oppositely disposed second end, said second end including a head member, said head member including at least one head opening;at least one interior hollow tube, said at least one hollow tube including a distal end, a proximal end, a relatively straight portion and a curved, bend portion, said bend portion being located at said distal end, said at least one interior hollow tube being relatively smaller than said tubular hollow body, and being positionable in said tubular body interior, and running parallel to said longitudinal axis; andat least one rod member positioned within said at least one hollow tube.

7. The support system of claim 6 wherein said bend portion deviates from said straight portion between 0 and 180 degrees.

9. The support system of claim 7 wherein said at least one hollow tube includes a tube opening at said proximal end and a tube opening at said distal end, and wherein said opening at said distal end is arranged for communication with said at least one head opening.

9. The support system of claim 9 wherein said head member includes a plurality of head openings.

10. The support system of claim 9 further including a plurality of hollow tubes, and a plurality of rod members, said each one of said plurality of rod members being positioned within a respective hollow tube, and being positioned to interface with each of the distal end tube openings.