Helical Drive Conversion System

Description

FIELD OF THE INVENTION

The present invention relates generally to construction. More specifically, the present invention is a helical drive conversion system to attach a helical member and coupling member to an H-beam or pipe pile thereby streamlining the installation process.

BACKGROUND OF THE INVENTION

In construction projects, installing pipe piles and H-beams into the ground is a critical process to provide foundational support for various structures. These piles transfer the load from the structure to deeper, more stable soil layers or bedrock. The installation process requires specialized equipment and techniques designed to penetrate the ground efficiently and securely, ensuring the structural integrity of the project.

Currently, pipe piles and H-beams are often installed using impact driving or rotary drilling techniques. Traditional impact driving methods involve repeatedly striking the pile with a heavy weight to drive it into the ground. While effective in certain soil types, this method can be disruptive to the surrounding environment, generating significant noise, vibrations, and potential damage to nearby structures. In challenging soil conditions, such as dense clay or rocky layers, impact driving may fail to achieve adequate penetration, resulting in insufficient bearing capacity and compromising the pile's stability.

Rotary drilling offers an alternative installation method by rotating the pile into the ground. This method is generally less disruptive to the surrounding soil and environment, making it a preferable option where minimizing ground disturbance is critical. However, existing methods for rotary installation often require additional equipment, including augers and conversion systems. While effective in certain conditions, the added complexity to the installation process, thereby increases the time required to complete the installation. Additionally, the need for specialized equipment on-site further escalates project costs and logistical challenges.

The present invention addresses the limitations of these prior art systems by eliminating the need for additional equipment and simplifying the installation process.

One key feature of the present invention is the integration of a bearing enhancement element with a drive tool element. The bearing enhancement element includes a helical plate that significantly increases the end-bearing surface area of the pile. This increased surface area is particularly advantageous in soils where impact driving fails to achieve sufficient penetration. By enhancing the stability and load-bearing capacity of the pile, the present invention allows for the use of shorter H-beams or pipe piles without compromising structural integrity, resulting in significant cost savings on both materials and labor.

Furthermore, the rotary installation method facilitated by the drive tool element in the present invention ensures a more controlled and efficient installation process. Unlike traditional impact driving methods, this rotary installation is less disruptive to the surrounding soil, making it particularly effective in challenging ground conditions such as dense clay or rocky layers. The present invention reduces environmental impact by minimizing vibrations and ground disturbance, while also decreasing the risk of damage to nearby structures. This makes it a more sustainable solution for urban or environmentally sensitive construction sites.

The present invention also offers significant adaptability for a wide range of construction applications. It is compatible with both H-beams and pipe piles, providing versatility for different project requirements. The modular design of the present invention allows for the use of multiple bearing enhancement elements in series, enabling customization based on the axial capacity required for each specific project. The modular nature also simplifies manufacturing and logistics, as users can source local H-beams or pipe piles and attach the various configurations of the present invention, thereby reducing the need for costly shipping across regions.

In summary, the present invention provides a versatile, cost-effective, and environmentally considerate solution for installing pipe piles and H-beams in construction projects. By enhancing the bearing capacity of piles, streamlining the installation process, and offering adaptability for different construction environments, the present invention represents a significant improvement over the prior art. Its composite design and rotary installation method eliminate the need for additional equipment, reducing time, cost, and environmental impact while improving the overall stability and load-bearing capacity of installed piles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a profile view of the present invention.

FIG. 2 is an alternate profile view of the present invention, further comprising details “FIG. 3” and “FIG. 4”.

FIG. 3 is a detail view of detail “FIG. 3” from FIG. 2.

FIG. 4 is a detail view of detail “FIG. 4” from FIG. 2.

FIG. 5 is an exploded profile view of one embodiment of the present invention.

FIG. 6 is an exploded perspective view of the present invention showing hidden features in broken lines.

FIG. 7 is a perspective view of one embodiment of the bearing member of the present invention.

FIG. 8 is a perspective view of one of the plates of the present invention.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure and are made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the ordinary artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” The following detailed description refers to the accompanying drawings.

Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.

Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

Unless otherwise indicated, the drawings are intended to be read together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up”, “down” and the like, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader.

Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of a helical drive conversion system 1, embodiments of the present disclosure are not limited to use only in this context.

The present invention, as shown in FIG. 1, is a helical drive conversion system 1 comprising an at least one coupling member 10 and an at least one bearing member 20. In the context of the present invention, the helical drive conversion system 1 is adjustably coupled to an elongated member 3, wherein said elongated member 3 comprises a first distal end 31, a second distal end 32, and a proximal portion 33. In the context of the present invention, the first distal end 31 and the second distal end 32 are opposing ends of the elongated member 3, wherein the proximal portion 33 of the elongated member 3 is the portion of said elongated member 3 interposed between said first 31 and second 32 distal ends. Additionally, in the preferred embodiment of the present invention, the elongated member 3 is an H-beam, also referred to herein as an “I-beam,” as is understood within the art, wherein said H-beam comprises an H-shaped cross section. In some embodiments of the present invention, the elongated member 3 is a pipe pile wherein said pipe pile comprises a circular cross section. Further, in the context of the present invention, the at least one coupling member 10 and the at least one bearing member 20 are offset one another along a longitudinal direction corresponding to a longitudinal axis 34 of the elongated member 3 when the helical drive conversion system 1 is positioned on the elongated member 3. In the preferred embodiment of the present invention, the at least one coupling member 10 is offset from the at least one bearing member 20 at a position that is higher along the elongated member 3.

Regarding FIG. 2 and FIG. 3, in the preferred embodiment of the present invention, the at least one coupling member 10 is removably coupled to the first distal end 31 of the elongated member 3. In the preferred embodiment of the present invention, the at least one coupling member 10 comprises a coupling casing 11 and a plurality of coupling plates 12 wherein the coupling casing 11 is a tubular member comprising opposing distal ends—a first distal end 112 and a second distal end 113—wherein the plurality of coupling plates 12 are integral an interior channel 111 of the coupling casing 11 such that each coupling plate of the plurality of coupling plates 12 is offset within the coupling casing 11. In the context of the present invention, the interior channel 111 of the at least one coupling member 10 traverses longitudinally through the at least one coupling member 10. Additionally, within the context of the present invention, the plurality of coupling plates 12—comprising a first coupling plate 121 and a second coupling plate 122—are positioned such that the first coupling plate 121 is adjacent the first distal end 112 of the coupling casing 11 and the second coupling plate 122 is adjacent the second distal end 113 of the coupling casing 11—offset from one another in a longitudinal direction aligned with the longitudinal axis 34 possessed by the elongated member 3.

Within the context of the present invention, the elongated member 3 is adjustably received within the interior channel 111 of the at least one coupling member 10. Further, in the preferred embodiment of the present invention, the at least one coupling member 10 comprises a through hole 115, extending into the interior channel 111, wherein a threaded fastener is able to be threadedly engaged with said through hole 115, thereby securing the at least one coupling member 10 to the elongated member 3. In the preferred embodiment of the present invention, the at least one coupling member 10 comprises a cross section wherein the interior channel 111 comprises a cross-sectional area that is configured to correspond to the cross-section of the elongated member 3. In some embodiments of the present invention, the at least one coupling member 10 is removably coupled to the first distal end 31 of the elongated member 3, thereby allowing a user to remove the at least one coupling member 10 from a first elongated member and utilize said coupling member in combination with a second elongated member, and so forth.

Similarly, as shown in FIG. 2 and FIG. 4, in the preferred embodiment of the present invention, the at least one bearing member 20 is coupled to the second distal end 32 of the elongated member 3. In the preferred embodiment of the present invention, the at least one bearing member 20 comprises a bearing casing 21, a plurality of bearing plates 22, and a helical member 23, wherein the bearing casing 21 is a tubular member comprising opposing distal ends—a first distal end 213 and a second distal end 214—such that the plurality of bearing plates 25 are integral an interior channel 211 of the bearing casing 21 such that each bearing plate of the plurality of bearing plates 22 is offset within the bearing casing 21. Further, in the context of the present invention, the helical member 23 spirally traverses about an exterior portion 212 of the bearing casing 21. Additionally, within the context of the present invention, the plurality of bearing plates 22—comprising a first bearing plate 221 and a second bearing plate 222—are positioned such that the first bearing plate 221 is adjacent the first distal end 213 of the bearing casing 21 and the second bearing plate 222 is adjacent the second distal end 214 of the bearing casing 21—offset from one another in a longitudinal direction aligned with the longitudinal axis 34 possessed by the elongated member 3.

In the preferred embodiment of the present invention, the bearing casing 21 comprises an interior channel 211 traversing longitudinally through the bearing casing 21. In the context of the present invention, the interior channel 211 comprises a cross section wherein said interior channel 211 comprises a shape configured to receive the elongated member 3. Additionally, in the preferred embodiment of the present invention, the at least one bearing member 20 further comprises a through hole 216 wherein said through hole 216 extends perpendicularly through the bearing casing 21, entering the interior channel 211 of the bearing casing 21. In the context of the present invention, a threaded fastener is able to be threadedly engaged with said through hole 216, thereby securing the at least one bearing member 20 to the elongated member 3.

In some embodiments of the present invention the at least one bearing member 20 is coupled to a location on the proximal portion 33 of the elongated member 3. In some embodiments of the present invention, as shown in FIG. 5, the at least one bearing member 20 comprises a plurality of bearing members 25 including a first bearing member 251 and a second bearing member 252 wherein the second bearing member 252 is coupled to the second distal end 32 of the elongated member 3 and the first bearing member 251 is coupled to the proximal portion 33 of the elongated member 3. In the context of the present invention, the elongated member 3 may be composed of a plurality of elongated members 3b, coaxially configured, such that the first bearing member 251 receives a distal end from both, a first elongated member and a second elongated member, positioning the second bearing member at a proximal position relative to the entire length of the elongated member. In the context of the present invention, the at least one bearing member 20 is fixedly coupled to the elongated member 3, wherein the user adjustably positions the at least one bearing member 20 onto the elongated member 3 and fixedly secures said bearing member into said position using an at least one fastener. In some embodiments of the present invention, the at least one fastener comprises a plurality of fasteners. Furthermore, in the context of the present invention, the at least one fastener is a threaded fastener.

Further, as shown in FIG. 5, in the context of the present invention, the at least one bearing member 20 may take form of a plurality of configurations including a proximal configuration 24b and a distal configuration 24a. In the context of the present invention, in the proximal configuration 24b, the at least one bearing member 20 is a tubular member comprising opposing distal ends 213,214 that are approximately parallel. Conversely, in the distal configuration 24a, the at least one bearing member 20 comprises a configuration wherein the opposing distal ends 213,214 of the bearing casing 21 are skewed such that the second distal end 214 of the bearing casing comprises a cut 2141 wherein said cut 2141 is at an oblique angle relative to a longitudinal axis traversing the bearing casing 21—as shown in FIG. 5. In the preferred embodiment of the present invention, in the distal configuration 24a of the at least one bearing member 20, the second distal end 214 is disposed on an angle, whereby the plane possessed by the first distal end 213 is intersecting the plane possessed by the second distal end 214. In the preferred embodiment of the present invention, the cut 2141 comprises an angle of 45 degrees, thereby producing a high-pressure interface at the bottom-most portion of the second distal end 214. As shown in FIG. 6, in some embodiments of the present invention, the helical drive conversion system 1 comprises one coupling member 10 and one bearing member 20 comprising a distal configuration 24a, offset in a longitudinal direction corresponding to a longitudinal axis 34 maintained by the elongated member 3. Additionally, in the preferred embodiment of the present invention, the cross section of the at least one bearing member 20 corresponds with the cross section of the elongated member 3. For example, in embodiments wherein the elongated member is an H-beam, the cross section of the at least one bearing member 20 is a rectangle. Likewise, in embodiments wherein the elongated member is a pipe pile, the cross section of the at least one bearing member 20 is a circle, as shown in FIG. 7.

Furthermore, the helical member 23, as shown in FIG. 6 and FIG. 7, in the preferred embodiment of the present invention spirally traverses about the exterior portion 212 of the bearing casing 21 one revolution. Additionally, within the context of the present invention, the helical member 23 extends outwardly from the bearing casing 21. In the preferred embodiment of the present invention, the helical member 23 extends outwardly at a ratio that is 3:1 in relation to a distance between the plurality of bearing members 25.

In the preferred embodiment of the present invention, as shown in FIG. 8, the plurality of plates including: the plurality of coupling plates 12 and the plurality of bearing plates 22; comprise a perimetrical profile 123,223 and a cutout 124,224 wherein the perimetrical profile 123,223 corresponds to the cross section of the interior channel 111,211 of the respective member (i.e. the at least one coupling member 10, the at least one bearing member 20) while the cutout 124,224 corresponds the cross section of the elongated member 3. In the context of the present invention, each plate—the plurality of coupling plates 12 and the plurality of bearing plates 22—is interposed between the respective member—the at least one coupling member 10 and the at least one bearing member 20, respectively—and the elongated member 3; thereby positioning the elongated member 3 along an approximate central longitudinal axis of each of the at least one coupling member 10 and the at least one bearing member 20.

In the context of the present invention the elongated member 3 traverses through the interior channels 111,211 of both the at least one bearing member 20 and the at least one coupling member 10, whereby the plurality of plates 12,22 are interposed between the elongated member 3 and the respective members. In the preferred embodiment, in the intended use, the coupling member 10 is coupled to the first distal end 31 of the elongated member 3, the at least one bearing member 20 is coupled to the second distal end 32 of the elongated member 3, and a tool capable of providing torque is attached to the at least one coupling member 10. Upon providing torque to the at least one coupling member 10, the helical drive conversion system 1 and attached elongated member 3 rotate, thereby driving the at least one bearing member 20 into the ground. In some embodiments of the present invention, a plurality of bearing members 25 are used to couple multiple elongated members 3 together.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention.