WING DIAMOND FOUNDATION
A foundation including first and second wings, each including first and second wing portions and a bent portion. The first and second wing portions and the bent portion, of each of the first and second wings, are made of a single sheet of metal. The first wing portions of the first and second wings are connected to each other. The second wing portions of the first and second wings are connected to each other. The bent portions of the first and second wings are spaced apart from each other.
This application claims the benefit of U.S. Provisional Patent Application No. 62/092,374, filed on Dec. 16, 2014, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND1. Field
Exemplary embodiments of the present invention relate to a foundation and method of fabricating and using the same. In particular, exemplary embodiments of the present invention relate to metal plates that are bent and bolted together, which can then be inserted into the ground and used as a foundation.
2. Discussion of the Background
Conventionally, various types of structural loads may be supported through the use of foundations inserted into the ground. Foundations may be used to support communication towers, transmission and utility poles, roadway signs, retaining and sound walls, and the like. Foundations may be subject to four testing forces comprising compression, uplift, lateral, and torsional. The effect of the testing forces may be understood by moment and shear stress calculations deduced by measuring deflection, rotation, settlement, and uplift of the foundation. Foundations may be subject to shear and bending stresses to measure settlement, uplift, rotation, and deflection before installation.
One type of foundation is a concrete caisson, where a hole is drilled in the ground and cast concrete fills the drilled hole. Structural reinforcement, such as steel rebar, may be disposed in the concrete. However, there are some disadvantages to concrete caissons, such as associated construction costs. For instance, it may be necessary to build roads leading to the installation site for the caisson so a truck can pour concrete therein. Construction costs may quickly escalate since multiple trucks carrying concrete may be needed to fill a single caisson. Further costs and time delays associated with caisson formation may be from rebar, rebar piers, machinery such as excavators, front loaders, and cranes, fuel, grounding wire, and labor.
There may also be a lengthy construction period for forming concrete caissons, including site selection, equipment deployment, hole excavation and dewatering, rebar installation, and concrete pouring. Concrete caissons may require strength testing between 14 and 28 days, and only after the concrete has set may the top load then be installed. There is also the potential for delays due to weather, further increasing the construction period.
Displacement pile foundations, which may be made of steel or other metal, may be used instead of concrete caissons. However, conventional displacement pile foundations may not be suitable for accommodating loads subject to the forces mentioned above, without requiring specialized structures that may make them large and expensive. One type of displacement pile foundation is disclosed in WO 2013/044125, where plates are welded to each other to form fins extending from a center point. However, there are structural drawbacks to using welding in pile foundations, such as when the foundation is installed in the ground, because if the welded foundation hits rock or other obstruction, structural integrity of the welds themselves may be compromised. Also, welding may have a negative impact on the environment and human health. Welding can produce carbon monoxide, hydrogen fluoride, and nitrogen oxide, exposure to which may affect the brain, nervous system, and other organs, on both a short and long term basis.
Another type of displacement pile foundation is the metal fin pipe foundation, such as disclosed in U.S. Pat. Pub. No. 2005/0232707, where metal fins are welded to a central metal tube or pipe. However, the metal fin pipe foundation may require the ground into which the foundation is to be installed to be pre-drilled, adding time and cost to the installation process.
Foundations may be galvanized in order to protect them from oxidation and rust. In foundations that are welded, the galvanization may be done after welding. If welding is performed after galvanization, the welding process may harm the zinc plating applied previously during galvanization and decrease the effectiveness thereof. However, if welding is performed prior to galvanization, then the metal fin pipe foundation may either need to be pre-formed before transportation to the installation site, or otherwise the galvanization and welding materials may be brought to the installation site to fabricate the metal fin pipe foundation on-site. In either instance, the cost and complexity of fabricating and installing the metal fin pipe foundation may be undesirably increased.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the inventive concept and therefore it may contain information that does not form any part of the prior art nor what the prior art may suggest to a person of ordinary skill in the art.
SUMMARYExemplary embodiments of the present invention provide a foundation including wings each made of a single metal sheet and that are connected together, and having a gap between the wings forming a diamond or triangle shape.
Additional features of the inventive concept will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the inventive concept.
An exemplary embodiment of the present invention discloses a foundation including first and second wings, each having first and second wing portions and a bent portion. The first and second wing portions and the bent portion, of each of the first and second wings, is made of a single sheet of metal. The first wing portions of the first and second wings are connected to each other and the second wing portions of the first and second wings are connected to each other. The bent portions of the first and second wings are spaced apart from each other.
An exemplary embodiment of the present invention also discloses a foundation including first and second wings, each having first and second wing portions and a bent portion, connectors connecting the first and second wing portions of the first and second wings to each other, and a base portion disposed on an edge of each of the first and second wings. The first and second wing portions and the bent portion, of each of the first and second wings, is made of a single sheet of metal. The bent portions of the first and second wings are spaced apart from each other.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the inventive concept as claimed.
The accompanying drawings, which are included to provide a further understanding of the inventive concept, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the inventive concept, and, together with the description, serve to explain principles of the inventive concept.
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary embodiments. It is apparent, however, that various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring various exemplary embodiments.
In the accompanying figures, the size and relative sizes of layers, films, panels, regions, etc., may be exaggerated for clarity and descriptive purposes. Also, like reference numerals denote like elements.
When an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it may be directly on, connected to, or coupled to the other element or layer or intervening elements or layers may be present. When, however, an element or layer is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. For the purposes of this disclosure, “at least one of X, Y, and Z” and “at least one selected from the group consisting of X, Y, and Z” may be construed as X only, Y only, Z only, or any combination of two or more of X, Y, and Z, such as, for instance, XYZ, XYY, YZ, and ZZ. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, and/or section from another element, component, region, layer, and/or section. Thus, a first element, component, region, layer, and/or section discussed below could be termed a second element, component, region, layer, and/or section without departing from the teachings of the present disclosure.
Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for descriptive purposes, and, thereby, to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms are intended to encompass different orientations of an apparatus in use, operation, and/or manufacture in addition to the orientation depicted in the drawings. For example, if the apparatus in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. Furthermore, the apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and, as such, the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used herein, the singular forms, “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Moreover, the terms “comprises,” “comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Various exemplary embodiments are described herein with reference to sectional illustrations that are schematic illustrations of idealized exemplary embodiments and/or intermediate structures. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, exemplary embodiments disclosed herein should not be construed as limited to the particular illustrated shapes of regions, but are to include deviations in shapes that result from, for instance, manufacturing. Thus, the regions illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to be limiting.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure is a part. Terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.
According to the present exemplary embodiment, the first and second wings 100 and 200 are formed to be substantially symmetrical. By forming each wing to be symmetrical, it is possible to utilize economies of scale. Also, symmetrical wings that have not yet been assembled into the two-wing diamond foundation 10 may be easily transported to a construction site, since the wings may be stacked on each other.
The first and second wings 100 and 200 each have holes 300 disposed therein, and the first and second wings 100 and 200 may be connected together using connectors (not shown) disposed through the holes 300. Although not shown, the entire first and second wings 100 and 200 may contain the holes 300. The connectors may include mechanical fasteners such as bolts, rivets, clips, studs, and clamps. That is, the first and second wings 100 and 200 are not welded together since connectors are used instead. Further, only two pieces of metal (excluding connectors) are required to form the two-wing diamond foundation 10, thus reducing the amount of work necessary to form the foundation compared to the conventional art.
The two-wing diamond foundation 10 having first and second wings 100 and 200 that are connected using the connectors may also have improved strength compared to conventional metal fin pipe foundations. Bolts, such as A325 galvanized steel, may generally have a 3:1 ratio of strength compared to a weld, so it is more difficult to break a bolt than a weld. The welds in a metal fin pipe foundation may be formed only along the connection point between each fin and the center pipe. However, the connectors may be spaced along the metal wings to connect them together. The two-wing diamond foundation 10 according to the present exemplary embodiment may be held together by at least one connector on either side of the diamond portion of the foundation, in the width direction.
When torsional, compression, lateral, and uplift forces act upon the metal fin pipe foundation, stresses may be focused on the welds. Since the two-wing diamond foundation 10 according to the present exemplary embodiment has first and second wings 100 and 200 that are made of a continuous piece of metal across the device, torsional, compression, uplift, and lateral forces may be dispersed along the wings and the diamond portion of the foundation. Further, because the first and second wings 100 and 200 have a large overlapping surface area, the two-wing diamond foundation 10 may be able to withstand substantially greater torsional, compression, uplift, and lateral forces than a conventional metal fin pipe foundation without incurring structural damage thereto. Forces acting on one wing are dispersed into the other wing, and into the diamond portion of the foundation. The metal, such as A50 steel, comprising the wings also doubles in thickness along the wings, further increasing resistance to torsional, compression, uplift, and lateral forces.
Since the two-wing diamond foundation 10 is designed to be installed in the ground, there is friction between the installed foundation and the ground surrounding it. Thus, downward axial and uplift forces are countered by friction plus the weight of the foundation, preventing the foundation from being pushed in or pulled out of the ground. Further, since the first and second wings 100 and 200 may have a large surface area, friction with the ground may be increased.
Because the first wing 100 is made of a single sheet of metal, there are various bend points used to form a half-diamond shape, including the first bent portion 130 and second bent portion 140. A first bend point 161 is located between the first wing 110 and the first bent portion 130. A second bend point 162 is located between the second wing 120 and the second bent portion 140. A third bent portion 163 is located between the first and second bent portions 130 and 140. The first and second bend points 161 and 162 may each form the same obtuse angle between the first wing portion 110 and the first bent portion 130, and the second wing portion 120 and the second bent portion 140, respectively. Accordingly, angle θ1, measured from the plane extending along the first wing portion 110 to the first bent portion 130, is an acute angle. In the present exemplary embodiment, θ1 may be 45 degrees. Angle θ2, measured at the interior of bend point 163, may be 90 degrees. That is, the interior area extending between the first and second bent portions 130 and 140, up to an imaginary line extending between the first and second wing portions 110 and 120, may form a right triangle. As illustrated in
Since the first and second wings 100 and 200 of the two-wing diamond foundation 10 according to the present exemplary embodiment are held together by bolts, rivets, etc. along the horizontal and vertical extent thereof, the two-wing diamond foundation 10 may be better able to withstand various forces acting on it after installation in the ground, compared to the conventional art. For example, unlike a pipe with fins welded thereto, there is no similar weak point at the corresponding bend points (i.e., 161 and 162), since each one of the first and second wings 100 and 200 of the two-wing diamond foundation 10 is formed of a single sheet of metal. Accordingly, the two-wing diamond foundation 10 according to the present exemplary embodiment may be less susceptible to torsional, compression, uplift, and lateral forces.
Base plate holes 430 are formed in the top plate 410, and connection holes 440 are formed in the angle irons 420, so the angle irons may be connected to the top plate 410 using connectors (not shown). Similar to the connectors used to connect the first and second wings 100 and 200, connectors may include mechanical fasteners such as bolts, rivets, clips, studs, and clamps. That is, the top plate 410 and the angle irons 420 are not welded together since connectors are used instead.
Referring again to
The base plate 400 provides the capability of testing its integrity with a load or structure that may be mounted on the top plate 410, since the base plate 400 may not be initially connected to the two-wing diamond foundation 11. That is, before the base plate 400 is connected to the first and second wings 100 and 200, it may be fitted to a separate load or structure (not shown), to ensure the compatibility of the base plate and the separate load or structure. Such prior fitting or testing may shorten an installation time by helping guarantee that the separate load or structure can be correctly installed on the wing diamond foundation.
In
A first bend point 161 is located between the first wing 110 and the bent portion 130, and a second bend point 162 is located between the bent portion 130 and the second wing portion 120. Accordingly, angle θ4, measured from the plane extending along the first wing portion 110 to the bent portion 130, at the first bend point 161, is an obtuse angle. In the present exemplary embodiment, θ4 is 150 degrees. As shown in
Referring to
As shown in
Although not shown in
Table 1 below illustrates data calculated similar to the graphs of
It will be apparent to those skilled in the art that various modifications and variation can be made in the present invention without departing from the spirit or scope of the inventive concept. Thus, it is intended that the present invention cover the modifications and variations of the inventive concept provided they come within the scope of the appended claims and their equivalents.
Claims
1. A foundation, comprising:
- first and second wings, each comprising: first and second wing portions; and a bent portion;
- wherein:
- the first and second wing portions and the bent portion, of each of the first and second wings, comprise a single sheet of metal;
- the entire first wing portions of the first and second wings are connected to each other, the first wing portions extending from a first distal end of the foundation to the bent portions;
- the entire second wing portions of the first and second wings are connected to each other, the second wing portions extending from a second distal end of the foundation to the bent portions; and
- the bent portions of the first and second wings are spaced apart from each other to form a diamond-shaped channel comprising at least one open end.
2. (canceled)
3. The foundation of claim 1, wherein the bent portions are respectively disposed between the first and second wing portions of each of the first and second wings along a horizontal direction.
4. The foundation of claim 3, wherein the bent portions of each of the first and second wings comprise first and second bent portions joined at lines extending in a vertical direction.
5. The foundation of claim 4, wherein the first and second wing portions of each of the first and second wings are substantially planar and extend in a vertical direction.
6. The foundation of claim 5, wherein:
- the first and second bent portions of the first wing are joined together at a first side of a vertical line extending parallel to the first and second wings; and
- the first and second bent portion of the second wing are joined together at a second side of a vertical line extending parallel to the first and second wings.
7. The foundation of claim 6, wherein:
- the first and second bent portions of the first and second wings are each substantially planar.
8. A foundation, comprising:
- first, second, and third wings, each comprising: first and second wing portions; and a bent portion;
- wherein:
- the first and second wing portions and the bent portion, of each of the first, second, and third wings, comprise a single sheet of metal;
- the entire first wing portion of the first wing is connected to the entire second wing portion of the third wing and extends from a first distal end of the foundation to the bent portions;
- the entire second wing portion of the first wing is connected to the entire first wing portion of the second wing and extends from a second distal end of the foundation to the bent portions;
- the entire second wing portion of the second wing is connected to the entire first wing portion of the third wing and extends from a third distal end of the foundation to the bent portions; and
- the bent portions of the first, second, and third wings are spaced apart from each other to form a triangle-shaped channel comprising at least one open end.
9. (canceled)
10. The foundation of claim 8, wherein:
- the first and second wing portions of each of the first, second, and third wings are substantially planar and extend in a vertical direction; and
- the bent portions are respectively disposed between the first and second wing portions of each of the first, second, and third wings along a horizontal direction.
11. The foundation of claim 10, wherein:
- the bent portions of the first, second, and third wings are each substantially planar.
12. A foundation, comprising:
- first, second, third, and fourth wings, each comprising: first and second wing portions; and a bent portion;
- wherein:
- the first and second wing portions and the bent portion, of each of the first, second, third, and fourth wings, comprise a single sheet of metal;
- the entire first wing portion of the first wing is connected to the entire second wing portion of the fourth wing and extends from a first distal end of the foundation to the bent portions;
- the entire second wing portion of the first wing is connected to the entire first wing portion of the second wing and extends from a second distal end of the foundation to the bent portions;
- the entire second wing portion of the second wing is connected to the entire first wing portion of the third wing and extends from a third distal end of the foundation to the bent portions;
- the entire second wing portion of the third wing is connected to the entire first wing portion of the fourth wing and extends from a fourth distal end of the foundation to the bent portions; and
- the bent portions of the first, second, third, and fourth wings are spaced apart from each other to form a diamond-shaped channel comprising at least one open end.
13. (canceled)
14. The foundation of claim 12, wherein:
- the first and second wing portions of each of the first, second, third, and fourth wings are substantially planar and extend in a vertical direction; and
- the bent portions are respectively disposed between the first and second wing portions of each of the first, second, third, and fourth wings along a horizontal direction.
15. The foundation of claim 14, wherein:
- the bent portions of the first, second, third, and fourth wings are each substantially planar.
16. The foundation of claim 1, further comprising connectors,
- wherein the connectors connect the first and second wing portions of the first and second wings to each other.
17. A foundation, comprising:
- first and second wings, each comprising: first and second wing portions; and a bent portion;
- connectors connecting the first and second wing portions of the first and second wings to each other; and
- a base plate disposed on and covering each top edge of each bent portion of the first and second wings,
- wherein:
- the first and second wing portions and the bent portion, of each of the first and second wings, comprise a single sheet of metal;
- the bent portions of the first and second wings are spaced apart from each other to form a diamond-shaped channel; and
- the base plate covers the diamond-shaped channel and comprises a mounting surface configured to have a device attached thereto.
18. The foundation of claim 17, wherein:
- the first and second wing portions of each of the first and second wings are substantially planar and extend in a first direction;
- the bent portions are respectively disposed between the first and second wing portions of each of the first and second wings along a second direction; and
- the base plate extends in a third direction perpendicular to the first direction.
19. The foundation of claim 18, wherein the base plate comprises:
- a top plate disposed on the top edges of each bent portion of the first and second wings, the top plate extending in the third direction perpendicular to the first direction; and
- angle portions connected to the top plate and the bent portions of the first and second wings.
20. (canceled)
21. The foundation of claim 1, wherein the first and second wings and the at least one open end of the diamond-shaped channel are configured to be inserted into the ground.
22. The foundation of claim 1, further comprising a base plate disposed on and covering:
- each top edge of each bent portion of the first and second wings; and
- the diamond-shaped channel.
23. The foundation of claim 8, wherein the first, second, and third wings and the at least one open end of the triangle-shaped channel are configured to be inserted into the ground.
24. The foundation of claim 8, further comprising a base plate disposed on and covering:
- each top edge of each bent portion of the first, second, and third wings; and
- the triangle-shaped channel.
25. The foundation of claim 12, wherein the first, second, third, and fourth wings and the at least one open end of the diamond-shaped channel are configured to be inserted into the ground.
26. The foundation of claim 12, further comprising a base plate disposed on and covering:
- each top edge of each bent portion of the first, second, third, and fourth wings; and
- the diamond-shaped channel.
Type: Application
Filed: Apr 10, 2015
Publication Date: Jun 16, 2016
Inventor: Michael M. POPE (Carnegie, PA)
Application Number: 14/683,479