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US 9,863,114 B2Granted
Interlocking, self-aligning and torque transmitting coupler assembly, systems and methods for connecting, installing, and supporting foundation elements
AssigneePier Tech Systems, LLC
InventorsKevin Kaufman, Michael D. Wilkis
Life of this patent
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Abstract
A self-aligning and torque transmitting coupler assembly includes an outer coupler coupled to a first shaft of and an inner coupler coupled to a second shaft. The outer coupler comprises an inner surface having primary and secondary alignment and torque transmitting features, and the inner coupler comprises an outer surface having primary and secondary alignment features. The primary and secondary alignment features are configured to interlock and facilitate alignment of the first and second shafts along a common axis in an exemplary application of a foundation support system.
Claims63
A shaft assembly comprising:
- a first shaft comprising a first distal end;
- a second shaft comprising a second distal end;
- an outer coupler extending on the first distal end, the outer coupler formed with at least a first alignment feature comprising a projection or a groove;
- and
- an inner coupler extending on the second distal end, the inner coupler comprising at least a second alignment feature that is configured to engage the at least one first alignment feature;
- wherein when the inner coupler and the outer coupler are partly mated and one of the inner coupler and outer coupler is rotated relative to the other of the inner coupler and the outer coupler, the first alignment feature is self-aligning with the second alignment feature;
- and
- wherein when the first alignment feature and the second alignment feature are aligned and mated, the inner coupler and the outer coupler are rotationally interlocked with one another to facilitate torque transmission from the first shaft to the second shaft without utilizing a fastener hole in either of the first shaft or the second shaft.
5 more elements
A foundation support system comprising:
- a first foundation element comprising a first shaft having a first distal end and a second end configured to be driven into the ground proximate a building foundation;
- a second foundation element comprising a second shaft having a second distal end;
- an outer coupler coupled to one of the first and second distal ends, the outer coupler comprising an inner surface having at least one first alignment feature formed with the inner surface;
- an inner coupler coupled to the other of the first and second distal ends, the inner coupler comprising an outer surface having at least one second alignment feature, the at least one second alignment feature formed with the outer surface;
- wherein the outer coupler and the inner coupler are configured to engage in a self-aligning manner via the first alignment feature and the at least one second alignment feature, wherein one of the first alignment feature and the secondary alignment feature comprises a projection and the other of the first alignment feature and the secondary alignment feature comprises a groove.
2 more elements
A foundation support system comprising:
- a first foundation support element comprising a first shaft configured to support a building foundation;
- a second foundation element comprising a second shaft configured to support the building foundation in combination with the first foundation element;
- and
- a coupler assembly configured to interconnect the first foundation element and the second foundation element to support the building foundation, the coupler assembly comprising:
- an outer coupler configured to be coupled to one of the first foundation element and the second foundation element, the outer coupler comprising an inner surface formed with at least one primary alignment feature and at least one secondary alignment feature;
- and
- an inner coupler configured to be coupled to the other of the first foundation element and the second foundation element, the inner coupler comprising an outer surface formed with at least one primary alignment feature and at least one secondary alignment feature;
- wherein the primary and secondary alignment features of the outer coupler are respectively configured to engage the alignment features of the inner coupler when the outer surface of the inner coupler and the inner surface of the outer coupler are assembled and engaged,
- wherein when the inner coupler and outer coupler are engaged, an interlocking torque transmission structure is established between the inner and outer coupler, and
- wherein each of the primary and secondary alignment features of the inner coupler and the outer coupler comprises one of a projection and a recess.
7 more elements
A coupled shaft assembly for a foundation support system comprising:
- a first foundation support shaft having a first distal end and a first coupler at the first distal end;
- a second foundation support shaft having a second distal end and a second coupler at the second distal end;
- wherein each of the first coupler and the second coupler comprises at least one primary alignment and torque transmitting feature that are engageable in a self-aligning manner when the first coupler and the second coupler are partly mated;
- wherein the at least one primary alignment and torque transmitting feature in the respective first and second couplers comprises one of an axially extending elongated projection or an axially extending elongated groove proximate the first distal end or the second distal end, and
- wherein when the axially extending elongated projection is received in the axially extending elongated groove, an interlocking torque transmission structure is established between the first distal end of the first shaft and the second distal end of the second shaft.
2 more elements
Dependencies are inferred from the claim text.