WO2016100357A1

WO2016100357A1 - Metal foundation

Info

Publication number: WO2016100357A1
Application number: PCT/US2015/065845
Authority: WO
Inventors: Michael Pope
Original assignee: New Generation Steel Foundations, LLC
Priority date: 2014-12-16
Filing date: 2015-12-15
Publication date: 2016-06-23

Abstract

A foundation includes a wing including first and second wing portions and a bent portion, a slot disposed in the bent portion, and an angle bracket connected to the bent portion and spaced apart from the slot. The first and second wing portions and the bent portion comprise a single sheet of metal, the first wing portion is bent perpendicular to the bent portion, the second wing portion is bent perpendicular to the bent portion, and the first and second wing portions extending away from the bent portion in opposite directions.

Description

Title of Invention: METAL FOUNDATION

TECHNICAL FIELD

[0001] 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 bent metal plates, which can then be inserted into the ground and used as a foundation.

BACKGROUND ART

[0002] Conventionally, various types of structural loads may be supported through the use of foundations inserted into the ground. Foundations may be used to support solar racking, 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.

[0003] 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.

[0004] 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.

[0005] Solar racking may be installed using concrete caissons as described above, as well as using Ή" pile foundations. Although Ή" piles may offer advantages over concrete caissons, Ή" piles have flat plates that require welding to be assembled. Further, the Ή" piles are pre-assembled before transportation, therefore limiting size and shape, and increasing fabrication expense.

[0006] 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.

SUMMARY OF THE INVENTION

[0007] Exemplary embodiments of the present invention a foundation a wing made of a single metal sheet.

[0008] 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.

[0009] A foundation includes a wing including first and second wing portions and a bent portion, a slot disposed in the bent portion, and an angle bracket connected to the bent portion and spaced apart from the slot. The first and second wing portions and the bent portion comprise a single sheet of metal, the first wing portion is bent perpendicular to the bent portion, the second wing portion is bent perpendicular to the bent portion, and the first and second wing portions extending away from the bent portion in opposite directions

[0010] 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 invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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.

[0012] Fig. 1 illustrates a side view of a metal foundation according to an exemplary embodiment of the present invention.

[0013] Fig. 2 illustrates a cross-sectional view of the metal foundation of Fig. 1.

[0014] Fig. 3 illustrates a side view of the metal foundation of Fig. 1.

[0015] Figs. 4A and 4B illustrate cross-sectional views of the metal foundation according of Fig. 1.

[0016] Fig. 5 illustrates a top view of an angle bracket of the metal foundation of

Fig. 1.

[0017] Fig. 6 illustrates a slot of the metal foundation of Fig. 1.

[0018] Fig. 7 illustrates a side view of a metal foundation according to an exemplary embodiment of the present invention.

[0019] Fig. 8 illustrates a top view of the metal foundation of Fig. 7. MODE FOR CARRYING OUT THE INVENTION

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] Fig. 1 illustrates a perspective view of the metal foundation 10 according an exemplary embodiment of the present invention, and Fig. 2 illustrates a cross-sectional view of the metal foundation 10.

[0029] The metal foundation 10 may include a wing 100, an angle bracket 200, and slots 400. The wing 100 may be made of galvanized steel or other metal suitable for permanent installation into the ground. The wing 100 may be formed through any process that can create a single metal sheet template having the proper dimensions. The final wing form is fabricated by placing the template in a brake and bending at appropriate angles.

[0030] According to the present exemplary embodiment, the wing 100 is formed to have a substantially "Z" shape. By forming the wing to have the "Z" shape, it is possible to easily accommodate and mount certain types of devices, such as solar panels or solar panel racking. Also, wings that have not yet been assembled into the metal foundation 10 may be easily transported to a construction site, since the wings may be stacked on each other. [0031] The wing 100 and angle bracket 200 may each have holes 300 disposed therein, and the wing 100 and angle bracket 200 may be connected together using connectors (not shown) disposed through the holes 300. Although not shown, the entire wing 100 may contain the holes 300. The connectors may include mechanical fasteners such as bolts, rivets, clips, studs, and clamps. That is, the wing 100 and angle bracket 200 are not welded together since connectors are used instead.

[0032] Since the metal foundation 10 according to the present exemplary

embodiment has wing 100 that is made of a continuous piece of metal, torsional, compression, uplift, and lateral forces may be dispersed along the foundation. Forces acting on part of the wing are dispersed into the other part of the wing of the foundation. The metal, such as A50 steel, further increases resistance to torsional, compression, uplift, and lateral forces.

[0033] Since the metal 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 wing 100 may have a large surface area, friction with the ground may be increased.

[0034] Fig. 2 illustrates a cross-sectional view of the wing 100 of the metal foundation 10. The various dimensions of the wing 100 are presently indicated. The metal forming the first wing 100 has a depth dl and a width wl . According to the present exemplary embodiment, the metal forming the wing 100 may have a depth dl of about 8.0 inches, and width wl of about 9.0 inches. The wing 100 has a first wing portion 110, second wing portion 120, and bent portion 130 between the first and second wing portions 110 and 120. [0035] Fig. 3 illustrates a side view of the metal foundation 10 according to the present exemplary embodiment. The metal foundation 10 has a width wl , and a width w2 that is at the mid-point of the metal foundation. The metal foundation 10 has a length 11 , which is in the range of 120.0 to 240.0 inches. Length 11 is about 180.0 inches according to the present exemplary embodiment. Length 11 includes portions 12, 13, 14, 15, and 16. Length 12 is the length of the wing 100 from the top of the metal foundation to where the tapered end of the metal foundation begins. Length 12 is about 96.0 inches according to the present exemplary embodiment. Length 13 is the length of the metal foundation from the top of the metal foundation 10 to the center of holes 300 in the angle bracket 200. Length 13 is about 50.0 inches according to the present exemplary embodiment.

[0036] Length 14 is the distance between the center of two slots 400 formed in the wing 100. The slots may be used to attach solar panel racking to the metal foundation 10. Length 15 is the distance between the top of the metal foundation 10 and the center of the uppermost slot 400. Length 14 is about 6.0 inches, and length 15 is about 2.0 inches, according to the present exemplary embodiment. Length 16 is the length along the tapered portion of the metal foundation, and is 9.0 inches according to the present exemplary embodiment. Angle Θ1 is formed at the end of length 12, and may be 150 degrees.

[0037] Figs. 4A and 4B illustrate cross-sectional views of the wing 100 of the metal foundation 10. The wing 100 has a thickness tl of 0.5 inches. Width w3 is the width of the wing 100 from first bend point 141 to second bend point 142. Angle Θ2 is formed between first wing portion 1 10 and bent portion 130, and second wing portion 120 and bent portion 130, and may be 90 degrees, in order to form the "Z" shape of the wing 100. Width w4 is the width of the substantially flat part of the bent portion 130 of the wing 100. That is, the surface of width w4 is suitable for flush mounting thereon. Widths w3 and w4 are 8.0 and 7.5 inches, respectively, according to the present exemplary embodiment. The first wing portion 1 10 has a depth d3, and the second wing portion 120 has a depth d2. Depths d2 and d3 may not be equal, and are 3.5 and 4.0 inches, respectively, according to the present exemplary embodiment.

[0038] Fig. 5 illustrates a side view of an angle bracket 200 having holes 300. The angle bracket 200 may be connected to bent portion 130 of the wing 100 via the holes 300. The angle bracket 200 has a width w5, which is less than or equal to width w4. Width w5 is 6.0 inches, according to the present exemplary embodiment. The angle bracket 200 has a length 17, which is 3.5 inches according to the present exemplary embodiment. The center of holes 300 are spaced apart from each other by spacing si , which may be 2.5 inches. The holes 300 are spaced apart from the front and side of the angle bracket 200 by spacing s2, which may be 1.75 inches. As shown in Fig. 2, the top of the angle bracket 200, once mounted on the wing 100, protrudes almost the depth d2 and/or d3 of the first and second wing portions 110 and 120. Thus, differently sized angle brackets 200 may be used for mounting on the wing 100, having different lengths 17, or a single length 17 may be used, such that the angle brackets 200 on each side of the wing 100 respectively have a length 17 that is less than d2 and d3.

[0039] Fig. 6 illustrates a side view of a slot 400, which is formed in a surface of the bent portion 130 of the wing 100 of the metal foundation 10. The slot has a length 18, which may be about 0.9 inches. The slot has a width w6 and an internal width w7. The width w6 is less than width w4, and is 4.75 inches according to the present exemplary embodiment. Width w7 corresponds to a substantially flat part of the slot 400 edge, which is suitable for flush mounting thereon, and is about 3.9 inches according to the present exemplary embodiment.

[0040] Fig. 7 illustrates a side view of a metal foundation 20 according to an exemplary embodiment of the present invention. The metal foundation 20 is similar to the metal foundation 10 of Fig. 1 , and may include a wing 100 and an angle bracket 200, but instead of slots 400, a base plate 500 is disposed on a top edge of the wing 100. According to the present exemplary embodiment, the angle bracket 200 is formed near the top edge of the wing 100, and is spaced apart from the top edge by spacing s5, which may be 4.0 inches. The angle bracket 200 is attached to the wing 100 by connectors (not shown) connected through holes 300. The holes 300 in the angle bracket 200 are spaced apart from each other by spacing si , and from side edges of the wing 100 by spacing s4. Spacings si and s4 are each 4.0 inches, according to the present exemplary embodiment.

[0041] Fig. 7 illustrates a top view of a metal foundation 20 according to the present exemplary embodiment. Holes 300 formed in the top part of the angle bracket 200 is connected to the base plate 500 using connectors (not shown). The holes 300 are spaced apart from the wing 100 by spacing s3, which is 2.0 inches according to the present exemplary embodiment. Although not shown, additional holes may be formed in the top of the base plate 500 in order to allow mounting of an external device to the surface of the base plate.

[0042] 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

CLAIM:

1. A foundation, comprising:

a wing, comprising:

first and second wing portions; and

a bent portion;

a slot disposed in the bent portion; and

an angle bracket connected to the bent portion and spaced apart from the slot, wherein:

the first and second wing portions and the bent portion comprise a single sheet of metal;

the first wing portion is bent perpendicular to the bent portion; and

the second wing portion is bent perpendicular to the bent portion, the first and second wing portions extending away from the bent portion in opposite directions.