UNDERGROUND BASE FOR A STATIC STRUCTURE

Abstract

An underground base configured for supporting an above-ground static structure includes a plurality of plates each having a distal end, a proximal end, and a body portion between the distal end and the proximal end. Each of the plurality of plates is connected to at least another plate of the plurality of plates such that the plurality of plates defines a three-dimensional structure having an open top end and an open bottom end. The underground base further includes a plurality of brackets each connected to one of the plurality of pile plates. At least one reinforcement plate is connected to the body portion of at least one of the plurality of plates. Each of the plurality of plates is made from a first material, and the at least one reinforcement plate is made from a second material different from the first material.

Claims

1. An underground base configured for supporting an above-ground static structure, the underground base comprising: a plurality of plates each having a distal end, a proximal end, and a body portion between the distal end and the proximal end, each of the plurality of plates connected to at least another plate of the plurality of plates such that the plurality of plates defines a three-dimensional structure having an open top end and an open bottom end; and at least one reinforcement plate connected to the body portion of at least one of the plurality of plates, wherein each of the plurality of plates is made from a first material, and wherein the at least one reinforcement plate is made from a second material different from the first material.

2. The base of claim 1, wherein the first material is steel, and wherein the second material is a polymer.

3. The underground base according to claim 1, wherein each of the plates comprises: a first bend line between the proximal end and the distal end extending along a longitudinal length of the body portion; and a second bend line between the proximal end and the distal end extending along the longitudinal length of the body portion.

4. The underground base according to claim 3, wherein the at least one reinforcement plate is connected to the body portion of at least one of the plurality of plates between the first bend line and the second bend line.

5. The underground base according to claim 4, wherein the first bend line is substantially parallel to the second bend line.

6. The underground base according to claim 4, wherein the first bend line defines an angle of 22.5° to 45° between a first portion and a second portion of the body portion, and wherein the second bend line defines an angle of 22.5° to 45° between the first portion and a third portion of the body portion.

7. The underground base according to claim 1, wherein the distal end of each of the plurality of plates tapers inwardly from an outer surface of the body portion toward an inner surface of the body portion to define a first taper, and wherein the distal end of the at least one reinforcement plate tapers outwardly from an inner surface toward an outer surface of the at least one reinforcement plate to define a second taper.

8. The underground base according to claim 7, wherein the first taper and the second taper define an angle of 45° to 65°.

9. The underground base of claim 1, further comprising a plurality of brackets each connected to one of the plurality of pile plates.

10. The underground base according to claim 9, wherein each of the plurality of brackets comprises: a bracket distal end; a bracket proximal end; a bracket body portion between the bracket proximal end and the bracket distal end; a first bend line between the bracket proximal end and the bracket distal end extending along a longitudinal length of the bracket body portion; a second bend line between the bracket proximal end and the bracket distal end extending along the longitudinal length of the bracket body portion; and a flap at the bracket proximal end.

11. The underground base according to claim 10, wherein the first bend line and the second bend line each extend along a full longitudinal length of the bracket.

12. The underground base according to claim 10, wherein the flap defines a third bend line that is substantially perpendicular to the first bend line and the second bend line.

13. The underground base according to claim 10, wherein the first bend line defines an angle of 22.5° to 45° between a first portion and a second portion of the bracket body portion, and wherein the second bend line defines an angle of 22.5° to 45° between the first portion and a third portion of the bracket body portion.

14. The underground base according to claim 10, wherein each of the plurality of brackets further comprises one or more gussets extending from the body portion of the bracket to the flap.

15. The underground base of claim 10, further comprising a base plate connected to the plurality of brackets and covering the open top end of the three-dimensional structure.

16. The underground base according to claim 15, wherein the base plate defines a plurality of holes for receiving a plurality of mechanical fasteners configured for connecting the static structure to the base plate.

17. The underground base according to claim 1, further comprising a support plate connected body portion of at least two of the plurality of plates and disposed between the distal end and the proximal end of the plurality of plates.

18. The underground base according to claim 1, further comprising at least one stabilizing bracket connected at a joint between adjacent plates of the plurality of plates and extending radially outward relative to the body portion of the plates.

19. The underground base according to claim 18, wherein the at least one stabilizing bracket has a first portion connected to the joint between adjacent plates of the plurality of plates and a second portion extending substantially perpendicular to the first portion.

20. An underground base configured for supporting an above-ground static structure, the underground base comprising: a plurality of plates each having a distal end, a proximal end, and a body portion between the distal end and the proximal end, each of the plurality of plates connected to at least another plate of the plurality of plates such that the plurality of plates defines a three-dimensional structure having an open top end and an open bottom end; a plurality of brackets each connected to one of the plurality of pile plates; at least one stabilizing bracket connected at a joint between adjacent plates of the plurality of plates and extending radially outward relative to the body portion of the plates; and at least one reinforcement plate connected to the body portion of at least one of the plurality of plates, wherein each of the plurality of plates is made from a first material, and wherein the at least one reinforcement plate is made from a second material different from the first material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Additional advantages and details of the disclosure are explained in greater detail below with reference to the exemplary embodiments or aspects that are illustrated in the accompanying schematic figures, in which:

[0048] FIG. 1 is a perspective view of an underground base for a static structure according to one embodiment or aspect of the present disclosure;

[0049] FIG. 2 is a top view of the underground base with a top plate shown in FIG. 1 removed;

[0050] FIG. 3 is a perspective view of one section of an underground base shown in FIG. 1;

[0051] FIG. 4 is a top view of the section shown in FIG. 3;

[0052] FIG. 5 is cross-sectional view of section A-A of the underground base shown in FIG. 2;

[0053] FIG. 6 is a detailed cross-sectional view of section B-B shown in FIG. 5;

[0054] FIG. 7 is a side view of a bracket plate for an underground base;

[0055] FIG. 8 is a bottom view of the bracket plate shown in FIG. 7;

[0056] FIG. 9 is top view of a top plate for an underground base;

[0057] FIG. 10 is a top view of a stiffener plate for an underground base;

[0058] FIG. 11 is a perspective view of an underground base for a static structure according to another embodiment or aspect of the present disclosure; and

[0059] FIG. 12 a perspective view of an underground base for a static structure according to another embodiment or aspect of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0060] As used herein, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0061] Spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, and the like, relate to the embodiments or aspects as shown in the drawing figures and are not to be considered as limiting as the embodiments or aspects can assume various alternative orientations.

[0062] All numbers used in the specification and claims are to be understood as being modified in all instances by the term “about”. By “about” is meant within plus or minus twenty-five percent of the stated value. However, this should not be considered as limiting to any analysis of the values under the doctrine of equivalents.

[0063] Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass the beginning and ending values and any and all subranges or subratios subsumed therein. For example, a stated range or ratio of “1 to 10” should be considered to include any and all subranges or subratios between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges or subratios beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less. The ranges and/or ratios disclosed herein represent the average values over the specified range and/or ratio.

[0064] The terms “first”, “second”, and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

[0065] All documents referred to herein are “incorporated by reference” in their entirety.

[0066] The term “at least” is synonymous with “greater than or equal to”.

[0067] As used herein, “at least one of” is synonymous with “one or more of”. For example, the phrase “at least one of A, B, or C” means any one of A, B, or C, or any combination of any two or more of A, B, or C. For example, “at least one of A, B, and C” includes A alone; or B alone; or C alone; or A and B; or A and C; or B and C; or all of A, B, and C.

[0068] The term “includes” is synonymous with “comprises”.

[0069] As used herein, the terms “parallel” or “substantially parallel” mean a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from 0° to 5°, or from 0° to 3°, or from 0° to 2°, or from 0° to 1°, or from 0° to 0.5°, or from 0° to 0.25°, or from 0° to 0.1°, inclusive of the recited values.

[0070] As used herein, the terms “perpendicular” or “substantially perpendicular” mean a relative angle as between two objects at their real or theoretical intersection is from 85° to 90°, or from 87° to 90°, or from 88° to 90°, or from 89° to 90°, or from 89.5° to 90°, or from 89.75° to 90°, or from 89.9° to 90°, inclusive of the recited values.

[0071] The discussion of various examples or aspects may describe certain features as being “particularly” or “preferably” within certain limitations (e.g., “preferably”, “more preferably”, or “even more preferably”, within certain limitations). It is to be understood that the disclosure is not limited to these particular or preferred limitations but encompasses the entire scope of the various examples and aspects described herein.

[0072] The disclosure comprises, consists of, or consists essentially of, the following examples or aspects, in any combination. Various examples or aspects of the disclosure are illustrated in separate drawing figures. However, it is to be understood that this is simply for ease of illustration and discussion. In the practice of the disclosure, one or more examples or aspects shown in one drawing figure can be combined with one or more examples or aspects shown in one or more of the other drawing figures.

[0073] With reference to FIG. 1, an underground base 100 (hereinafter referred to as “base 100”) configured for supporting above-ground static structures is shown in accordance with one embodiment or aspect of the present disclosure. The underground base 100 is configured for underground installation by being hydraulically pushed or otherwise driven into the soil. For example, the base 100 may be configured for being pushed or otherwise driven into the soils by a hydraulic ram. In some embodiments or aspects, at least a portion of a longitudinal length of the base 100 is configured for being installed underground. In some embodiments or aspects, the base 100 may be configured for supporting an above-ground static structure, such as a utility pole used in the power transmission industry, or a lattice tower in the cellular industry. In this manner, at least a portion of the base 100 may be exposed from the ground to allow for connection of the above-ground static structure to the base 100. The base 100 may be construed as a single-piece structure (FIG. 1), or as a plurality of separate structures 100a, 100b that are joined together at a joint 101 to form the base 100 (FIGS. 11-12). In this manner, the separate structures 100a, 100b can be made to have a shorter length for easier transport, and then assembled on site for final installation as a full-length base 100.

[0074] The base 100 provides a lightweight structure compared to conventional reinforced concrete bases while meeting the same load and soil support requirements as the concrete bases. The reduced weight of the base 100 compared to conventional concrete bases allows the base to be easily and efficiently transported to the installation site. Additionally, the base 100 can be installed into the soil in a matter of hours and does not require lengthy curing times associated with pouring conventional concrete bases. Unlike the concrete bases, the installation of the base 100 is not dependent on the weather conditions.

[0075] With reference to FIG. 1, the base 100 has a body 102 made from a plurality of plates 104 that are connected together to define a three-dimensional structure that defines an outer shape of the base 100. In some embodiments or aspects, the plurality of plates 104 are connected to each other via one or more fasteners 105. In other embodiments or aspects, the plurality of plates 104 are connected to teach other via welding, adhesive, fasteners, and any combination thereof.

[0076] With continued reference to FIG. 1, the plates 104 may be identical to each other. In some embodiments or aspects, at least one of the plates 104 may be different from the remaining plates 104. In some embodiments or aspects, the plurality of plates 104 may be arranged to define various cross-sectional shapes of the base 100. For example, the plurality of plates 104 may include eight plates that define an octagonal cross-sectional shape of the base 100 (see FIG. 2). In other embodiments or aspects, the plurality of plates 104 may include six plates that define a hexagonal cross-sectional shape of the base 100 (see FIG. 12). In further embodiments or aspects, the plurality of plates 104 may be 3 to n plates, where n is an integer number greater than 3. The three-dimensional structure defined by the plurality of plates 104 has an open top end 106 (shown in FIG. 2) and an open bottom end (not shown). The size and shape of the base 100 is desirably selected to meet the load requirements for the above-ground static structure that will be supported by the base 100. The wider that a diameter of the base 100 is, the better suited the base 100 is for withstanding an overturning moment force to prevent the static structure from tipping over.

[0077] With continued reference to FIG. 1, the base 100 has a distal portion 108 that is configured to be furthest from the soil surface when the base 100 is installed in the soil and an opposite proximal portion 110 that is configured to be closest to the soil surface (i.e. slightly above, at the same level, or slightly below).

[0078] With continued reference to FIG. 1, each of the plurality of plates 104 has a first or distal end 112, a second or proximal end 114, and a body portion 116 extending between the distal end 112 and the proximal end 114. The plates 104 may be connected to each other along at least a portion of a longitudinal length of the body portion 116. For example, the plates 104 may be connected to each other along an entire longitudinal length of the body portion 116. Each of the plurality of plates 104 may be made from the same material or a different material. The plates 104 may be made from a planar or sheet stock. In some embodiments or aspects, each of the plurality of plates 104 is made from a first material, such as steel. The steel may be carbon steel. Each plate 104 may have a thickness of 0.5″ to 1.0″.

[0079] With reference to FIGS. 3-4, a single plate 104 is shown without the remaining plates 104 of the base 100. Each plate 104 has a first bend line 118 between the proximal end 114 and the distal end 112 extending along a longitudinal length of the body portion 116. Each plate 104 further has a second bend line 120 between the proximal end 114 and the distal end 112 extending along the longitudinal length of the body portion 116. The first bend line 118 and the second bend line 120 are substantially parallel to each other and extend along the entire length of the body portion 116. In this manner, the first bend line 118 and the second bend line 120 divide the body portion 116 into a first flap portion 122, a second flap portion 124, and a central portion 126. In some non-limiting embodiments or aspects, the first bend line 118 may define an angle of 22.5° to 45° between the first flap portion 122 and the central portion 126, and the second bend line 120 may defines an angle of 22.5° to 45° between the second flap portion 124 and the central portion 126. The angles defined at the first and second bend lines 116, 118 are determined based on a desired shape of the three-dimensional structure. Each of the first and second flap portions 122, 124 may have a plurality of through holes 128 configured for receiving fasteners for connecting the plate 104 to adjoining plates 104.

[0080] With continued reference to FIGS. 3-4, at least one of the plates 104 has least one reinforcement plate 130 connected thereto. In some embodiments or aspects, the reinforcement plate 130 may be connected to the central portion 126 of the plate 104 such that it is positioned between the first and second flap portions 122, 124. The reinforcement plate 130 may be connected to what is an inner surface of the plate 104 such that the reinforcement plates 130 are positioned within an interior of the three-dimensional structure defined by the plates 104. In some embodiments or aspects, the reinforcement plate 130 may be connected to the plate 104 by a plurality of fasteners 132. In other embodiments or aspects, the reinforcement plate 130 may be adhesively connected to the plate 104 or be welded to the plate 104.

[0081] The reinforcement plate 130 may extend along at least a portion of the longitudinal length of the plate 104. The reinforcement plate 130 may have a thickness of 0.25″ to 1.0″. The reinforcement plate 130 is desirably made from a material different from the material of the plate 104. In some embodiments or aspects, the reinforcement plate 130 may be made from a polymer material. In other embodiments or aspects, the reinforcement plate 130 may be made from the same material as the plate 104. For example, the reinforcement plate 130 may be made from carbon steel. The reinforcement plate 130 increases the strength of the plate 104 without adding a substantial weight to the overall assembly. For example, the reinforcement plate 104 prevents buckling of the plates 104 and reinforces the base 100.

[0082] In some non-limiting embodiments or aspects, and with reference to FIG. 6, the distal end 112 of each of the plurality of plates 104 may taper inwardly from an outer surface 134 of the plate 104 toward an inner surface to define a first taper 136. In embodiments where a distal end 138 of the reinforcement plate 130 extends to the terminal surface of the distal end 112 of the plate 104, the distal end 138 of the reinforcement plate 130 may taper outwardly from an inner surface 140 toward an outer surface of the at least one reinforcement plate to define a second taper 142. In some non-limiting embodiments or aspects, the first taper 136 and the second taper 142 may define an angle of 45° to 65°. The beveled edge provided by the first taper 136 and the second taper 142 makes it easier for the base 100 to penetrate the soil during installation and helps reduce the installation costs, since additional equipment, such as a backhoe, dump truck, and related operators and laborers, is not required.

[0083] With reference to FIGS. 1 and 7-8, the base 100 (shown in FIG. 1) further may include a plurality of brackets 150 each connected to one of the plurality of plates 104. Each bracket 150 may be configured for connecting to the proximal end 114 of the plate 104. In some embodiments or aspects, the bracket 150 may be connectable to the plate 104 via one or more bracket fasteners 152 (shown in FIG. 1).

[0084] With reference to FIGS. 7-8, each bracket 150 has a bracket distal end 154, a bracket proximal end 156, a bracket body portion 158 between the bracket proximal end 156 and the bracket distal end 154. The bracket 150 further has a first bend line 160 between the bracket proximal end 156 and the bracket distal end 154 extending along a longitudinal length of the bracket body portion 158, and a second bend line 162 between the bracket proximal end 156 and the bracket distal end 154 extending along a longitudinal length of the bracket body portion 158. The first bend line 160 and the second bend line 162 may be substantially parallel to each other.

[0085] The first bend line 160 and the second bend line 162 may extend along the entire length of the bracket body portion 158. In this manner, the first bend line 160 and the second bend line 162 divide the bracket body portion 158 into a first flap portion 164, a second flap portion 166, and a central portion 168. In some non-limiting embodiments or aspects, the first bend line 160 may define an angle of 22.5° to 45° between the first flap portion 164 and the central portion 168, and the second bend line 162 may define an angle of 22.5° to 45° between the second flap portion 166 and the central portion 168. The angles defined at the first and second bend lines 160, 162 are determined based on a desired shape of the three-dimensional structure. The first and second flap portions 164, 166 and the central portion 168 may have a plurality of through holes 170 configured for receiving the bracket fasteners for connecting the bracket 160 to the plate 104.

[0086] With continued reference to FIGS. 7-8, the bracket 150 further has a top flap 174 at the bracket proximal end 156. The top flap 174 defines a third bend line 176. The third bend line 176 may be substantially perpendicular to the first and second bend lines 160, 162. In some embodiments or aspects, a plurality of gussets 172 may be connected to the bracket body portion 158 and the top flap 174. The top flap 174 may be configured for supporting a top plate, as further discussed herein.

[0087] With reference to FIG. 9, a base plate 180 is provided for connecting to the proximal portion 110 of the body 108 of the base 100. The base plate 180 is configured to connect to the plurality of brackets 150 and encloses the open top end of the base 100 (see FIG. 1). The base plate 180 defines a plurality of first holes 182 for receiving a plurality of mechanical fasteners configured for connecting the static structure to the base plate 180. The base plate 180 further has a plurality of second holes 184 for receiving a plurality of mechanical fasteners configured for connecting the brackets 150 to the base plate 180. The base plate 180 may be made from the same material as the plurality of plates 104, such as steel. The base plate 180 may have a central opening 185.

[0088] With reference to FIG. 10, a support plate 190 is provided for supporting an interior of the base 100 between the proximal portion 110 and the distal portion 108 (shown in FIG. 1). The support plate 190 is configured to connect to the inner surface of the plurality of plates 104 to support the plates 104 from buckling inwardly due to soil pressure (see FIG. 2). The support plate 190 may be connected to the plurality of plates 104 via fasteners, welding, adhesive, one or more brackets, and any combination thereof. The support plate 190 may have a central opening 191.

[0089] Referring back to FIGS. 1-2, the base 100 further includes at least one stabilizing bracket 192 connected at a joint between adjacent plates 104 of the plurality of plates 104 and extending radially outward relative to the plates 104. In some non-limiting embodiments or aspects, the at least one stabilizing bracket 192 may have a first portion 194 connected to the joint between adjacent plates 104 and a second portion 196 extending substantially perpendicular to the first portion 194. The at least one stabilizing bracket 192 increases the stability of the base 100 by resisting lateral loads imposed on the base 100 due to side loading on the above-ground static structure.

[0090] Although the present disclosure has been described in detail for the purpose of illustration based on what are currently considered to be the most practical and preferred embodiments or aspects, it is to be understood that such detail is solely for that purpose and that the disclosure is not limited to the disclosed embodiments or aspects, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present disclosure contemplates that, to the extent possible, one or more features of any embodiment or aspect can be combined with one or more features of any other embodiment or aspect.