Apparatus for assembling tubing structures

Abstract

A structural supporting bearing is comprised of a flange with a hole in the center and a cylindrical hollow tube. The cylindrical tube section is inserted through an appropriately sized hole in hollow fiberglass plastic tubing. The flange creates a stop for the cylinder against the outer wall of the tube. The length of the cylindrical tube is sized to approximately one-half the cross-section of the tube, so as to allow a similar bearing to be mounted to the other side of the tube. A plurality of other structural members is placed over the flanges as desired. The aforementioned assembly is configured to receive a suitably sized bolt through it and be secured in place with a receiving nut.

Claims

1. A structural element suitable for use in assembling a cooling tower comprising a tube made of Fiberglass Reinforced Polymer (FRP tube) of square or rectangular cross section so as to have an outer cross dimension and an inner open space with an inner cross dimension and having aligned coaxial holes in opposite sides of the FRP tube, and two structural supporting bearings, one in each of the aligned coaxial holes on opposite sides of the FRP tube to protect the FRP tube when the FRP tube is connected to another item with a nut and bolt, each bearing being a molded plastic item having a cylinder and a flange that has a bottom face at one end of the cylinder, an axial bore through the flange and cylinder, the cylinder having a length from the bottom face of the flange to a distal end of the cylinder that is slightly greater than one half of the outer cross dimension of the FRP tube, the distal ends of the cylinders of the bearings contacting each other within the open space in the FRP tube and at least one of the flanges of the bearings being slightly spaced from respective outside faces of the FRP tube, whereby a bolt can be extended through the bores of the bearings and receive a nut on an opposite side of the FRP tube, and when the nut is tightened onto the bolt the bearings compress sufficiently so that the flanges are pressed into contact with their respective outside faces of the FRP tube.

2. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders each have a length to enable a nut to be tightened onto the bolt to compress the flanges sufficiently to torque the bolt to 75% of the maximum rating of the bolt.

3. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders are of a length so that the flanges of the bearings are spaced 0.005 inch from the outside faces of the FRP tube before being compressed by the nut and bolt.

4. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the bores of the bearings are tapered from a wider end at the flange to a narrower portion toward the distal end.

5. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders each have external ribs extending the length from the bottom face of the flange to the distal end of the cylinder.

6. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders each have eight external ribs extending the length from the bottom face of the flange to the distal end of the cylinder.

7. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders each have a snap retention latch sloping radially outward from the cylinder with the slope starting toward the distal end of the cylinder and ending at a location that is spaced below the flange and that extends radially outward a distance slightly beyond an edge of the hole in the side of the FRP tube.

8. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein the cylinders each have a snap retention latch sloping radially outward from the cylinder with the slope starting toward the distal end of the cylinder and ending in a latch portion at a location that is spaced below the flange and that extends radially outward a distance slightly beyond an edge of the hole in the side of the FRP tube, the latch portion being free of other cylinder material radially inward of the latch portion, so the latch portion can flex inward during insertion into the hole in the side of the FRP tube and outward after clearing the hole in the side of the FRP tube to prevent the bearing from falling out of the hole in the side of the FRP tube before being held in place with a nut and bolt.

9. A structural element suitable for use in assembling a cooling tower as claimed in claim 1 wherein each cylinder has a snap retention latch extending radially outward a distance beyond an edge of the hole in the side of the FRP tube that prevents the bearing from falling out of the hole in the side of the FRP tube before being held in place with a nut and bolt.

10. A method of assembling a cooling tower comprising providing a structural tube made of Fiberglass Reinforced Polymer (FRP tube) of square or rectangular cross section that has an outer cross dimension and an inner open space with an inner cross dimension and having aligned coaxial holes in opposite sides of the FRP tube, inserting two structural supporting bearings in each of the aligned coaxial holes on opposite sides of the FRP tube until distal ends of the bearings contact one another within the open space in the FRP tube and the flange of at least one of the bearings remain spaced slightly from the outside face of the FRP tube, extending a bolt through aligned bores in the bearings, and tightening a nut to a distal end of the bolt to compress the bearings sufficiently so that the flanges are pressed into contact with their respective outside faces of the FRP tube.

11. A method as claimed in claim 10 wherein tightening the nut comprises compressing the flanges sufficiently to torque the bolt to 75% of the maximum rating of the bolt.

12. A method as claimed in claim 10 wherein inserting two structural supporting bearings includes flexing snap retention latches on the bearings to prevent the bearings from falling out of the hole in the side of the FRP tube before being held in place with a nut and bolt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be better understood by a reading of the Detailed Description of the Examples of the Invention along with a review of the drawings, in which:

(2) FIG. 1 is a perspective view of a prior art cooling tower support structure;

(3) FIG. 2 is a side perspective view of a prior art lumber column splice using FRP channels;

(4) FIG. 3 is a side perspective view of a prior art FRP column splice using FRP channels;

(5) FIG. 4 is a side perspective view of a prior art horizontal channel connection to a column member;

(6) FIG. 5 is a bottom perspective view of a prior art horizontal channel connection to a column member;

(7) FIG. 6 a schematic view of a prior art column member showing distortions;

(8) FIG. 7 is a bottom view of a horizontal channel connection with a prior art bearing;

(9) FIG. 8 is an exploded view of a prior art assembly using stainless steel tubes;

(10) FIG. 9 is a bottom perspective view of a bearing according to a first embodiment of the invention;

(11) FIG. 10 is a top perspective view of a bearing according to a first embodiment of the invention;

(12) FIG. 11 is a view of two bearings installed in opposed sidewalls of an FRP tube;

(13) FIG. 12 is a side view of tube and channel with a bearing according to a first embodiment of the invention;

(14) FIG. 13 is a bottom view of the tube and channel with a bearing according to a first embodiment of the invention;

(15) FIG. 14 is a side view of a second embodiment of the invention;

(16) FIG. 15 is an enlarged bottom view of the second embodiment of the invention;

(17) FIG. 16 is an enlarged partial side view of detail F of FIG. 14;

(18) FIG. 17 is an enlarged partial view of detail G of FIG. 15;

(19) FIG. 18 is a top side perspective view of the second embodiment of the invention;

(20) FIG. 19 is a top view of the second embodiment of the invention;

(21) FIG. 20 is a sectional view of FIG. 19 taken along lines E-E and looking in the direction of the arrows;

(22) FIG. 21 is an enlarged partial view of detail G of FIG. 20;

(23) FIG. 22 is a side view of the second embodiment of the invention;

(24) FIG. 23 is a sectional view of FIG. 22 taken along lines B-B and looking in the direction of the arrows;

(25) FIG. 24 is a bottom view of the second embodiment of the invention;

(26) FIG. 25 is a sectional view of FIG. 24 taken along lines C-C and looking in the direction of the arrows;

(27) FIG. 26 is a sectional view of FIG. 22 taken along lines A-A and looking in the direction of the arrows;

(28) FIG. 27 is an enlarged partial view of detail D of FIG. 24;

(29) FIG. 28 is an enlarged partial view of detail D of FIG. 24;

(30) FIG. 29 is bottom perspective view of the second embodiment of the invention; and

(31) FIG. 30 is a top view of the second embodiment.

DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION

(32) This disclosure describes a structural bearing that is useful for connecting FRP structural elements. One embodiment is shown in FIGS. 9 through 13, and a second embodiment is shown in FIGS. 14 through 29.

(33) FIG. 11 shows the bearings 50 installed in a FRP tube. The bearings are designed as cylinders 51 with compression ribs 52 that can hold them tightly in a 1.000-inch diameter hole. They also have snap retention latches 54 that secure them loosely in a larger hole, such as one that is up to 1.080 inches in diameter. A top flange 55 holds the bearing on the outside face of tube. A gap 57 between the flange 55 and the latches 54 provide space for the sidewall of the tube. This allows for a significant manufacturing tolerance to be allowed for the holes in the FRP. The retention feature allows the bearings to be factory installed or pre-installed in the field before the tower is erected. This saves considerable labor expense. The opening 56 enables the molding of the bearing in a single injection molding step, since the mold components can pass through the openings 56 to help shape the latches 54.

(34) The draft required for the mold ejection of the bearing has been placed on the inside diameter of the bearing to break in approximately the center of the part. This results in a slight taper that allows for lead-in of the bolt into the bore and self-alignment of the bolt in the opposite bearing.

(35) When the nut 34 and bolt 39 are tightened, the bearing cylinders 51 first compress before force develops on the FRP tube cross section.

(36) As the torque applied to the nut 34 and bolt 39 is increased to develop the recommended 28-30 foot-pounds of tension in the fastener connection, the cylinders absorb the bulk of the reaction force required. The flange 55 distributes the remaining compressive load on the FRP tube, as do conventional bearings, but the flange 55 designed is much larger and thicker than is conventional to better distribute load and absorb shear and torsional forces. Thus, a friction-type connection is achieved.

(37) The assembly shown in FIG. 11 serves as the basic structural element in the system. Various channels and flat straps can be assembled over this element and secured with the normal bolt-nut-lock washer system to build structures of infinite variety. An example showing horizontal channel members is shown in FIG. 12 and FIG. 13.

(38) FIGS. 14-29 show a second, preferred embodiment. This embodiment differs in reducing the cylinder wall thickness and adding ribs. By reducing the thickness of the cylinder wall, the amount of material consumed is reduced, and the cycle time of the molding process is reduced, creating two sources of savings.

(39) As seen in FIGS. 14-29, the second embodiment of the bearing 50 is configured as a molded plastic item having a cylinder 51 and a flange 55 that has a bottom face 68 at one end of the cylinder 51. An axial bore 70 extends through the flange 55 and cylinder 51. As can be seen in particular in FIG. 23, the bore 70 is tapered from a wider end at the flange 55 to a narrower end at the distal end 72 of the cylinder 51, although a portion, particularly the portion closer to the distal end, can be untapered or have a reverse taper (widening) past a particular length 84 (See FIG. 20). The cylinder 51 has a length from the bottom face 68 of the flange to the distal end 72 that is slightly greater than one half of the outer cross dimension of the FRP tube. The cylinder 51 has eight external ribs 74 extending the length from the bottom face 68 of the flange to the distal end 72 of the cylinder. As can be seen in FIG. 29, the face of the distal end 72 is uniformly flat, so that when the two bearings are in contact within the FRP tube, they make solid contact with one another.

(40) The cylinder 51 also has two snap retention latches 54. Embodiments with other numbers of latches (such as one or three) are within the scope of the invention. As best seen in FIGS. 20, 22 and 25, each snap retention latch 54 slopes radially outward from the cylinder 51 with the slope starting toward the distal end 72 of the cylinder and ending in a latch portion 76 at a location that is spaced below the flange 55 and that extends radially outward a distance larger than a diameter of the hole in the side of the FRP tube. The latch portion is free of other cylinder material radially inward of the latch portion as at 78, so the latch portion can flex inward during insertion into the hole in the side of the FRP tube. The resilience of the latch portion 76 returns it to its outward shape after clearing the hole in the side of the FRP tube. As a result, the latch portion prevents the bearing 50 from falling out of the hole in the side of the FRP tube before being held in place with a nut and bolt.

(41) The FRP tube can be pre-drilled with holes for the bearings or drilled at a jobsite. After drilling, the bearings can be installed so that two of them are installed in opposition to one another. There is ample clearance between the FRP tube walls and the latches to accommodate the slight interference between the bearing cylinders 51.

(42) Embodiments of structural bearing apparatus for constructing supporting towers using tubular plastic components according to the invention provide one or more of the following benefits: Transfer a large portion of the compressive forces on the tube to the cylindrical bodies of the bearings. Allow for a higher level of torque to be applied to the nut and bolt or other fastener, resulting in better connection integrity. The higher torque allows for 75% proof-tension to be attained in the fastener, assuring the fastener remains tight over the expected life of the structure (such as a cooling tower). Allow for a much wider window of fastener torque to be safely applied during assembly while still resulting in maintenance of tension in the connection over the life of the structure being assembled. Eliminate creep of the FRP tubing resulting in fasteners becoming loose over time. Creep is avoided by avoiding fractures and undue bowing. Distribute compressive, shear and torsional forces over a large flange face of increased thickness, producing a friction-type connection. Press into a hole of tightly controlled dimension. Snap into a larger hole and be retained until final assembly. Allow for a wide tolerance on the diameter of the receiving hole. Be able to be preassembled in factory or field location. As a result the invention can be considered to be an FRP tube or channel with at least one installed bearing as described. Be manufactured of an engineering-grade polymer using injection molded process in high volume at a low cost, but is not limited to that material or process. Nylon is not preferred because it is hydroscopic. Polypropylene is also not preferred due to inadequate strength and high flammability, but many other engineering grade polymers may be used. In some cases a metal die-cast or sintered-powdered metal process can be used to fabricate the part. Be used for the construction of cooling towers, but is not limited to that application. Be used for hollow tubing made of FRP material, but is not limited to use with only that material. One embodiment is designed for tubing that is 3.5” x 3.5” outside dimensionally, other sizes can be used. The design can be extended to larger or smaller, square or rectangular structural tubing sizes. The bearing can also be varied in sized to work with various dimensions of bolts and nuts. One embodiment is designed for use with ½-inch diameter fastener system, but other designs within the scope of the invention can be developed for use with structural fasteners of other sizes. The preferred embodiment provides for lead-in for the incoming fastener and a self-alignment lead-in on the opposing bearing. The bearings helps keep bolt threads out of contact with the FRP tube. Bearing sheer stresses are more uniformly distributed in the clearance holes and the forces in the overall structural system are better distributed between the tube, strap or channel, and bolt so the bearing surfaces in the FRP tubes are not the weak link in the system. A much stronger, more consistent, and more durable structure can be expected. It’s not unusual for the diagonal members of typical cooling towers to routinely withstand cyclic loads of more than 6,200 pounds. Peak loading can exceed 8,500 pounds during severe hurricane conditions or seismic events.

(43) Certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It should be understood that all such modifications and improvements have been omitted for the sake of conciseness and readability, but are properly within the scope of the following claims.