One-piece Z-shaped flat plate foundations and method of forming same

Abstract

A one-piece, Z shaped steel plate foundation comprising a main plate body extending the longitudinal length of the foundation from a top to a bottom of the foundation, a single rear flange extending perpendicular to the main plate body in a first direction at a rear edge of the main plate body, wherein the single rear flange does not extend past the main plate body in the direction opposite the first direction, a single front flange extending perpendicular to the main plate body in the direction opposite the first direction at a front edge of the main plate body, wherein the single front flange does not extend past the main plate body in the first direction; and a plurality of mounting holes at the top of the one-piece metal plate foundation configured for attachment to the structure to be supported.

Claims

1. A one-piece metal plate foundation comprising: A) a main plate body extending a longitudinal length of the foundation from a top edge surface of the main plate body to a bottom end of the main plate body, the main plate body further including: i) a longitudinal centerline extending along the longitudinal length of the foundation from the top edge surface of the main plate body to the bottom end of the main plate body; ii) a rear side edge of the main plate body on one side of the longitudinal centerline and extending from the top edge surface of the main plate body in a direction parallel to the longitudinal centerline; iii) a front side edge of the main plate body on a side of the longitudinal centerline opposite the side of the rear side edge of the main plate body and extending from the top edge surface of the main plate body in a direction parallel to the longitudinal centerline; iv) a bottom edge surface extending between the rear side edge of the main plate body and the front side edge of the main plate body; v) first and second elongated mounting holes each having upper and lower linear portions extending parallel to the top edge surface of the main plate body, the second elongated mounting hole located between the first elongated mounting hole and the top edge surface of the main plate body; B) a single rear flange extending at an angle from the rear side edge of the main plate body in a first flange direction at the rear side edge of the main plate body, wherein the single rear flange does not extend past the main plate body in a direction opposite the first flange direction, the single rear flange further including: i) a top edge surface of the single rear flange which extends from and is coplanar with the a top edge surface of the main plate body; ii) an inner side edge of the single rear flange extending from one end of the top edge surface of the single rear flange and which is adjacent to and coextensive with the rear side edge of the main plate body; iii) an outer side edge surface of the single rear flange extending from an end of the top edge surface of the single rear flange opposite from the one end from which the inner side edge of the single rear flange extends, wherein the outer side edge surface of the single rear flange extends from the top edge surface of the single rear flange in a direction parallel to the longitudinal centerline and extends for a distance less than a longitudinal distance of the inner side edge of the single rear flange; iv) a bottom side edge surface of the single rear flange extending between the outer side edge surface of the single rear flange and the inner side edge of the single rear flange; C) a single front flange extending at an angle from the front side edge of the main plate body at the front side edge of the main plate body in a direction opposite the first flange direction of the single rear flange, wherein the single front flange does not extend past the main plate body in the first flange direction, the single front flange further including: i) a top edge surface of the single front flange which extends from and is coplanar with the a top edge surface of the main plate body; ii) an inner side edge of the single front flange extending from one end of the top edge surface of the single front flange and which is adjacent to and coextensive with the front side edge of the main plate body; iii) an outer side edge surface of the single front flange extending from an end of the top edge surface of the single front flange opposite from the one end from which the inner side edge of the single front flange extends, wherein the outer side edge surface of the single front flange extends from the top edge surface of the single front flange in a direction parallel to the longitudinal centerline and extends for a distance less than a longitudinal distance of the inner side edge of the single front flange; iv) a bottom side edge surface of the single front flange extending between the outer side edge surface of the single front flange and the inner side edge of the single front flange; D) wherein the top edge surface of the main plate body and the top edge surface of the single rear flange and the top edge surface of the single front flange are co-planar and contiguous and combine to form a continuous, unbroken bearing surface for the foundation extending from the outer side edge surface of the single rear flange to the outer side edge surface of the single front flange.

2. The one-piece metal plate foundation according to claim 1, wherein the single rear flange and the single front flange extend in directions which are substantially parallel to each other.

3. The one-piece metal plate foundation according to claim 2, wherein the single rear flange and the single front flange extend substantially perpendicular to the main plate body.

4. The one-piece metal plate foundation according to claim 3, wherein the one piece metal plate foundation is formed from a single flat steel plate bent to form the single rear flange and the single front flange.

5. The one-piece metal plate foundation according to claim 3, wherein the one-piece metal plate foundation is galvanized.

6. The one-piece metal plate foundation according to claim 5, wherein the bottom edge surface of the main plate body includes a rear bottom edge surface portion extending between the rear side edge of the main plate body and the longitudinal centerline of the main plate body and a front bottom edge surface portion extending between the longitudinal centerline of the main plate body and the front side edge of the main plate body, and wherein a length of the main plate body along the longitudinal centerline is greater than a length of the main plate body along the rear side edge or the front side edge of the main plate body.

7. The one-piece metal plate foundation according to claim 6, wherein the first and second elongated mounting holes are configured for attachment to a structure to be supported.

8. A method of forming a one-piece metal plate foundation comprising providing a planar one piece steel plate and bending a rear side of the steel plate to form a single rear flange extending in a first flange direction from a main plate body of the steel plate and bending a front side of the steel plate to form a single front flange extending in direction opposite to the first flange direction from a main plate body of the steel plate, and wherein the foundation includes: A) the main plate body extending a longitudinal length of the foundation from a top edge surface of the main plate body to a bottom end of the main plate body, the main plate body further including: i) a longitudinal centerline extending along the longitudinal length of the foundation from the top edge surface of the main plate body to the bottom end of the main plate body; ii) a rear side edge of the main plate body on one side of the longitudinal centerline and extending from the top edge surface of the main plate body in a direction parallel to the longitudinal centerline; iii) a front side edge of the main plate body on a side of the longitudinal centerline opposite the side of the rear side edge of the main plate body and extending from the top edge surface of the main plate body in a direction parallel to the longitudinal centerline; iv) a bottom edge surface extending between the rear side edge of the main plate body and the front side edge of the main plate body; v) first and second elongated mounting holes each having upper and lower linear portions extending parallel to the top edge surface of the main plate body, the second elongated mounting hole located between the first elongated mounting hole and the top edge surface of the main plate body; B) the single rear flange extending at an angle from the rear side edge of the main plate body in the first flange direction at the rear side edge of the main plate body, wherein the single rear flange does not extend past the main plate body in a direction opposite the first flange direction, the single rear flange further including: i) a top edge surface of the single rear flange which extends from and is coplanar with the a top edge surface of the main plate body; ii) an inner side edge of the single rear flange extending from one end of the top edge surface of the single rear flange and which is adjacent to and coextensive with the rear side edge of the main plate body; iii) an outer side edge surface of the single rear flange extending from an end of the top edge surface of the single rear flange opposite from the one end from which the inner side edge of the single rear flange extends, wherein the outer side edge surface of the single rear flange extends from the top edge surface of the single rear flange in a direction parallel to the longitudinal centerline and extends for a distance less than a longitudinal distance of the inner side edge of the single rear flange; iv) a bottom side edge surface of the single rear flange extending between the outer side edge surface of the single rear flange and the inner side edge of the single rear flange; C) the single front flange extending at an angle from the front side edge of the main plate body at the front side edge of the main plate body in a direction opposite the first flange direction of the single rear flange, wherein the single front flange does not extend past the main plate body in the first flange direction, the single front flange further including: i) a top edge surface of the single front flange which extends from and is coplanar with the a top edge surface of the main plate body; ii) an inner side edge of the single front flange extending from one end of the top edge surface of the single front flange and which is adjacent to and coextensive with the front side edge of the main plate body; iii) an outer side edge surface of the single front flange extending from an end of the top edge surface of the single front flange opposite from the one end from which the inner side edge of the single front flange extends, wherein the outer side edge surface of the single front flange extends from the top edge surface of the single front flange in a direction parallel to the longitudinal centerline and extends for a distance less than a longitudinal distance of the inner side edge of the single front flange; iv) a bottom side edge surface of the single front flange extending between the outer side edge surface of the single front flange and the inner side edge of the single front flange; D) wherein the top edge surface of the main plate body and the top edge surface of the single rear flange and the top edge surface of the single front flange are co-planar and contiguous and combine to form a continuous, unbroken bearing surface for the foundation extending from the outer side edge surface of the single rear flange to the outer side edge surface of the single front flange.

9. The method of forming a one-piece metal plate foundation according to claim 8, wherein the single rear flange and the single front flange extend in directions which are substantially parallel to each other.

10. The method of forming a one-piece metal plate foundation according to claim 9, wherein the single rear flange and the single front flange extend substantially perpendicular to the main plate body.

11. The method of forming a one-piece metal plate foundation according to claim 10, wherein the one-piece metal plate foundation is galvanized.

12. The method of forming a one-piece metal plate foundation according to claim 11, wherein the bottom edge surface of the main plate body includes a rear bottom edge surface portion extending between the rear side edge of the main plate body and the longitudinal centerline of the main plate body and a front bottom edge surface portion extending between the longitudinal centerline of the main plate body and the front side edge of the main plate body, and wherein a length of the main plate body along the longitudinal centerline is greater than a length of the main plate body along the rear side edge or the front side edge of the main plate body.

13. The method of forming a one-piece metal plate foundation according to claim 12, wherein the first and second elongated mounting holes are configured for attachment to a structure to be supported.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1A is a side view of a flat plate foundation support according to one embodiment of the present invention.

(2) FIG. 1B is an enlarged side view of a single fin of the flat plate foundation support shown in FIG. 1A.

(3) FIG. 2 is a cross-sectional view of the foundation support taken along lines A-A, shown in FIG. 1A.

(4) FIG. 3 is a cross-sectional view of the foundation support taken along lines B-B, shown in FIG. 1A

(5) FIG. 4A is a side view of a flat plate foundation support according to another embodiment of the present invention.

(6) FIG. 4B is an enlarged side view of a single fin of the flat plate foundation support shown in FIG. 4A.

(7) FIG. 5 is a cross-sectional view of the foundation support taken along lines A-A, shown in FIG. 4A.

(8) FIG. 6 is a top plan view of the foundation support of FIG. 4A.

(9) FIG. 7 is a detailed side view of the foundation support of FIG. 4A, illustrating a connection between the foundation support and a ground supported structure.

(10) FIG. 8A is a front side view of a flat plate foundation support according to another embodiment of the present invention.

(11) FIG. 8B is an enlarged side view of a single fin of the flat plate foundation support shown in FIG. 8A taken along lines D-D of FIG. 8A.

(12) FIG. 9 is a left side view of the flat plate foundation of FIG. 8A.

(13) FIG. 10 is a top plan view of the flat plate foundation of FIG. 8A.

(14) FIG. 10A is an enlarged top plan view of an adjustable mounting hole configuration of the flat plate foundation of FIG. 10.

(15) FIG. 11 is a detailed view of a gusset plate for use in the flat plate foundation support of FIG. 8.

(16) FIG. 12 is a perspective view of a one-piece, z-shaped flat metal plate foundation support according to one embodiment of the present invention;

(17) FIG. 13 is a front elevation view of the one-piece, z-shaped flat metal plate foundation support shown in FIG. 12;

(18) FIG. 14 is a side elevation view of the one-piece, z-shaped flat metal plate foundation support shown in FIG. 12;

(19) FIG. 15 is a top plan view of the one-piece, z-shaped flat metal plate foundation support shown in FIG. 12.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(20) For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific devices illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting.

(21) FIGS. 1-3 illustrate a flat plate foundation support 10, or anchor 10, for supporting and anchoring a ground supported structure according to one embodiment of the present invention. The foundation support 10 extends longitudinally along a central longitudinal axis. A lower portion of the support is adapted to be inserted into a ground surface below the grade 12. The lower portion of the support 10 includes a plurality of flat plates 14 and 16 that are mutually connected along the central longitudinal axis.

(22) As shown in FIGS. 2 and 3, the lower portion is made up of two flat plates 14 and 16, a longer first plate 14 that is bent at an angle in the middle and a second flat plate 16 that is attached to the first plate 14 at the apex angle by a suitable method, such as welding. Each side of the single bent plate 14 forms a flat plate 14 extending radially from the center axis. Accordingly, the lower portion of the foundation support 10 is made up of three longitudinal fins (14 and 16) that extend laterally or radially from the central longitudinal axis (corresponding to the apex of the angle of the bent flat plate) and are equally spaced at angles of 120. It is to be appreciated that the lower portion of the foundation support 10 may be of a variety of different configurations of flat plates having two or more fins.

(23) As shown in FIG. 1A, the flat plates 14 and 16 making up the lower portion of the foundation support 10 are beveled at an angle of 60 at the lower end and as shown in FIG. 1B have sharpened leading edges to facilitate placement of the foundation support 10 into the ground surface 12.

(24) With further reference to FIG. 1, an upper portion of the foundation support 10 is provided for connecting to and supporting the ground supported structure. As shown, the upper portion is a cylindrical pipe 18 that is disposed over a top end of the lower portion so that the upper and lower portions are co-extensive along the central longitudinal axis for a certain length, such as 6 inches shown at 20. An inner surface of the cylindrical pipe 18 is connected to the lateral edges of the flat plates 14 and 16 by a suitable method, such as welding along the lateral edges of the fins in the longitudinal direction.

(25) It is to be appreciated that the foundation support 10 may be of any longitudinal length and the upper and lower portions may be of varying relative longitudinal lengths depending on the conditions of use. Additionally, the flat plates 14 and 16 may also be of varying thickness and lateral lengths extending from the central longitudinal axis and the diameter of the cylindrical pipe of the upper portion may be of a corresponding diameter depending on the conditions of use.

(26) It is also to be appreciated that individual foundation supports may be pre-assembled and then shipped to a construction site for installation. In particular, the individual foundation supports 10 may be inserted into the ground surface individually by using a vibrator or push-it machine to apply vibration to the lower portion of the foundation support 10 while pushing downward on the top end in order to insert the foundation support into the ground 12 beginning with the beveled lower end. It is also to be appreciated that, depending on the application and conditions of the ground surface 12, the foundation support 10 may be inserted into the ground surface 12 without the necessity of pre-drilling a hole in the ground surface 12. Alternatively, the foundation support 10 may be installed in a pre-drilled hole depending on the conditions of the ground surface 12. Additionally, use of the foundation support 10 according to this embodiment substantially eliminates the need for backfilling of soil and/or concrete to complete the foundation, thus saving substantial construction time and costs. A ground supported structure may then be attached to the top of the cylindrical pipe. In operation, one or more foundation supports 10 may be provided to support a single structure.

(27) FIGS. 4-7 illustrate a flat plate foundation support 30, or anchor 30 according to another embodiment of the present invention. As shown, the lower portion of the foundation support 30 is substantially the same as the embodiment of support 10 discussed above with reference to FIGS. 1-3.

(28) The upper portion is distinct and comprises a top plate 32 that is disposed on the top end of the lower portion such that the top plate 32 extends across the top edges of the flat plates 14 and 16 of the lower portion, which are disposed flush with the ground surface 12 such that the top plate 32 is disposed on or near the ground surface 12. A ground supported structure is then attached to the top plate. Typically, the ground supported structure will include a mounting plate 34 having a corresponding structure to the top plate 32 of the support foundation 30. The two plates 32 and 34 may then be connected by known methods, such as bolt fasteners 36, as best shown in FIG. 7.

(29) FIGS. 8-11 illustrate another flat plate foundation support 50, or anchor according to an embodiment of the present invention. As shown in FIGS. 8-10, the lower portion of the foundation support 50 includes an elongated flat plate 54 having two beveled portions. A center portion of the elongated plate 54 is beveled at 56, with respect to the longitudinal axis of the lower portion, at a relatively shallow angle. A bottom portion of the plate 54 is more sharply beveled at 58 with respect to the longitudinal axis. The leading edges of both the center and bottom portions of the elongated plate are sharpened.

(30) The lower portion of the foundation support 50 also includes a pair of side plates 60, or side fins 60, disposed on opposing sides of the elongated plate 54 and connected to the elongated plate 54 along the central longitudinal axis by a known method, such as welding of the plates 60 along the central longitudinal axis. The lower ends of the side plates 60 are also beveled and include sharpened leading edges. It is to be appreciated that the beveled portions and sharpened edges are provided to facilitate the installation of the lower portion of the foundation support 50 without the necessity of pre-drilling or digging of a hole in the ground surface. The length of the side plates 60 along the central longitudinal axis is shorter than the length of the elongated plate 54, such that the side plates 60 are buried in the ground surface 12, while the top end of the elongated plate 54 extends above the ground surface 12.

(31) As shown in FIGS. 8-10, the upper portion of the support includes a pair of support plates 62 disposed on top of opposing lateral ends of the elongated plate 54. As shown in FIG. 10, the support plates 62 include adjustable mounting holes 64 to facilitate attachment of varying configuration of mounting plates of the ground supported structure. Each support plate 62 may additionally be supported by one or more triangular gussets 66 (four are shown for each plate 62) extending between the elongated plate 54 and the support plate 62, as shown in FIGS. 9 and 11. One structure, such as an A-frame structure 70 shown in FIG. 8, or plural ground supported structures may be anchored by a single foundation support 50 according this embodiment. In particular, each of the legs of the A-frame structure 70 shown in FIG. 8 includes a mounting plate 72 attached to the top plate 62 of the foundation support 50 by one or more fasteners. The A-frame structure supports a solar collector array.

(32) It is to be appreciated that the foundation support 50 shown in FIGS. 8-11 may be of any longitudinal length and the elongated and side plates 54 and 60 may be of varying lateral widths extending from the central longitudinal axis. Additionally, the top plates 62 may also be of varying thickness depending on the conditions of use.

(33) It is also to be appreciated that individual foundation supports 50 may be pre-assembled and then shipped to a construction site for installation. In particular, the individual foundation supports 50 may be inserted into the ground surface individually by using a vibrator or push-it machine to apply vibration to the foundation support 50 while pushing downward on the top end in order to insert the foundation support 50 into the ground 12 beginning with the beveled lower end 58. It is also to be appreciated that, depending on the application and conditions of the ground surface 12, the foundation support 50 may be inserted into the ground surface 12 without the necessity of pre-drilling a hole in the ground surface 12. Alternatively, the foundation support 50 may be installed in a pre-drilled hole depending on the conditions of the ground surface. Additionally, use of the foundation support 50 according to this embodiment eliminates the need for backfilling of soil and/or concrete to complete the foundation, thus saving substantial construction time and costs. A ground supported structure, such as 70, may then be attached to the top plates 62 at the lateral ends of the elongated plate 54, as discussed above.

(34) FIGS. 12-13 illustrate another flat plate foundation support 80, or anchor according to an embodiment of the present invention. Specifically the support 80 is a one-piece, Z shaped steel plate foundation 80. The foundation 80 includes a main plate body 82 extending the longitudinal length of the foundation 80 from a top to a bottom of the foundation 80.

(35) The foundation 80 includes a single rear flange 84 extending at an angle, preferably perpendicular, to the main plate body 82 in a first direction at a rear edge of the main plate body 82, wherein the single rear flange 84 does not extend past the main plate body 82 in the direction opposite the first direction.

(36) The foundation 80 includes a single front flange 86 extending at an angle, preferably perpendicular, to the main plate body 82 in the direction opposite the first direction at a front edge of the main plate body 82, wherein the single front flange 86 does not extend past the main plate body 82 in the first direction.

(37) The foundation 80 includes a plurality of mounting holes 88 at the top of the one-piece metal plate foundation 80 configured for attachment to the structure 100 to be supported. A pair of elongated oval shaped mounting holes in the main body 82 extending at an angle relative to elongated mounting holes on the associated structure 100 give adjustment in two directions for the coupling of the foundation 80 to the structure 100 (i.e horizontal adjustment along mounting holes 88 and vertical adjustment along mounting holes in the structure 100).

(38) In the one one-piece metal plate foundation 80 according to FIGS. 12-15, it is preferred that the rear flange 84 and the front flange 86 extend substantially parallel to each other and having them extend substantially perpendicular to the main plate body 82 is preferred.

(39) The one-piece metal plate foundation 80 according to FIGS. 12-15 preferably provides a bottom of the main plate body 82 which is beveled and wherein a bottom of the rear flange 84 and the front flange 86 are beveled. This construction assists in installation of the foundation 80.

(40) It is to be appreciated that the above-described embodiments of a flat plate foundation supports 10, 30 and 50 may be manufactured according to any technique known to be suitable to those having ordinary skill in the art and may be made from any material known to be suitable to those having ordinary skill in the art. According to one embodiment of the present invention, the flat plate foundation supports 10, 30 and/or 50 are made from steel and individual steel pieces of the foundation support are connected by welding and are pre-assembled and shipped to a construction site ready for installation.

(41) A preferred method of forming the one-piece Z-shaped steel plate foundation 80 of FIGS. 12-15 comprising the steps of: providing a single flat steel plate wherein a central portion of the single flat plat forms the main plate body 82 extending the longitudinal length of the foundation 80 from a top to a bottom of the foundation 80; bending the single rear flange 84 extending at an angle from the main plate body 82 in a first direction at a rear edge of the main plate body; and bending the single front flange 86 extending at an angle from the main plate body 82 in the direction opposite the first direction at a front edge of the main plate body 82. As noted above, preferably the rear flange 84 and the front flange 86 are bent to extend substantially parallel to each other and to extend substantially perpendicular to the main plate body 82. The method of forming the one-piece metal plate foundation 80 according to FIGS. 12-15 may further include the step of hot dip galvanizing the one-piece metal plate foundation. The method of forming the one-piece metal plate foundation 80 according to FIGS. 12-15 may further include the step of beveling a bottom of the main plate body and of beveling a bottom of both the rear flange 84 and the front flange 86.

(42) According to another embodiment of the present invention, the flat plate foundation supports 10, 30, 50 and/or 80 may be installed by a metal foundation push-it and installation apparatus of the type disclosed in U.S. Pat. Nos. 5,660,504, 5,733,068, and 5,944,452, all of which are incorporated herein by reference.

(43) While several embodiments of a flat plate foundation support were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims and all changes to the invention that fall within the meaning and the range of equivalency of the claims are embraced within their scope.