Composite support member for helical piles

Abstract

A support member for a helical pile assembly includes a hollow shaft configured to receive a pile shaft, and a plurality of fins positioned around a perimeter of the support member shaft. At least one of the fins includes a composite material comprising a polymer resin and reinforcing fibers. Each fin can include a first outer layer, a second outer layer, and an inner layer positioned therebetween, where the outer layers comprise a composite material and the inner layer comprises a filler material. A reinforcement member can be positioned between the outer layers adjacent the inner layer to provide additional support to a leading edge of the fin. The fins can be manufactured through a resin transfer molding process.

Description

Docket No. 34704.2595 (990-322-CC WOoi)COMPOSITE SUPPORT MEMBER FOR HELICAL PILESRELATED APPLICATION(S)[OOO1] This application is based on U.S. provisional application Serial No.63 / 790,440, filed April 17, 2025, the disclosure of which is incorporated herein by reference in its entirety and to which priority is claimed.FIELD

[0002] The present disclosure relates generally to helical piles and support members used to form support columns.BACKGROUND

[0003] Piles are used to support structures where surface soil is weak by penetrating the ground to a depth where a competent load-bearing stratum is found. Piles are often required to be placed into the ground for providing support for foundations or other structures. It is desirable to install such piles quickly and efficiently so as to reduce construction costs. Often it is beneficial to form the piles in place, i.e., at the job site.

[0004] Helical anchors / piles are extendable deep foundation systems having one or more helix plates welded to a central steel shaft or lead section. Load is transferredthrough the shaft to the soil through the helix plates. Helical anchors are installed such that the helical plate(s) at the tip of the anchor are deep enough into the soil to bear the uplift. Helical anchors are rotated under down pressure such that the tension resisting / load bearing helical plates at the lower end of the pile effectively screw the pile into the soil to a desired depth. Helical piles are used extensively by power utilities as guy anchors and tower foundations and are finding increased popularity in civil construction applications such as building foundations, tie-downs and retaining walls because of their versatility, ease of use and cost-effectiveness.SUMMARY

[0005] Certain implementations are directed to polymer composite components for an anchor pile system.

[0006] A support member for a helical pile assembly may include a hollow shaft. The hollow shaft may be configured to receive a lead shaft or an extension shaft of a pile assembly so that the hollow shaft may be movable independent of the lead shaft or the extension shaft. A plurality of fins may be positioned around a perimeter of the hollow shaft and may extend away from the hollow shaft. At least one of the plurality of fins may include a composite material.

[0007] A method of forming a composite fin for a support member may include preparing a preform configured to form a stabilizer fin. The preform may include aplurality of glass fibers. The prepared preform may be placed in a mold. The mold may be closed and secured. A resin may be injected into the mold to impregnate the preform with the resin. The resin may be cured to bond with the preform and create a finished stabilizer fin. The finished stabilizer fin may be demolded.

[0008] A support member for a helical pile assembly may include a support shaft configured to rotatably engage a lead shaft or an extension shaft. A plurality of composite fins may be connected to the support shaft. Each composite fin may include an upper edge, an outer edge, an inner edge, and a leading edge, wherein the leading edge may be tapered from at or adjacent the inner edge toward the outer edge. Each composite fin may further include a U-shaped channel member secured along the upper edge of the fin and connected to the support shaft. Each composite fin may further include a first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer may comprise a composite material.

[0009] A composite fin for a support member of a helical pile assembly may include a first outer layer comprising a composite material. A second outer layer may comprise a composite material. An inner layer may be positioned between the first outer layer and the second outer layer, and the inner layer may include a central opening. A core may be received in the central opening of the inner layer, and the core may comprise a filler material. A reinforcement member may be positioned between the first outer layer andthe second outer layer adjacent the inner layer, and the reinforcement member may be configured to provide additional support to a leading edge of the fin.[OO1O] A helical pile system may include a lead comprising a lead shaft having an end portion with a pointed tip and one or more helical plates secured thereto, and a head portion having an attachment member with a plurality of mounting apertures. A support member may be connected to the lead. The support member may include a hollow support member shaft having an inner diameter larger than an outer diameter of the lead shaft such that the support member shaft may receive the lead shaft and may be movable independent of the lead shaft. A flange may be secured to a first end of the support member shaft, and the flange may include one or more mounting apertures configured to align with the mounting apertures of the attachment member for securing the support member to the lead. A plurality of fins may be positioned around a perimeter of the support member shaft at or near a second end of the support member shaft and may extend away from the support member shaft, wherein at least one of the plurality of fins may comprise a composite material including a polymer resin and reinforcing fibers.

[0011] Certain implementations are directed to polymer composite components for an anchor pile system. A support member for a helical pile assembly may include a hollow shaft. The hollow shaft may be configured to receive a pile shaft so that the hollow shaft may be movable independent of the pile shaft. A plurality of fins may bepositioned around a perimeter of the hollow shaft and may extend away from the hollow shaft. At least one of the plurality of fins may include a composite material. In certain implementations, the composite material may include fiberglass. In certain implementations, at least one of the plurality of fins may include a first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer may comprise a composite material. In certain implementations, at least one of the plurality of fins may be connected to the hollow shaft by a U-shaped channel member secured along an upper edge of the fin, the U-shaped channel member being connected to the hollow shaft.

[0012] A method of forming a composite fin for a support member may include preparing a preform configured to form a stabilizer fin. The preform may include a plurality of glass fibers. The prepared preform may be placed in a mold. The mold may be closed and secured. A resin may be injected into the mold to impregnate the preform with the resin. The resin may be cured to bond with the preform and create a finished stabilizer fin. The finished stabilizer fin may be demolded. In certain implementations, a vacuum may be applied to the closed mold prior to injecting the resin to remove air from the preform and to prevent void formation in the finished stabilizer fin. In certain implementations, the preparing of the preform may include combining a plurality oflayers of different fiberglass materials to create a reinforcement structure that provides targeted mechanical properties in specific areas of the stabilizer fin.

[0013] A support member for a helical pile assembly may include a support shaft configured to rotatably engage a lead shaft or an extension shaft. A plurality of composite fins may be connected to the support shaft. Each composite fin may include an upper edge, an outer edge, an inner edge, and a leading edge, wherein the leading edge may be tapered from at or adjacent the inner edge toward the outer edge. Each composite fin may further include a U-shaped channel member secured along the upper edge of the fin and connected to the support shaft. Each composite fin may further include a first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer may comprise a composite material. In certain implementations, the first outer layer, the second outer layer, and the inner layer may be sandwiched together and secured by the U-shaped channel member and the one or more brackets.

[0014] A composite fin for a support member of a helical pile assembly may include a first outer layer comprising a composite material. A second outer layer may comprise a composite material. An inner layer may be positioned between the first outer layer and the second outer layer, and the inner layer may include a central opening. A core may be received in the central opening of the inner layer, and the core may comprise a filler material. A reinforcement member may be positioned between the first outer layer andthe second outer layer adjacent the inner layer, and the reinforcement member may be configured to provide additional support to a leading edge of the fin. In certain implementations, the reinforcement member may include an angled leading edge configured to match the leading edge of the fin and an upper angled edge configured to mate with an angled lower edge of the inner layer. In certain implementations, the reinforcement member may include one or more openings defined at least partially by one or more crossbars.

[0015] A helical pile system may include a lead comprising a lead shaft having an end portion with a pointed tip and one or more helical plates secured thereto, and a head portion having an attachment member with a plurality of mounting apertures. A support member may be connected to the lead. The support member may include a hollow support member shaft having an inner diameter larger than an outer diameter of the lead shaft such that the support member shaft may receive the lead shaft and may be movable independent of the lead shaft. A flange may be secured to a first end of the support member shaft, and the flange may include one or more mounting apertures configured to align with the mounting apertures of the attachment member for securing the support member to the lead. A plurality of fins may be positioned around a perimeter of the support member shaft at or near a second end of the support member shaft and may extend away from the support member shaft, wherein at least one of the plurality of fins may comprise a composite material including a polymer resin andreinforcing fibers. In certain implementations, the support member shaft may be free floating relative to the lead shaft such that a gap may exist between the support member shaft and the lead shaft, the gap being sufficient to permit the lead shaft to rotate relative to the support member shaft during installation. In certain implementations, the plurality of fins may comprise four fins spaced at 90-degree intervals around the perimeter of the support member shaft, and a leading edge of each fin may be tapered.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The following drawings depict exemplary configurations and implementations of the inventive concepts of the disclosure.

[0017] FIG. 1 is a perspective view of an exemplary configuration of a helical pile assembly including a lead and a support member.

[0018] FIG. 2 is an exploded perspective view of the helical pile assembly of FIG. 1.

[0019] FIG. 3 is a perspective view of the support member of FIG. 1.

[0020] FIG. 4 is a side view of the support member of FIG. 3.

[0021] FIG. 5 is a cross-sectional view of the lead shaft and support member of FIG.1, illustrating a gap between the lead shaft and the support member shaft so that the support member is free floating relative to the lead shaft.

[0022] FIG. 6 is a perspective view of the helical pile assembly of FIG. 1 being inserted into the soil with an exemplary drive system.

[0023] FIG. 7 is a perspective view of the pile assembly of FIG. 6 being inserted into the ground.

[0024] FIG. 8 is a perspective view of the pile assembly of FIG. 6 installed in the ground and a support flange connected thereto.

[0025] FIG. 9 is an exploded side perspective view of another exemplary configuration of a pile assembly including a lead, an extension, and a support member.

[0026] FIG. io is a perspective view of another exemplary configuration of a support member.

[0027] FIG. n is a perspective view of a fin of the support member of FIG. 10.

[0028] FIG. 12 is a side view of the fin of FIG. 11.

[0029] FIG. 13 is an enlarged view of a section of the fin of FIG. 12 taken from section 13.

[0030] FIG. 14 is a perspective view of another exemplary configuration of a fin for a support member.

[0031] FIG. 15 is a flow chart of an exemplary molding process for a composite component.DETAILED DESCRIPTION

[0032] Certain implementations are directed to support pile assemblies that can use composite materials for one or more components. For example, a composite supportmember can be used with a helical pile to provide resistance to lateral and torsional loads. The use of a composite support member can provide a more efficient support assembly with a longer lifespan. The pile assembly can include any combination of lead sections, extension sections, and other components as would be understood by one of ordinary skill in the art.

[0033] FIGS. 1 and 2 show an exemplary configuration of a pile 10 that includes a lead 20 and a support member 50. The lead 20 includes a lead shaft 22 that is circular in cross-section. However, other configurations of the lead shaft 22 can have other cross-sectional shapes, such as square, rectangular, pentagonal or hexagonal.

[0034] The length of the lead shaft 22 can range from, for example, about 3 feet to about 10 feet. The diameter or width of the shaft 22 can range from, for example, about 1 inch to about 7 inches. The lead shaft 22 can be fabricated from steel or galvanized steel, although other materials can also be used. The lead shaft 22 can be hollow or solid. For hollow shafts 22, the thickness of the wall of the shaft can range from, for example, about 0.2 of an inch to about 0.4 of an inch. The dimensions of the lead shaft 22 for a particular installation would depend upon the load the pile 10 is to carry, the soil conditions and the type of equipment used for installation such that other configurations can be used.

[0035] In certain configurations, the lead shaft 22 has an end portion 24 that can include a pointed tip 26 and one or more load bearing helical plates 28. During aninstallation procedure, rotation of the shaft 22 and the secured helical plates 28 can drive the pile 10 into the soil with minimal disruption to the surrounding soil. The diameter of the helical plates 28 can range from, for example, about 6 inches to about 48 inches. In the event there are multiple helical plates 28 attached to the lead shaft 22, the helical plates 28 can have the same outer diameter, or the helical plates 28 can have different outer diameters that are, for example, in a tapered arrangement. For example, the tapered arrangement can be such that the smallest outer diameter helical plate 28 is closest to the lead tip 26 and the largest helical plate is at a distance away from the lead tip 26.

[0036] If multiple helical plates 28 are employed, the helical plates on the lead shaft 22 are spaced apart at a predefined distance that is sufficient to promote individual plate load bearing capacity. In other words, the helical plates 28 are spaced apart such that the helical plates behave or act as individual load bearing elements without interference or influence from adjacent helical plates 28. To accomplish this independent performance, a helical plate 28 is located at a specific distance from adjacent helical plates 28. In certain configurations, a helical plate 28 is located a predefined multiple of the diameter of the lower helical plate 28 to an adjacent helical plate above it. For example, a predefined distance between the helical plates 28 can be a multiple, e.g., three times, of the diameter of the lowest helical plate 28. Thus, if the outer diameter of the lowest helical plate 28 is ten inches, the distance to the next helicalplate 28 would be three times that ten inch diameter, which in this example is thirty inches. The helical plates 28 may be fabricated from steel or galvanized steel, and may be welded to or otherwise attached to the lead shaft 22, although other materials can be used.

[0037] As shown in FIGS. 1 and 2, the lead shaft 22 can also include a head portion 30 having an attachment member 32 secured to the proximal end of the lead shaft. This attachment can be through mechanical fasteners or a joining process, for example, a weld joint. The attachment member 32 is configured to couple the head portion 30 to a drive system 200. In certain configurations, the attachment member 32 can be fabricated from steel or galvanized steel, although other materials can be used. In the illustrated configuration, the attachment member 32 is a plate. The attachment member 32 includes a plurality of mounting apertures 34 positioned around a perimeter of the attachment member. The mounting apertures 34 can be used to connect the lead shaft 22 to the support member 50, as described below, and possibly to connect the lead shaft 22 to a drive system (e.g., drive system 200 shown in FIG. 6). The attachment member 32 can also include a cavity 36 preferably in the center of the attachment member 32. The cavity 36 is provided to act as a socket to receive a portion of the drive system 200, such as a drive wrench 202 shown in FIG. 6. As the drive wrench 202 is rotated, the attachment member 32 and thus the lead shaft 22 is rotated. The cavity 36 may come in different shapes, such as a square shape, a rectangular shape, a pentagonal shape, or ahexagonal shape. To ensure the drive wrench 202 is secured to the attachment member 32, the cavity 36 can include one or more threaded apertures 38 that receive bolts that are passed through apertures in the drive wrench 202.

[0038] FIGS. 3-5 show an exemplary configuration of the support member 50. The support member 50 includes a support member shaft 52, a flange 54 and one or more fins 56. The support member shaft 52 is a hollow shaft with an inner diameter "D" that is larger than and outer diameter (or width) of the lead shaft 22 so that the support member shaft 52 can receive the lead shaft 22 and move independent of the lead shaft. For example, the support member shaft 52 can rotate and move longitudinally independent of the lead shaft 22. As a non-limiting example, the inner diameter "D" of the support member shaft 52 can be in the range of, for example, about 1 inch and about 8 inches. By having the support member shaft 52 independent of the lead shaft 22, as the lead shaft 22 is rotated to screw or drive the lead 20 into the soil, the lead shaft 22 can freely rotate relative to the support member shaft 52 so that the one or more fins 56 do not rotate and thus do not disturb the soil.

[0039] The support member shaft 52 is preferably circular in cross-section such that the support member shaft 52 is tubular. However, in other exemplary embodiments the support member shaft 52 can have other cross-sectional shapes, such as square, rectangular, pentagonal or hexagonal. The length "L" of the support member shaft 52 may range from, for example, about 1 foot to about 5 feet.

[0040] The diameter or width of the support member shaft 52 is greater than a diameter or width of the lead shaft 22 so that there is a gap "G" between the support member shaft 52 and the lead shaft 22, as shown in FIG. 5. The gap "G" is sufficient to permit the support member shaft 52 to be free floating relative to the lead shaft 22. As a non-limiting example, the diameter or width of the support member shaft 52 may be in the range from, for example, about 1 inch to about 8 inches. The support member shaft 52 can be fabricated from steel or galvanized steel. The thickness of the wall of the support member shaft 52 may be in the range of, for example, about 0.2 of an inch to about 0.5 of an inch. However, it is noted that the dimensions of the support member shaft 52 for a particular installation would depend upon the lateral and torsional loads the pile is to withstand, the soil conditions and the type of equipment used for installation.

[0041] In certain configurations, the flange 54 is a circular or ring like member secured to a first end 52a of the support member shaft 52. The flange 54 includes one or more mounting apertures 58 around a perimeter of the flange 54. The one or more mounting apertures 58 can be used to attach the support member 50 to the lead shaft 22 after the lead shaft is driven into the soil. More specifically, the one or more mounting apertures 58 are positioned around a perimeter of the flange 54 and can be aligned with the mounting apertures 34 in the attachment member 32 so that the flange 54 can besecured to the attachment member 32 using one or more mechanical fasteners, for example nuts and bolts.

[0042] In certain configurations, the one or more fins 56 are spaced around the perimeter of the support member shaft 52 at or near a second end 52b of the support member shaft 52. The fins 56 provide resistance to lateral and torsional loads on the piles 10. However, the one or more fins 56 can be positioned at any location along the support member shaft 52. In the exemplary configuration shown, there are four fins 56 spaced apart at 90 degree intervals around the support member shaft 52 so that a bottom edge 56a of each fin 56 is positioned at the second end 52b of the support member shaft 52. However, there can be more than four fins 56 or less than four fins spaced around the perimeter of the support member shaft 52. The fins 56 can be spaced at equidistant intervals or at varied intervals as needed. Each fin 56 can have the same shape or they can have different shapes. For example, each fin 56 can have a substantially square shape with a flat bottom edge 56a and a flat top edge 56b. The dimensions of the square shaped fin 56 may be in the range of, for example, about 6 inches by about 24 inches. The dimensions of each fin 56 for a particular installation would depend upon the lateral and torsional loads the pile is to withstand, the soil conditions and the type of equipment used for installation. Preferably, the bottom or leading edge 56a of each fin 56 is tapered to facilitate easier insertion of the fin 56 intothe soil. The angle "a" of the taper can range from, for example, about o degrees and about 45 degrees.

[0043] FIGS. 6-8 show an exemplary installation of the lead 20 and the support member 50 into the soil. After the drive system 200, e.g., the drive wrench 202 and drive head 204, is attached to the attachment member 32 of the lead shaft 22, the lead shaft 22 is rotated by the drive system so that the helical plates 28 screw the lead 20 into the soil with minimal disruption to the surrounding soil. As the lead shaft 22 rotates, the support member 50 can move without rotation due to the independent relationship between the lead shaft 22 and the support member shaft 52 described above.

[0044] As the lead shaft 22 continues to be driven into the soil, the fins 56 of the support member 50 contact the soil. As the lead shaft 22 continues to be driven into the soil, the lead 20 continues to move into the soil as the support member 50 can remain touching the soil without rotating. When the attachment member 32 of the lead 20 contacts the flange 54 of the support member 50, the lead 20, which is still being driven into the soil, pulls the support member shaft 52 and the fins 56 into the soil with little or no rotation to prevent disturbing the soil.

[0045] Once the fins 56 are pulled into the soil to a desired depth, the drive system 200 is stopped and detached from the attachment member 32 of the lead 20. The attachment member 32 of the lead 20 is then secured to the flange 54 of the support member 50 using the nuts 60 and the bolts 62, seen in FIG. 8. This attachment connectsthe lead 20 to the support member 50 so that as the structure supported by the pile 10 moves laterally and / or rotates, the fins 56 on the support member 50 will resist such lateral and / or rotational movement of the lead 20.

[0046] FIG. 9 shows an exemplary configuration of a pile assembly too that includes a lead 110, one or more extensions 130 and a support member 50. The lead 110 includes a lead shaft 112 that is preferably circular in cross-section. However, in other exemplary embodiments the lead shaft 112 may have other cross-sectional shapes, such as square, rectangular, pentagonal or hexagonal.

[0047] The lead shaft 112 has an end portion 114 that may include a pointed tip 116 and one or more load bearing helical plates 118 secured thereto that when rotated screw the pile too into the soil with minimal disruption to the surrounding soil. The diameter of the helical plates 118 may range from, for example, about 6 inches to about 48 inches. In the event there are multiple helical plates 118 attached to the lead shaft 112, the helical plates 118 may have the same outer diameter, or the helical plates 118 may have different outer diameters. If multiple helical plates 118 are employed, the helical plates on the lead shaft 112 can be spaced apart at predefined distances.

[0048] The lead shaft 112 also includes a head portion 120 configured to connect to an extension, such as extension 130. Typically, the lead head portion 120 is connected to an extension using one or more fasteners, such as bolts 126 and corresponding nuts 128, and preferably using galvanized nuts and bolts. The lead head portion 120 is configuredto be received by an end portion of the extension 130 and includes one or more connection apertures 122. The one or more connection apertures 122 are configured and dimensioned to receive the bolts 126.

[0049] The extension 130 includes an extension shaft 132 having an extension end portion 134 and an extension head portion 136. The extension shaft 132 is illustrated as circular in cross-section, however, in other configurations the extension shaft 132 can have other cross-sectional shapes, such as square, rectangular, pentagonal or hexagonal. The length of the extension shaft 132 may range from, for example, about 3 feet to about 10 feet. The diameter or width of the extension shaft 132 may range from, for example, about 1 inch to about 7 inches. The extension shaft 132 may be fabricated from steel or galvanized steel and may be hollow or solid, although other materials can be used. For hollow extension shafts 132, the thickness of the wall of the shaft may range from, for example, about 0.2 of an inch to about 0.4 of an inch. It is noted that the dimensions of the extension shaft 132 for a particular installation would depend upon the load the pile too is to carry, the soil conditions and the type of equipment used for installation.

[0050] The extension end portion 134 can include a coupler 133, e.g., a female coupler, that is configured and dimensioned to receive the lead head portion 120. The coupler 133 includes one or more connection apertures 135 therethrough that are capable of receiving the bolt 126. The one or more connection apertures 135 in the female coupler 133 are configured and positioned to align with the one or moreconnection apertures 122 in the lead head portion 120. In this configuration, the extension end portion 134 can be secured to the lead head portion 120 using the bolt 126 that is passed through the apertures 135 and 122, and the nut 128 is secured to the bolt.

[0051] In certain configurations, the extension head portion 136 includes an extension attachment member 138. The attachment member 138 is configured to couple the head portion 136 of the extension 130 to the drive system 200. The attachment member 138 may be fabricated from steel or galvanized steel. In the embodiment shown, the attachment member 138 is a plate. The extension attachment member 138 includes a plurality of mounting apertures 140 positioned around a perimeter of the extension plate 138. The mounting apertures 140 can be used to connect the extension shaft 132 to the support member 50, and possibly to connect the extension shaft 132 to a drive system, e.g., drive system 200. Other configurations of helical piles using fins is described in U.S. Published Application 2023 / 0383492, the disclosure of which is hereby incorporated by reference in its entirety.

[0052] In certain implementations, the support members can include one or more portions made from a composite material. For example, the fin members may be formed partially or entirely from a composite material using one or more manufacturing processes. The fins may be formed as single units or may be formed from one or more components that are later attached. Portions of the fins can be formed from metal and / or metal / polymer composite materials. Different metal inserts may be addedduring the manufacturing process. The polymer composite materials may include one or more additives to provide additional strength, abrasion resistance, UV resistance etc. Reinforcing fibers which may be glass, carbon, basalt, aramid, etc. or combinations thereof can be utilized. The parts can be joined during the polymer composite material manufacturing process or joined by welding, mechanical fastening, etc.

[0053] In certain implementations the fins can include one or more polymer composite materials which are high in strength and stiffness, lightweight, and are easily processed. The polymer can be a thermosetting resin (Polyester, Vinyl ester, Epoxy, etc.) or Thermoplastic (PP, PE, PET, TPU, PA6, PA66, POM, PEEK, PAEK, PPS, etc. or combinations thereof). Reinforcing fibers which can be glass, carbon, basalt, aramid, etc. or combinations thereof may be utilized. The reinforcing fibers can be in the form of strands, chopped or an interwoven mat. The composite can include one or more additives to provide additional strength, abrasion resistance, ultra-violet (UV) light protection, etc. Examples of abrasion resistance material can include Alumina Trihydrate, Titanium dioxide, and Calcium Carbonate.

[0054] The manufacturing process for forming the fins can be resin transfer molding (RTM), sheet molded compound (SMC), bulk molding compound (BMC), injection molding, compression molding, etc. or combinations thereof and can include, for example, long fiber thermoplastic-direct (LFTD) compression molding and / or injection molding.

[0055] FIG. 10 shows an exemplary configuration of a support member 350 having a support shaft 352 and plurality of fins 356. The support shaft 352 can be configured as to rotatably engage a lead shaft 112 or an extension shaft 132 as described in the prior configurations. A top plate, support member, or other structure can be provided at the top of the shaft 352 to secure the support member 350 to other components as previously discussed or to provide a support for a connected above-ground structure. The fins 356 can be connected to the support shaft 352 via mechanical fastening, welding, and / or adhesion bonding. The composite fins 356 can provide resistance to lateral and / or torsional loads experienced by helical piles.

[0056] FIG. 11 shows an exemplary configuration of a fin 356. Each of the fins 356 can include an upper edge 360, an outer edge 362, and inner edge 364, and a leading edge 366. The leading edge 366 can be tapered from at or adjacent the inner edge 364 toward the outer edge 362. As shown, the leading edge 366 extends at an oblique angle to the outer edge 362 and the inner edge 364.

[0057] The upper edge 360 can be bound by a bracket or channel member, for example a U-shaped channel 368. One or more brackets 370 can also be secured to other portions of the fin 356, for example along the inner edge 364. The channel member 368 and the brackets 370 can be connected by one or more mechanical fasteners or through a joining process such as welding or adhesives. In other configurations, the fin 356 can be formed as a unitary structure through one or moremanufacturing processes such as molding. In an exemplary configuration, the fin 356 is bonded to the U-shaped channel 368 and the channel is welded to the shaft 352.

[0058] FIGS. 12 and 13 show an exemplary configuration of the fm 356 including a first outer layer 372 a second outer layer 374 and an inner layer 376. In certain implementations, at least one of the layers is a composite material. For example, the outer layers 372, 374 can be composite materials and the inner layer 376 can be a filler material. The filler material can be a lightweight material that fills the internal volume, such as a foam, a lightweight fiber material such as balsa wood, bamboo, a honeycomb fibers material such as paperboard, or other similar material. The three layers can be sandwiched together and secured using the channel member 368 and brackets 370. In other configurations, the materials can be formed as a unitary member through the manufacturing process.

[0059] Other configurations can use three composite layers instead of a filler layer, or can utilize more composite layers, for example two outer composite layers on each side. The composite materials could be fiberglass reinforced polymer where the polymer is a polyester resin. The resin could be Polyester, Epoxy, Vinyl ester, Polypropylene, Polyamide, Polyethylene, etc. The fabric could be fiberglass, carbon fibers, aramid fibers, etc. If multiple outer layers are used, the orientations of the fibers in each layer can be shifted to provide greater strength and rigidity.

[0060] FIG. 14 shows another exemplary configuration of a fin 456. The fin 456 can include an upper edge 460, an outer edge 462, and inner edge 464, and a leading edge 466. The leading edge 466 can be tapered from at or adjacent the inner edge 464 toward the outer edge 462. As shown, the leading edge 466 extends at an oblique angle to the outer edge 462 and the inner edge 464.

[0061] The upper edge 460 can be bound by a bracket or channel member, for example a U-shaped channel 468. One or more brackets can also be secured to other portions of the fin 456, for example along the inner edge 464. The channel member 468 and the brackets can be connected by one or more mechanical fasteners or through a joining process such as welding or adhesives. In other configurations, the fin 456 can be formed as a unitary structure through one or more manufacturing processes such as molding.

[0062] FIG. 14 shows the fin 456 with the first outer layer removed, showing only the second outer layer 474 and the inner layer 476. The first outer layer can be identical or substantially identical to the second outer layer 474. In certain configurations, the first outer layer, the second outer layer 474, and the inner layer 476 can be made from a composite material. In certain implementations the composite material is a fiberglass material, for example the fiberglass materials described herein. The first outer layer and the second outer layer 474 extend continuously along the fin 456.

[0063] The inner layer 476 can extend partially along the length of the fin and include a central opening to receive a core 480. The core 480 can include a filler material. The filler material can be a lightweight material that fills the internal volume, such as a foam, a lightweight fiber material such as balsa wood, bamboo, a honeycomb fibers material such as paperboard, or other similar material.

[0064] A reinforcement member 482 can be positioned between the first outer layer and the second outer layer 474 adjacent the inner layer 476. In certain implementations, the reinforcement member 482 can be used to provide additional support to the leading edge 466 of the fin 456. This can provide greater stability and easier ground insertion during an installation operation. The reinforcement member 482 can be optionally used depending, for example, on the load bearing needs and the soil type.

[0065] The reinforcement member 482 can have any configuration depending on the installation needs. The illustrated configuration shows the reinforcement member 482 having an angled leading edge 484 to match the fin 456. An upper angled edge 486 is configured to mate with an angled lower edge of the inner layer 476. Openings 488 can be provided at certain points to receive fasteners if necessary. Depending on the operational requirements, the reinforcement member 482 can have one or more central openings defined at least partially by one or more crossbars 490. The openings can be filled with a filler material or left open as needed. Certain configurations can utilize a solid, continuous reinforcement member 482 without any openings. The configuration,such as the size and shape, of the reinforcement member 482 can be modified as needed.

[0066] Use of the composite components can make the assembly lighter weight, easier to install, and cheaper compared to the fully metallic assemblies. Other implementations can utilize a fully composite assembly for the entire support member.

[0067] In certain implementations, the fins can be made through a Resin Transfer Molding (RTM) process. The process can include placing dry reinforcing fibers or fabric inside of a closed mold that has the shape of the final fin. Resin is then injected under pressure until the mold is filled. Once the resin is fully cured, the fin is demolded, and the cycle starts from the beginning. This process creates a strong bond between the resin matrix and the fiberglass reinforcement, resulting in components with excellent strength-to-weight ratios and dimensional stability. The process can also allow for precise control of the placement and density of the fiber, allowing optimization for specific structural performance and loading conditions as needed to support different loads in different soil types.

[0068] Each layer of the fin can be molded separately and joined together or they can be molded together as unitary structure using one or more additional molding steps. Besides RTM, alternative processes include spraying, bulk molding compound (BMC), sheet molding compounding (SMC), etc.

[0069] FIG. 15 shows an exemplary method of using RTM to prepare a composite fin 500. In certain implementations, the RTM process can include preparing a fiberglass preform 502. The preform can be a contoured reinforcement shaped to match the final geometry of the desired fin. The preform serves as the skeletal structure of the component and determines many of its final mechanical properties. For example, various types of glass fiber reinforcements, including random mats, woven rovings, stitched fabrics, or specialty directional reinforcements can be used, depending on the structural requirements of the fin. The fiberglass material is typically cut to shape and may undergo a preforming operation where it is pressed into a near-net shape that closely resembles the final fin.

[0070] During preform preparation, binders or tackifiers can also be applied to hold the fibers in position and maintain the desired shape prior to being placed in the mold. In some implementations, multiple layers of different fiberglass materials can be combined to create a custom reinforcement structure that provides targeted mechanical properties in specific areas of the fin.

[0071] Once the preform is ready, it is positioned within the mold cavity 504. The mold for RTM can be constructed from various materials, including steel, aluminum, nickel, or even composite materials, depending on the production volume and specific application requirements. The mold can be designed with strategically placed injection ports and vents to ensure optimal resin flow and complete air evacuation. The interiormold surfaces can optionally be treated with release agents to facilitate easy removal of the cured component.

[0072] After the fiberglass preform is properly positioned, the mold is closed 506 and secured, for example using bolts, toggle clamps, or a hydraulic press. The clamping system must apply sufficient force to keep the mold halves tightly sealed against the injection pressure that will follow. The upper and lower mold sections can be rigid and reinforced with metal frames to prevent deflection during resin injection. In certain implementations, the perimeter is tightly locked using metal fasteners to create a completely sealed mold cavity, although other securements can be used.

[0073] The closed mold cavity can precisely define the part dimensions, including wall thickness, surface textures, and features such as ribs or bosses. Proper mold closure can also help ensure consistent fiber volume fraction throughout the part, which directly affects mechanical properties such as strength, stiffness, and impact resistance.

[0074] Once closed, the mold may undergo a vacuum check to ensure proper sealing before resin injection. A vacuum feature can be applied to remove air from the fiberglass preform and help prevent void formation in the finished component. The vacuum also helps draw the resin through the reinforcement during the subsequent injection phase, promoting complete wet-out of the fibers.

[0075] The next phase can involve the preparation and injection of the resin 508. For fiberglass components, various resin systems can be used, including polyester,vinylester, epoxy, phenolic, and methyl methacrylate resins. The selected resin is precisely measured and mixed with appropriate catalysts or hardeners to initiate the curing reaction. The mixing process can be carefully controlled to ensure complete homogeneity while avoiding excessive air entrapment. Mixing and metering equipment can optionally be used to achieve consistent resin formulations.

[0076] Before injection, the resin mixture can be optionally degassed to remove entrapped air bubbles that could compromise the quality of the finished component. The resin is then transferred to an injection system that will deliver it into the mold cavity under controlled pressure. The amount of pressure can change during the injection cycle.

[0077] The injection process begins with the introduction of the catalyzed resin through strategic injection ports in the mold. In certain implementations, resin can be injected from central injection points and flows outward to peripheral vents. As the resin enters the mold cavity, it progresses through the fiberglass preform, displacing air which escapes through vent ports.

[0078] Once the mold cavity is completely filled with resin and all air is displaced, the curing phase begins 510. The resin undergoes a chemical reaction, transforming from a liquid to a solid state while forming strong bonds with the fiberglass reinforcement. The curing process can be accelerated by maintaining the mold at an elevated temperature, which allows for faster production cycles compared to open molding techniques. Theexact curing temperature and time depend on the specific resin system used and the thickness of the fin being produced.

[0079] During curing, the mold temperature can be controlled to ensure optimal cross-linking of the resin molecules. This temperature control can directly impact the final mechanical properties, dimensional stability, and surface quality. The curing profile may include several temperature stages to optimize the reaction kinetics and minimize internal stresses. Sensors embedded in the mold can provide real-time monitoring of the curing process, allowing for adaptive control of temperature and pressure parameters.

[0080] As the resin cures, it undergoes volumetric shrinkage, which must be accounted for in the mold design to achieve the desired final dimensions. The fiber reinforcement helps to minimize overall shrinkage and provides dimensional stability during cure. The presence of the fiberglass in the RTM process results in more uniform shrinkage compared to unreinforced resin systems. The curing phase is complete when the resin has reached sufficient cross-linking to allow demolding without risk of distortion.

[0081] Once cured, the fin is demolded 512. Once the resin has fully cured, the mold is opened, and the finished fin is carefully removed. After demolding, the fin can undergo optional finishing operations depending on the specific applicationrequirements. These can include trimming of excess material at parting lines, drilling or machining of holes, sanding of edges, and final inspection for quality assurance.

[0082] Composite fins can provide a number of advantages over metallic systems. Although structurally sound, metallic fins are heavy, difficult to manufacture, and expensive. In addition, metallic fins are difficult to handle and require specialized equipment during installation (cranes, fork truck, etc.). The use of composite fins can result in lighter weight, easier to install, and cheaper components compared to metallic fins. In addition, the composite fins have better corrosion resistance and longer service life.

[0083] The use of composite materials for other components in helical piles is described in U.S. Published Application 2024 / 0125071, the disclosure of which is hereby incorporated by reference in its entirety.

[0084] The foregoing detailed description has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various configurations and implementations, and with various modifications as are suited to the particular uses contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to what is disclosed. Any of the configurations and / or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional configurations and implementations arepossible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.

[0085] As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present disclosure, and are not intended to limit the structure of the exemplary embodiments of the present disclosure to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. The words “member,” “component,” “module,” “mechanism,” “element,” “device,” and the like are not a substitute for the word “means.” As such, no claim element should be construed as a means plus function unless the element is expressly recited using the phrase “means for.”

Claims

What is Claimed:

1. A support member for a helical pile assembly comprising:a hollow shaft configured to receive a pile shaft of a pile assembly so that the hollow shaft is movable independent of the pile shaft; anda plurality of fins positioned around a perimeter of the hollow shaft and extending away from the hollow shaft,wherein at least one of the plurality of fins includes a composite material.

2. The support member of claim 1, wherein the composite material includes fiberglass.

3. The support member of claim 1, wherein the composite material is formed through a resin transfer molding process.

4. The support member of claim 1, wherein at least one of the plurality of fins comprises a first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer comprise a composite material.

5. The support member of claim 4, wherein the inner layer comprises a filler including foam, balsa wood, bamboo, or a honeycomb material.

6. The support member of claim 4, further comprising a reinforcement member positioned between the first outer layer and the second outer layer adjacent the inner layer, the reinforcement member configured to provide additional support to a leading edge of the fin.

7. The support member of claim 1, wherein at least one of the plurality of fins includes an upper edge, an outer edge, an inner edge, and a leading edge, and wherein the leading edge is tapered from at or adjacent the inner edge toward the outer edge at an oblique angle to the outer edge and the inner edge.

8. The support member of claim 1, wherein at least one of the plurality of fins is connected to the hollow shaft by a U-shaped channel member secured along an upper edge of the fin, the U-shaped channel member being connected to the hollow shaft.

9. The support member of claim 8, further comprising one or more brackets secured to the fin along an inner edge of the fin.

10. The support member of claim 1, wherein the composite material comprises a polymer resin and reinforcing fibers, and wherein the reinforcing fibers include glass fibers, carbon fibers, basalt fibers, aramid fibers, or a combination thereof.

11. A method of forming a composite fin for a support member comprising:preparing a preform configured to form a stabilizer fin, wherein the preform includes a plurality of glass fibers;placing the prepared preform in a mold;closing and securing the mold;injecting a resin into the mold to impregnate the preform with the resin; curing the resin to bond with the preform and create a finished stabilizer fin;anddemolding the finished stabilizer fin.

12. The method of claim 11, further comprising applying a vacuum to the closed mold prior to injecting the resin to remove air from the preform and to prevent void formation in the finished stabilizer fin.

13. The method of claim 11, further comprising degassing the resin prior to injecting the resin into the mold to remove entrapped air bubbles.

14. The method of claim 11, further comprising applying a binder or tackifier to the plurality of glass fibers during the preparing of the preform to hold the fibers in position and maintain a desired shape prior to placing the preform in the mold.

15. The method of claim 11, wherein the curing comprises maintaining the mold at an elevated temperature, and wherein the curing includes a plurality of temperature stages to optimize reaction kinetics and minimize internal stresses.

16. The method of claim 11, wherein the resin includes polyester, vinylester, epoxy, phenolic, or methyl methacrylate resins.

17. The method of claim 11, wherein the plurality of glass fibers in the preform comprises one or more of random mats, woven rovings, stitched fabrics, and directional reinforcements.

18. The method of claim 11, further comprising, after the demolding, performing one or more finishing operations on the finished stabilizer fin, the one or more finishing operations selected from the group consisting of trimming excess material, drilling holes, machining holes, sanding edges, and inspection.19- The method of claim 11, wherein the preparing of the preform comprises combining a plurality of layers of different fiberglass materials to create a reinforcement structure that provides targeted mechanical properties in specific areas of the stabilizer fin.

20. A support member for a helical pile assembly comprising:a support shaft configured to rotatably engage a lead shaft or an extension shaft of a pile assembly; anda plurality of composite fins connected to the support shaft, each composite fin including,an upper edge, an outer edge, an inner edge, and a leading edge, wherein the leading edge is tapered from at or adjacent the inner edge toward the outer edge,a U-shaped channel member secured along the upper edge of the fm and connected to the support shaft, anda first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer comprise a composite material.

21. The support member of claim 20, wherein the inner layer comprises a filler material including foam, balsa wood, bamboo, or a honeycomb material.

22. The support member of claim 20, further comprising one or more brackets secured to each composite fin along the inner edge of the fin.

23. The support member of claim 22, wherein the first outer layer, the second outer layer, and the inner layer are sandwiched together and secured by the U-shaped channel member and the one or more brackets.

24. The support member of claim 20, wherein the composite fins are connected to the support shaft via one or more of mechanical fastening, welding, and adhesion bonding.

25. A composite fin for a support member of a helical pile assembly, the composite fin comprising:a first outer layer comprising a composite material;a second outer layer comprising a composite material;an inner layer positioned between the first outer layer and the second outer layer, the inner layer including a central opening;a core received in the central opening of the inner layer, the core comprising a filler material; anda reinforcement member positioned between the first outer layer and the second outer layer adjacent the inner layer, the reinforcement member configured to provide additional support to a leading edge of the fin.

26. The composite fin of claim 25, wherein the inner layer comprises a composite material.

27. The composite fin of claim 25, wherein the filler material of the core includes foam, balsa wood, bamboo, or a honeycomb material.

28. The composite fin of claim 25, further comprising a U-shaped channel member secured along an upper edge of the fin.

29. The composite fin of claim 25, wherein the reinforcement member includes an angled leading edge configured to match the leading edge of the fin and an upper angled edge configured to mate with an angled lower edge of the inner layer.

30. The composite fin of claim 29, wherein the reinforcement member includes one or more openings defined at least partially by one or more crossbars.

31. A helical pile system comprising:a lead including a lead shaft having an end portion with a pointed tip and one or more helical plates secured thereto, and a head portion having an attachment member with a plurality of mounting apertures; anda support member connected to the lead, the support member including,a hollow support member shaft having an inner diameter larger than an outer diameter of the lead shaft such that the support member shaft receives the lead shaft and is movable independent of the lead shaft, a flange secured to a first end of the support member shaft, the flange including one or more mounting apertures configured to align with the mounting apertures of the attachment member for securing the support member to the lead, anda plurality of fins positioned around a perimeter of the support member shaft at or near a second end of the support member shaft and extending away from the support member shaft, wherein at least one of the plurality of fins comprises a composite material including a polymer resin and reinforcing fibers.

32. The helical pile system of claim 31, wherein the support member shaft is free floating relative to the lead shaft such that a gap exists between the support member shaft and the lead shaft, the gap being sufficient to permit the lead shaft to rotate relative to the support member shaft during installation.

33. The helical pile system of claim 31, further comprising one or more extensions positioned between the lead and the support member, each extension including an extension shaft having an extension end portion configured to connect to the head portion of the lead and an extension head portion configured to connect to a drive system.

34. The helical pile system of claim 31, wherein at least one of the plurality of fins comprises a first outer layer, a second outer layer, and an inner layer positioned between the first outer layer and the second outer layer, wherein at least the first outer layer and the second outer layer comprise the composite material.

35. The helical pile system of claim 31, wherein the plurality of fins comprises four fins spaced at 90-degree intervals around the perimeter of the support member shaft, and wherein a leading edge of each fin is tapered.

36. The helical pile system of claim 31, wherein the composite material is formed through a process selected from the group consisting of resin transfer molding, sheet molding compound, bulk molding compound, injection molding, and compression molding.

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