Multipart Pile Cap Bolted Connection Eliminates Welding

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Solution Overview

Problem

The existing foundation pile welding process is hazardous and time-consuming due to the need for inspection and potential re-welding of defective welds, making it an expensive and inefficient method for securing foundation piles to structural frames.

Innovation Solution

A multiple-part pile cap system that eliminates welding by using bolted connections between the pile cap and foundation piles, with a bottom portion matched to the pile's webbing width and featuring holes for secure bolt attachment, allowing for mechanical interfacing without welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to secure foundation piles to structural frames, then strong mechanical connection is achieved, but the process becomes hazardous and time-consuming

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidwelding process time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a bolted mechanical connection system. The pile cap includes a bottom portion with holes that receive bolts to secure the foundation pile to the structural frame, eliminating the need for welding while maintaining mechanical connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The pile cap acts as an intermediary component between the foundation pile and the structural frame. It provides a pre-fabricated connection interface with bolt holes that mediates the connection, replacing the direct welding process and enabling faster, safer assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding is used to secure foundation piles, then mechanical connection is achieved, but inspection and re-welding of defective areas increases costs

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent substitutes welding with bolted connections, which are inherently more reliable and easier to inspect. Bolted connections allow for visual verification of proper installation and can be easily re-tightened or replaced if defective, eliminating the costly re-welding process while maintaining connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If welding process is used, then foundation piles can be secured to frames, but the process becomes expensive due to inspection and re-welding

Engineering Contradiction:

Improvesecuring capabilityVSAvoidprocess cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the expensive welding process with a cost-effective bolted connection system. The pile cap is designed with pre-drilled holes for bolts, allowing for rapid assembly without the need for expensive welding equipment, skilled welders, inspection procedures, and potential re-welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240026626A1Multipart pile cap for a foundation pile

Publication Date: 2024.01.25 ROSENDIN ELECTRIC INC

AI summary

A multiple-part pile cap can include a top portion and a bottom portion that are configured to supply a mechanical interface between a first foundation pile providing a foundation for a structure and a frame of a structure itself. The multiple-part pile cap can be installed onto the first foundation pile of a set of foundation piles driven into the ground to provide the foundation for the structure using the multiple-part pile cap as the mechanical interface between the first foundation pile and the frame of the structure being secured to the first foundation pile. The bottom portion of the multiple-part pile cap can be i) matched in width to a width of a webbing of the first foundation pile and ii) has one or more holes in a first flange of the multiple-part pile cap to be bolted to the webbing of the first foundation pile.