Steel Pipe Pile Coupler with Secondary End Forming
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Solution Overview
Problem
Existing methods for coupling driven steel pipe piles lack sufficient resistance to lateral and tension forces, often requiring field welding, specialized segments, and are costly, while conventional couplings may create hinge points that reduce structural integrity.
Innovation Solution
A coupler with cylindrical pipe segments featuring formed ends that undergo secondary end forming and cold extrusion, providing resistance to compressive, lateral, and tension forces without extensive field welding, using standard pipe segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If field welding is used to couple pile segments, then the coupling strength is improved, but the installation time and cost increase
Solution Approach 1:
The coupler is pre-fabricated with formed ends that are designed to receive and secure pile segments. The formed ends are created in advance during manufacturing, eliminating the need for field welding operations. This preliminary preparation of the coupling mechanism resolves the contradiction by providing strong coupling without the time-consuming field welding process.
2Ease of operation
If conventional couplings are used to join pile segments, then the installation process is simplified, but the resistance to lateral forces decreases
Solution Approach 1:
The coupler features formed ends with specific local geometries designed to engage with pile segments. These formed ends create interference fits and mechanical interlocking that specifically enhance lateral force resistance at the coupling points, while the rest of the coupler body maintains simplicity for easy installation. This localized structural enhancement resolves the contradiction between installation simplicity and lateral force resistance.
3Reliability
If specialized pile segments are used for coupling, then the coupling reliability is improved, but the material cost and manufacturing complexity increase
Solution Approach 1:
The coupler acts as an intermediary component that provides the specialized coupling features, while the pile segments themselves can remain standard, simple cylindrical sections. The complex formed ends are located on the coupler rather than on the pile segments, allowing standard segments to be used while still achieving reliable coupling. This resolves the contradiction by placing the complexity in the coupling device rather than in the primary structural elements.
4Force
If the coupler uses formed ends with secondary end forming, then the resistance to tension forces is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The formed ends of the coupler are designed with specific geometric parameters including tapered surfaces and interference fit dimensions that enable secondary end forming during installation. The axial compression force applied during installation transforms the material parameters of the formed ends, creating mechanical interlocking that resists tension forces. This parameter-based design allows the complex tension-resisting behavior to be achieved through controlled deformation rather than complex manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coupler offers strong, cost-effective coupling with enhanced resistance to lateral and tension forces, allowing flexibility in installation and adaptability to site conditions, using standard pipe segments.
Implementation Method 1
when an axial force is applied to the extension pile segment, each of the first and second formed ends of the coupler undergo secondary end forming to thereby achieve a final length of each formed end, wherein the final length of each formed end exceeds the initial length of each formed end
Implementation Method 2
The coupler offers strong, cost-effective coupling with enhanced resistance to lateral and tension forces
Implementation Method 3
The coupler offers strong, cost-effective coupling with enhanced resistance to lateral and tension forces
Implementation Method 4
The coupler offers strong, cost-effective coupling with enhanced resistance to lateral and tension forces
Data Source
AI summary
A coupler for coupling together a lead pile segment and an extension pile segment of a driven pile comprises: a cylindrical pipe segment, having first and second formed ends and a cylindrical body extending therebetween, each of the first and second formed ends having an inner diameter that is greater than an inner diameter of the cylindrical body. The first formed end is sized to snugly receive an end of the lead pile segment and the second formed end is sized to snugly receive an end of the extension pile segment. Each of the first and second formed ends has an initial length. When an axial force is applied to the extension pile segment, each of the first and second formed ends undergo secondary end forming to thereby achieve a final length of each formed end, wherein the final length exceeds the initial length of each formed end.