Snap-Lock Coupler Assembly for Anti-Reverse Rotation Foundation Supports
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Solution Overview
Problem
Conventional foundation support systems using helical piers face issues with couplers separating due to reverse rotation and uplift forces, compromising the integrity of the foundation support system, particularly when subjected to mechanical shear stress.
Innovation Solution
The coupler assembly features a multi-turn spring element and built-in anti-reverse rotation design, ensuring a limited degree of relative rotation and axial interlock, eliminating the need for separate fasteners and preventing coupler separation under reverse rotation and uplift forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional couplers are used in foundation support systems, then installation is simple, but the couplers separate under reverse rotation and uplift forces
Solution Approach 1:
The coupler is divided into an inner coupler and an outer coupler with distinct functional features. The inner coupler contains helical ribs for torque transmission, while the outer coupler has corresponding grooves and anti-reverse rotation sections. This segmentation allows each component to specialize in specific functions, improving overall reliability without requiring a completely new complex design.
Solution Approach 2:
The anti-reverse rotation sections are designed with asymmetric geometry, featuring discontinuous laterally extending projections that create unequal engagement surfaces. This asymmetry prevents the coupler from rotating in the reverse direction by creating mechanical interference, while still allowing forward rotation during installation. The helical ribs also utilize asymmetric threading to differentiate between driving and reverse rotation directions.
2Strength
If separate fasteners are used to prevent coupler separation, then connection strength improves, but device complexity and installation time increase
Solution Approach 1:
The invention merges the functions of separate fasteners into the coupler structure itself. The helical ribs and grooves provide torque transmission and axial interlock, while the anti-reverse rotation sections integrated into the coupler bodies prevent separation. This consolidation eliminates the need for additional fasteners, maintaining connection strength while reducing device complexity and installation steps.
Solution Approach 2:
The coupler assembly is designed to be self-securing through its inherent structural features. When the inner coupler is inserted into the outer coupler, the spring element automatically engages to provide axial interlock, and the helical ribs automatically transmit torque. The anti-reverse rotation sections passively prevent separation without requiring active fastening operations, making the system self-sufficient.
3Force
If helical ribs and grooves are used for torque transmission, then torque transmitting capability improves, but reverse rotation resistance deteriorates
Solution Approach 1:
The torque transmission function is segmented from the reverse rotation resistance function. Helical ribs in the inner coupler handle torque transmission during installation, while separate anti-reverse rotation sections in both couplers handle prevention of reverse rotation. This functional segmentation allows each feature to optimize its specific purpose without compromising the other.
Solution Approach 2:
The anti-reverse rotation sections are designed to preemptively counteract reverse rotation forces before they can cause separation. The discontinuous laterally extending projections create mechanical interference that blocks reverse rotation at its source, preventing the harmful effect rather than reacting to it after occurrence.
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 solution provides a secure, fast, and reliable connection that maintains the integrity of the foundation support system by preventing coupler separation, even under adverse conditions, thus ensuring stable foundation support.
Implementation Method 1
a spring element automatically establishing an axial, snap-lock connection between an exterior portion of the inner coupler and the outer coupler
Data Source
AI summary
A coupled shaft assembly for a foundation support system includes inner and outer couplers with mating helical ribs and grooves, and spring element that resiliently interlocks the inner and outer couplers in an axial direction. Built-in anti-reverse rotation elements in each coupler accommodates a limited degree of relative rotation of the couplers and thereafter precludes further relative rotation that could otherwise negatively impact the spring element and lead to an undesirable disengagement of the inner and outer couplers.