Spun Pile End Plate With Interlocking Segments

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Solution Overview

Problem

Existing concrete pile connectors are cumbersome, costly, and prone to weakness due to multiple fragile parts, and they fail to withstand heavy pile driving impacts without damaging interlocking grooves, while also requiring additional material and complexity for load transfer and grout sealing.

Innovation Solution

An interlocking end plate connector with 45-degree rotated square openings and segmental protrusions/recesses, allowing for a tapered square pin to create a larger contact surface and axial clamping force, reducing material thickness by 30-45% and eliminating the need for intermediate connectors, while securing a circular steel skirt to prevent grout seepage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple small and fragile parts (bolts, pins, washers, shear keys) are used to create a mechanical pile connector, then the connector can provide mechanical joining capability, but the device complexity increases and reliability decreases due to the fragile nature of multiple components

Engineering Contradiction:

Improvejoining capabilityVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (bolts, pins, washers, shear keys) into a single integrated end plate structure. The end plate incorporates all joining functions in one monolithic component, eliminating the need for multiple discrete parts and their associated assembly hardware.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The end plate is segmented into functional zones: interlocking grooves for mechanical engagement, flattened regions for load transfer, and reinforced zones for impact resistance. This segmentation allows each region to optimize its specific function while remaining part of a unified structure.

Inventive Principle:

Principle #1Segmentation

2Strength

If additional opened accesses (grooves or holes) are created in the end plate for connector parts, then the mechanical joining function is enabled, but the contact surface area for load transfer is reduced

Engineering Contradiction:

Improvemechanical joiningVSAvoidcontact surface area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The interlocking grooves are designed with tapered geometry that allows dynamic adaptation during assembly. The grooves deform elastically to accommodate the insertion of opposing end plates, then lock into place, providing mechanical joining without requiring large open holes that would compromise the contact surface.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the end plate is designed to withstand heavy hammer impact, then the durability under pile driving is improved, but the device complexity increases to accommodate impact forces without damaging interlocking grooves

Engineering Contradiction:

Improveimpact resistanceVSAvoidstructural modifications for impact

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The end plate incorporates a sloping edge that acts as a protective feature before impact occurs. This sloping geometry directs hammer blows away from the vulnerable interlocking grooves, cushioning them against direct impact forces and preventing damage before it can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Area of stationary object

If the square openings are rotated 45 degrees to the vertical axis, then the contact surface between the tapered square pin and tapered square passageway is maximized, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvecontact surface areaVSAvoidrotation angle accuracy

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The square openings are deliberately rotated 45 degrees from the vertical axis, creating an asymmetric orientation that maximizes the contact surface area between the tapered pin and passageway. This asymmetric configuration optimizes the mechanical interlocking geometry for load transfer.

Inventive Principle:

Principle #4Asymmetry

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 enhanced bending and tension capacity, improved load transfer, and reduced material usage, enabling efficient heavy pile driving without damaging the connector, while maintaining structural integrity and preventing grout leakage.

Implementation Method 1

The 45 degrees rotation of the square openings to the vertical axis of the pile resulting in the edges of the segmental protrusion and recesses having like dovetail grooves when viewed from the side elevation. This 45 degrees orientation gives maximum contact surface between the tapered square pin and tapered square passageway.

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

a tapered square pin can be jammed therethrough an opening (4) to securely interlocked the end plates together

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 3

securing a circular steel skirt to prevent grout seepage

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS9739024B2End plate for concrete piles

Publication Date: 2017.08.22 ONG CHIN CHAI

AI summary

A system for joining two separate spun piles by interlocking together a top end plate located at a bottom end of a first spun pile to a bottom end plate located at a top end of a second spun pile, wherein the end plates each have a plurality of segments comprising an equal number of segmental protrusions and segmental recesses.