Modular helical pier foundation support systems, assemblies and methods with snap-lock couplings

Abstract

Improved couplers for a building foundation support system include helical ribs and helical grooves in combination with an integrated spring retainer element that automatically snaps into place as the couplers are engaged. Rotational and axial interlocking attachment of support piles is therefore possible without utilizing separately provided fasteners such as bolts.

What is claimed is: 
     
         1 . A foundation support system comprising:
 a first coupler having a first outer circumference and a first inner circumference;   a second coupler having a second outer circumference and a second inner circumference; and   a resilient spring extending partly on each of the first outer circumference and the second outer circumference, the resilient spring being configured to automatically engage and axially interlock the first and second outer circumferences with snap-fit engagement as the first and second couplers are mated;   wherein the axial interlock avoids a separation of the first and second couplers at a below ground location due to axially directed uplift forces when the foundation support system is installed in a building site to support the foundation.   
     
     
         2 . The foundation support system of  claim 1 , wherein each of the first and second outer circumference is formed with a retainer groove thereon to respectively receive a portion of the resilient spring. 
     
     
         3 . The foundation support system of  claim 1 , wherein the first outer circumference is configured to establish a rotational interlock with the second inner circumference when the first and second couplers are mated. 
     
     
         4 . The foundation support system of  claim 3 , wherein the first outer circumference includes a plurality of ribs or a plurality of grooves, wherein the second inner circumference includes a plurality of ribs or a plurality of grooves, and the rotational interlock is established between the ribs or grooves in the first outer circumference or the second outer circumference. 
     
     
         5 . The foundation support system of  claim 4 , wherein the plurality of ribs define a retainer groove receiving a portion of the resilient spring in the snap-fit engagement. 
     
     
         6 . The foundation support system of  claim 4 , wherein the plurality of ribs are helical ribs. 
     
     
         7 . The foundation support system of  claim 4 , wherein the plurality of ribs are spaced unevenly from one another. 
     
     
         8 . The foundation support system of  claim 3 , wherein the first outer circumference includes a polygonal body having a number of sides, and wherein the second inner circumference defines a receiving area complementary to the polygonal body. 
     
     
         9 . The foundation support system of  claim 8 , wherein the polygonal body has six sides. 
     
     
         10 . The foundation support system of  claim 8 , wherein the polygonal body has four sides. 
     
     
         11 . The foundation support system of  claim 3 , wherein the first outer circumference and the second inner circumference are at least partly tapered along an axial centerline of the first coupler or the second coupler. 
     
     
         12 . The foundation support system of  claim 1 , wherein the resilient spring is permanently attached to one of the first and second couplers. 
     
     
         13 . The foundation support system of  claim 1 , wherein the resilient spring extends around the first outer circumference of the first coupler and around the second outer circumference of the second coupler for a radial distance less than 360°. 
     
     
         14 . The foundation support system of  claim 13 , wherein the resilient spring is an annular spring. 
     
     
         15 . The foundation support system of  claim 13 , wherein the first outer circumference defines at least one ramp causing the resilient spring element to expand as the first and second couplers are mated. 
     
     
         16 . The foundation support system of  claim 1 , further comprising a first pile and a second pile rotationally interlocked to one another through the first and second coupler. 
     
     
         17 . The foundation support system of  claim 16 , wherein one of the first and second piles includes a helical auger. 
     
     
         18 . The foundation support system of  claim 16 , further comprising one of a bracket, a plate, or a lifting assembly for supporting the foundation. 
     
     
         19 . The foundation support system of  claim 16 , wherein the first pile and the second pile are filled with a cementitious material. 
     
     
         20 . The foundation support assembly of  claim 1 , wherein neither of the first or second coupler includes a fastener hole. 
     
     
         21 . The foundation support assembly of  claim 1 , wherein the axial interlock is realized solely by the spring retainer element without any threaded fastener. 
     
     
         22 . A foundation support system comprising:
 a first coupler having a first outer circumference and a first inner circumference;   a second coupler having a second outer circumference and a second inner circumference; and   a resiliently deflectable spring extending around the first outer circumference and around the second outer circumference for a radial distance less than 360° and being configured to automatically engage and axially interlock the first outer circumference and the second outer circumference with snap-fit engagement as the first and second couplers are mated;   wherein the first outer circumference defines at least one ramp causing a diameter of the resiliently deflectable spring to expand and a retaining groove for the resiliently deflectable spring to return to a reduced diameter as the first and second couplers are mated; and   wherein the axial interlock avoids a separation of the first and second couplers at a below ground location due to axially directed uplift forces when the foundation support system is installed in a building site to support the foundation.   
     
     
         23 . The foundation support assembly of  claim 22 , wherein neither of the first or second coupler includes a fastener hole. 
     
     
         24 . The foundation support assembly of  claim 22 , wherein the axial interlock is realized solely by the spring retainer element without any threaded fastener. 
     
     
         25 . The foundation support system of  claim 22 , wherein the resilient spring is permanently attached to the second coupler. 
     
     
         26 . The foundation support system of  claim 22 , wherein the first outer circumference is configured to establish a rotational interlock with the second inner circumference when the first and second couplers are mated. 
     
     
         27 . The foundation support system of  claim 22 , further comprising a first pile and a second pile rotationally interlocked to one another through the first and second coupler. 
     
     
         28 . The foundation support system of  claim 27 , wherein one of the first and second piles includes a helical auger. 
     
     
         29 . A foundation support system comprising:
 a first coupler having a first outer circumference and a first inner circumference;   a second coupler having a second outer circumference and a second inner circumference;   a resilient spring extending on the second outer circumference and having an expandable diameter;   wherein the first outer circumference is configured to cause the diameter of the resilient spring element to expand when the first outer circumference is partly mated to the second inner circumference; and   wherein the first outer circumference is configured to receive a portion of the resilient spring at a reduced diameter with snap-fit engagement, thereby automatically establish an axial interlock of the first and second outer circumference when the first outer circumference is fully mated to the second inner circumference;   wherein the axial interlock avoids a separation of the first and second couplers at a below ground location due to axially directed uplift forces when the foundation support system is installed in a building site to support the foundation.   
     
     
         30 . The foundation support assembly of  claim 29 , wherein neither of the first or second coupler includes a fastener hole. 
     
     
         31 . The foundation support assembly of  claim 29 , wherein the axial interlock is realized solely by the spring retainer element without any threaded fastener.