Tapered, locking, anti-reverse coupler assembly for foundation support system

Abstract

A coupled shaft assembly for a foundation support system includes conical-shaped inner and outer couplers with mating helical ribs and grooves, and an anti-reverse element extending through different shaped openings in the inner and outer couplers that accommodates a limited degree of relative rotation of the couplers and thereafter precludes further relative rotation and an undesirable disengagement of the inner and outer couplers when subjected to reverse rotation.

What is claimed is: 
     
         1 . A foundation support system comprising:
 a coupled shaft assembly comprising:
 a first coupler extending on a first end of a first hollow foundation support shaft, the first coupler formed with a first main body having a first sidewall and a pair of elongated openings configured to accept a single fastener extending therebetween and to define a continuous guide path for a limited movement of the single fastener relative to the first sidewall; 
 wherein the continuous guide path allows a vertical and horizontal movement of the single fastener relative to the first sidewall when the coupled shaft assembly is subjected to a reverse rotation or an uplift force. 
   
     
     
         2 . The foundation support system of  claim 1 , wherein the first coupler is configured as an inner coupler having at least one rib projecting from an outer circumference of the first main body. 
     
     
         3 . The foundation support system of  claim 2 , wherein the at least one rib is a helical rib projecting from the circumference of the outer coupler. 
     
     
         4 . The foundation support system of  claim 1 , wherein the pair of openings includes a first opening and a second opening, each of the first and second openings being elongated oval-shaped openings. 
     
     
         5 . The foundation support system of  claim 4 , wherein the elongated oval-shaped openings extend helically on the first main body. 
     
     
         6 . The foundation support system of  claim 1 , wherein the first main body is a conical body. 
     
     
         7 . The foundation support system of  claim 1 , wherein the first main body is round. 
     
     
         8 . The foundation support system of  claim 1 , further comprising a second coupler extending on a second end of a second hollow foundation support shaft, the outer coupler formed with a second main body having a second sidewall and at least a second pair of openings formed through the second sidewall,
 wherein the second pair of openings is configured to accept the single fastener extending therebetween and to snugly fit an outer diameter of the single fastener.   
     
     
         9 . The foundation support system of  claim 8 , wherein the second main body is formed with a groove extending from an interior circumference of the second coupler. 
     
     
         10 . The foundation support system of  claim 9 , wherein the groove is a helical groove. 
     
     
         11 . The foundation support system of  claim 8 , wherein the second coupler is configured as an outer coupler which receives the first coupler. 
     
     
         12 . The foundation support system of  claim 8 , wherein the second main body is a conical body. 
     
     
         13 . The foundation support system of  claim 8 , wherein the second main body is round. 
     
     
         14 . The foundation support system of  claim 8 , wherein the second pair of openings includes a first circular opening and a second circular opening. 
     
     
         15 . The foundation support system of  claim 8 , wherein the first pair of openings and the second pair of openings are self-aligning when the first and second couplers are mated. 
     
     
         16 . The foundation support system of  claim 8 , wherein one of the first and second hollow foundation support shafts includes a helical auger. 
     
     
         17 . The foundation support system of  claim 1 , wherein the single fastener is a bolt. 
     
     
         18 . The foundation support system of  claim 1 , further comprising a cap, a plate, or a lift bracket to support a building foundation in combination with the coupled shaft assembly. 
     
     
         19 . The foundation support system of  claim 1 , in combination with a grout or cementitious material to enhance a structural strength and capacity of the coupled shaft assembly in the installed foundation support system. 
     
     
         20 . The foundation support system of  claim 1 , wherein the first hollow foundation support shaft is a steel shaft. 
     
     
         21 . The foundation support system of  claim 1 , wherein the first coupler is separately fabricated from the first hollow foundation support shaft. 
     
     
         22 . A foundation support system comprising:
 a coupled shaft assembly comprising:
 a first coupler extending on a first end of a first hollow foundation support shaft; 
 a second coupler extending on a second end of a second hollow foundation support shaft; and 
 a bolt extending through and between the first coupler and the second coupler to secure the first coupler to the second coupler when the first and second couplers are mated; 
 wherein the bolt is snugly received by one of the first and second couplers and continuously movable relative to the other of the first and second coupler in a vertical and horizontal direction when the coupled shaft assembly is subjected to a reverse rotation or an uplift force. 
   
     
     
         23 . The foundation support system of  claim 22 , wherein the first and second couplers include ribs or grooves that mate with one another to establish a torque transmitting connection between the first and second coupler. 
     
     
         24 . The foundation support system of  claim 22 , wherein the ribs and grooves are helical ribs and grooves. 
     
     
         25 . The foundation support system of  claim 22 , wherein each of the first and second coupler includes a conical body. 
     
     
         26 . The foundation support system of  claim 22 , wherein the bolt is continuously movable along a helical guide path in one of the first and second couplers. 
     
     
         27 . A foundation support system comprising:
 a coupled shaft assembly comprising:
 a first coupler extending on a first end of a first hollow foundation support shaft, the first coupler having a first pair of openings of a first shape; and 
 a second coupler extending on a second end of a second hollow foundation support shaft, the second coupler having a second pair of openings of a second shape different from the first shape; and 
 wherein a bolt extending through and between the first coupler and the second coupler through the first and second pair of openings is continuously movable relative to one of the first and second couplers in a vertical and horizontal direction when the coupled shaft assembly is subjected to a reverse rotation or an uplift force while otherwise being stationary relative to the other of the first and second couplers. 
   
     
     
         28 . The foundation support system of  claim 27 , wherein the first shape is an elongated oval shape and the second shape is a circular shape. 
     
     
         29 . The foundation support system of  claim 27  wherein each of the first and second couplers includes a conical body. 
     
     
         30 . The foundation support system of  claim 27 , wherein the first and second couplers establish a torque transmitting relationship via ribs and grooves formed in the first and second couplers.