Snap lock, anti-reverse rotation coupler assembly for foundation support system

Abstract

A coupled shaft assembly for a foundation support system includes a first coupler extending on a first end of a first hollow foundation support provided with a helical auger. The first coupler is formed with a first main body and a plurality of ribs or grooves formed in the first main body. The plurality of ribs or grooves are respectively formed with an asymmetric section along a portion of a length of the ribs or grooves. The asymmetric section defines an anti-reverse rotation stop surface

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 provided with a helical auger, the first coupler formed with a first main body and a plurality of ribs or grooves formed in the first main body; 
 wherein the plurality of ribs or grooves are respectively formed with an asymmetric section along a portion of a length of the ribs or grooves, the asymmetric section defining an anti-reverse rotation stop surface. 
   
     
     
         2 . The foundation support system of  claim 1 , wherein the coupled shaft assembly further comprises:
 a second coupler extending on a second end of a second hollow foundation support shaft, the second coupler comprising:
 a second main body configured to establish a mating torque transmitting relationship with the plurality of ribs or grooves of the first coupler to drive the first hollow foundation support shaft below ground when the second hollow foundation shaft and the second coupler are rotated in a first direction; and 
 wherein the second main body is configured to permit a limited degree of rotational movement relative to the first main body when the second hollow foundation shaft and the second coupler are rotated in a second direction opposite to the first direction. 
   
     
     
         3 . The foundation support system of  claim 2 , further comprising a retainer coupled to and extending around an exterior of one of the first main body or the second main body, and while the mating torque transmitting relationship is being established the retainer is configured to automatically extend around an exterior of the other of the first main body or second main body to couple the first main body and second main body with a snap-lock connection. 
     
     
         4 . The foundation support system of  claim 1 , wherein the plurality of ribs or grooves includes a first longitudinal side edge and a second longitudinal side edge opposite the first longitudinal side edge, the asymmetric section extending from only the first longitudinal side edge. 
     
     
         5 . The foundation support system of  claim 4 , wherein each of the first and second longitudinal side edges are curved. 
     
     
         6 . The foundation support system of  claim 5 , wherein the first and second longitudinal side edges extend helically on the inner coupler or the outer coupler. 
     
     
         7 . The foundation support system of  claim 4 , wherein the built-in anti-reverse rotation section projects discontinuously from the first longitudinal side edge. 
     
     
         8 . The foundation support system of  claim 1 , wherein the plurality of ribs or grooves define less than one complete turn of a helix. 
     
     
         9 . The foundation support system of  claim 1 , wherein the asymmetric section further defines an uplift bearing surface. 
     
     
         10 . The foundation support system of  claim 9 , wherein the anti-reverse rotation stop surface is curved and wherein the uplift bearing surface is flat. 
     
     
         11 . The foundation support system of  claim 10 , wherein the anti-reverse rotation stop surface extends helically. 
     
     
         12 . The foundation support system of  claim 11 , wherein the uplift bearing surface extends perpendicularly to a longitudinal axial centerline of first coupler. 
     
     
         13 . The foundation support system of  claim 1 , wherein the retainer element is a monolithic spring element. 
     
     
         14 . The foundation support system of  claim 13 , wherein the spring element is a multiple turn spring element. 
     
     
         15 . The foundation support system of  claim 1 , wherein the first coupler includes a plurality of exterior spaced-apart retaining grooves. 
     
     
         16 . The foundation support system of  claim 15 , wherein a retainer is pre-installed on the first coupler in the exterior spaced-apart retaining grooves. 
     
     
         17 . The foundation support system of  claim 16 , wherein the retainer has a resiliently expandable diameter. 
     
     
         18 . The foundation support system of  claim 17 , wherein the retainer element is a monolithic spring. 
     
     
         19 . 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. 
     
     
         20 . 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. 
     
     
         21 . The foundation support system of  claim 1 , wherein one the first hollow foundation support shaft includes a helical auger. 
     
     
         22 . The foundation support system of  claim 1 , wherein the first coupler is separately fabricated from the first or second hollow foundation support shaft. 
     
     
         23 . 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 coupler formed with a first main body and a plurality of ribs or grooves formed in the first main body; 
 wherein the plurality of ribs or grooves are respectively formed with an asymmetric section along a portion of a length of the ribs or grooves; and 
 wherein the asymmetric section defines an anti-reverse rotation stop surface and an uplift bearing surface. 
   
     
     
         24 . The foundation support system of  claim 23 , wherein the coupled shaft assembly further comprises:
 a second coupler extending on a second end of a second hollow foundation support shaft, the second coupler comprising:
 a second main body configured to establish a mating torque transmitting relationship with the plurality of ribs or grooves of the first coupler to drive the first hollow foundation support shaft below ground when the second hollow foundation shaft and the second coupler are rotated in a first direction; 
 wherein the second main body is configured to move relative to the first main body by no more than a predetermined amount when the first coupler when the second hollow foundation shaft and the second coupler are rotated in a second direction opposite to the first direction. 
   
     
     
         25 . The foundation support system of  claim 24 , further comprising a retainer coupled to and extending around an exterior of one of the first main body or the second main body, and while the mating torque transmitting relationship is established the retainer is configured to automatically extend around an exterior of the other of the first main body or second main body to couple the first main body and second main body with a snap-lock connection.