US20090151302A1 - Connector assembly and method for connecting misaligned elongated members and a connection formed by the connector assembly - Google Patents

Abstract

The present invention relates generally to a connector assembly for connecting misaligned elongated members using a combination of a pivotable connection and a tolerant connection comprising a tolerance which accommodates the ends of misaligned elongated members. The connector assembly of the present invention connects pivotably to one or the other of the first or second elongated members and forms a tolerant connection with the other. The invention is described as applied to connecting an earth anchor driven into the ground with an extension rod connected to a structure requiring support, regardless of whether the earth anchor and extension rod are in functional alignment. The connector assembly forms pivotable and tolerant connections which cooperate to facilitate connection of the earth anchor to the extension rod, even after each has been affixed to a corresponding structure and are misaligned.

Description

FIELD OF INVENTION
• The present invention relates generally to connector assemblies for connecting misaligned elongated members. More particularly, the connector assembly of the present invention forms a pivotable connection and a tolerant connection comprising a tolerance which accommodates and connects the ends of misaligned elongated members, such as an earth anchor and an extension rod, without having to reposition them into functional alignment.
BACKGROUND
• It is well-known to use earth anchors to provide support for buildings, retaining walls, or other structures. For example, earth anchors may be used as an anchoring device for guy wires, and to tie back retaining walls. One or more earth anchors may be used as foundations for billboards, traffic signs, light poles, utility poles, and other similar structures. They may also be used in groups to provide foundational support for residential and light commercial buildings.
• An earth anchor typically has a shaft with a pointed leading end and an opposite, trailing end. One or more load bearing elements are often attached to the shaft proximate the leading end. Generally, earth anchors are installed by first driving, or screwing, each one into the ground to a desired depth, leading end first. The earth anchor is often driven into the ground using a drive machine having a motor and a rotatable torque coupling, such as a torque head or Kelly bar, which is attached to the trailing end of the shaft of the earth anchor, either directly with connectors or using one or more adapters.
• After the earth anchor has been driven into the ground, it must be somehow secured to the building, retaining wall, or other structure that is to be supported. The trailing end of the shaft is disconnected from the drive machine and then attached to the structure using any one or more of various types of coupling devices and adapters which are first attached or mounted onto the structure. Coupling devices and adapters commonly known and used in the industry include, but are not limited to, wires, cables, tie rods, brackets, adapter bars, and threaded sleeves, and combinations of these, among others.
• When the shaft of the earth anchor does not extend far enough, one or more extenders, such as cables or extension rods, can be attached end-to-end with each other and to the coupling devices or adaptors already attached to the structure. The extender most remote from the structure is attached, by its leading end, to the trailing end of the shaft, using one or more connector assemblies. If multiple extenders are needed to add further length, they are typically arranged and connected with one another end-to-end, using connectors such as, but not limited to, threaded bolts, bolt holes, nuts, threaded sleeves, etc. The connectors may be integrally formed with the extenders, or they may be provided separately.
• Various types of connector assemblies have been developed to connect earth anchors to extenders in different situations and environments. The trailing end of the shaft of the earth anchor is sometimes provided with an attachment feature, such as an internally threaded socket recess or sleeve, a protruding wrench element, a threaded bar or bolt extension, or one or more threaded openings sized and shaped to securely receive a threaded bar or a bolt therethrough, any of which may be integrally formed with the shaft. Alternatively, the attachment feature may be or include a separate connector, such as a coupling sleeve, a threaded bar adapter, or a bracket or adapter having an internally threaded socket recess or opening. The attachment feature is sized and shaped to cooperate with a complementary attachment feature affixed to the leading end of an extender, or to the torque coupling of a drive machine, or to coupling devices or adapters mounted to a structure.
• A problem is often encountered during installation when it is necessary to connect an extender already connected to a structure, either directly, or indirectly with coupling devices or adapters, with an earth anchor which has also already, separately, been driven securely into the ground. Extenders and the shafts of earth anchor both tend to be fairly rigid, i.e., with little lateral tolerance, especially after they are installed, which means there is limited opportunity to reposition them to attain functional alignment. To attach the leading end of the extender to the trailing end of the shaft of the earth anchor requires that they be longitudinally aligned and then secured to one another with a connector assembly and this is often hindered and time-consuming due to the aforesaid lack of sufficient lateral tolerance in either device.
• For example, as often happens in the industry, the trailing end of an earth anchor and the leading end of an extension have complementary threaded features. The threaded features are sized and shaped to be screwed securely together and, thereby, connect the earth anchor and extension rod. However, very close, functional alignment of the earth anchor and extension rod is required to be able to successfully screw the threaded features. Where the longitudinal axes of the earth anchor and extension rod are misaligned (i.e., not in functional alignment), it can require additional time and great effort to reposition them to achieve functional alignment, if it is possible at all.
• The present invention addresses the foregoing situation by providing a connector assembly which forms a tolerant end-to-end connection between elongated members which is capable of accommodating misalignment of the elongated members. Using the connector assembly of the present invention has saved much time and effort in the field when constructing earth anchor-based supports requiring connection of misaligned earth anchors and extension rods.
SUMMARY OF THE INVENTION
• The present invention provides a connector assembly for end-to-end connection of misaligned elongated members. The connector assembly comprises a first attachment feature which is affixed proximate to one end of a first elongated member having a longitudinal axis; and a first coupling feature which is affixed proximate to one end of a second elongated member having a longitudinal axis. The connector assembly also includes; a bracket for connecting the first and second elongated members to one another, having: 1) a bridge plate with a second coupling feature sized and shaped to cooperate with said first coupling feature on the first elongated member to connect the first and second elongated members to one another with a tolerant connection capable of accommodating misalignment between the longitudinal axes of the first and second elongated members, and 2) at least one side plate, each of which extends from a side of said bridge plate and each of which has a complementary attachment feature sized and shaped for cooperating with said first attachment feature of the first elongated member to form a pivotable connection between the first and second elongated members.
• In one embodiment, the connector assembly includes a bracket, the first elongated member includes an earth anchor, and the second elongated member includes an extension rod. The first attachment feature on the earth anchor includes a pair of aligned transverse holes through the trailing end of the earth anchor's shaft and a fastener, such as a threaded bolt and nuts. The first coupling feature on the extension rod includes external threads on the leading end of the extension rod. The bracket preferably has an L-shaped or a U-shaped profile, but may be otherwise shaped depending on the application.
• In another embodiment, the present invention provides an end-to-end connection between elongated members, which were misaligned prior to being connected and each of which has an end and a longitudinal axis and the connection includes: a pivotable connection between a first elongated member and a connector; and a tolerant connection between the connector and a second elongated member. The tolerant connection includes one or more attachment features affixed to the connector and one or more complementary attachment features affixed to the second elongated member, and the attachment features and complimentary attachment features cooperate to accommodate and connect misaligned elongated members.
• In still another embodiment, the present invention provides a method for connecting misaligned elongated members, in the absence of repositioning the elongated members into functional alignment, which involves the steps of: A) connecting a first elongated member, having a trailing end and a longitudinal axis, to a first structure, wherein the first elongated member extends longitudinally from the first structure and the trailing end is remote from the first structure; and B) connecting a second elongated member, having a leading end and a longitudinal axis, to a second structure, wherein the longitudinal axes of the first and second elongated members extend toward one another but are not parallel, the leading end of the second elongated member is remote from the second structure and proximate the trailing end of the first elongated member. The method further includes C) pivotably connecting either the trailing end of the first elongated member, or the leading end of the second elongated member, to a connector; and D) connecting the other of either the trailing end trailing end of the first elongated member, or the leading end of the second elongated member, to the connector, with a tolerant connection capable of accommodating the misaligned first and second elongated members without repositioning them into functional alignment. The tolerant connection has a tolerance of between about 0.125 inch and about 0.25 inch for allowing movement of at least one of the first and second elongated members relative to the another, in a direction which is transverse, axial, or both.
• In one embodiment of the method of the present invention, the first structure may be the ground, the first elongated member may be an earth anchor having a shaft with at least one load-bearing element affixed thereto, and the connecting step A) involves rotating and driving the earth anchor into the ground. Furthermore, the second structure is at least one structure requiring support, the second elongated member may be an extension rod, and the connecting step B) involves securely affixing the extension rod to the second structure. The structure may be, for example, a bulkhead, a retaining wall, a foundation or a sea wall.
BRIEF DESCRIPTION OF THE FIGURES
• For a better understanding of the present invention, reference is made to the following detailed description, considered in conjunction with the accompanying drawings, in which like reference numbers denote like features and in which:
• FIGS. 1-3 are schematic top views of similar adjacent elongated members in various orientations and states of alignment, relative to one another;
• FIG. 2 is a schematic elevational view of a first elongated member (an earth anchor) connected to a second elongated member (an extension rod) by a connector assembly in accordance with the present invention;
• FIG. 3 is an enlarged schematic front view of the connector assembly ofFIG. 1, in use connecting an earth anchor to an extension rod and having a U-shaped bracket;
• FIG. 4 is an enlarged schematic side view of the connector assembly ofFIG. 2;
• FIG. 5 is an enlarged schematic front view of another embodiment of the connector assembly of the present invention in use and having an L-shaped bracket; and
• FIG. 6 is the enlarged schematic side view of the connector assembly ofFIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
• The present invention provides a connector assembly for connecting misaligned elongated members to one another end-to-end, which saves time and energy during installation in the field. The present invention will now be described as applied to connecting misaligned earth anchors and extension rods during construction of tie back assemblies to support a bulkhead. It should, however, be understood that this is not intended to limit the scope or application of the invention. Persons of ordinary skill will readily recognize other contexts and fields in which the present invention would be useful and advantageous, such as any context where elongated members, which are each already affixed to other structures and, therefore, cannot be easily repositioned, are to be connected end-to-end with one another, but are misaligned to a degree that the customary connectors are inoperable, or are operable only with great effort and additional time. All such applications and embodiments are contemplated as coming within the scope of the present invention.
• FIGS. 1A,1B and1C are schematic drawings showing adjacent elongated members in various orientations and states of alignment, relative to one another, as may develop during their installation and attempted connection to one another.FIGS. 1A,1B and1C, along with the following text, will define and demonstrate the meanings of the terms “functional alignment” and “misalignment.”
• As used herein and shown inFIG. 1A, “functional alignment” means very close, or near exact, linear axial alignment of two adjacent elongated members, for instance an earth anchor E1, and an extension rod E2 when placed end-to-end, such that their longitudinal axes form a single, substantially straight line L1, rather than a disconnected line, or an angle, or a combination thereof. As a practical matter, functional alignment is achieved when the internal threads of a threaded feature F1 (shown schematically only) on one elongated member E1 are sufficiently matched and proximate to the external threads of a complementary threaded feature F2 (shown schematically only) on the other elongated member E2 that the threaded features F1, F2 can be securely screwed together.
• Likewise, as used herein and shown inFIGS. 1B,1C and1D, “misaligned” is intended to describe the orientation of adjacent elongated features that are not in functional alignment. It is noted that elongated members may be misaligned even though they are generally oriented end-to-end with one another. As shown particularly inFIGS. 1B and 1C, the longitudinal axes of misaligned elongated members E3, E4, E5, E6 will form a feature other than a single, substantially straight line, such as, for example, a broken line L2, or an angle A, respectively.
• Generally, to construct tie back assemblies for supporting a structure, such as a bulk head, a plurality of elongated members, such as earth anchors, are driven securely into the ground, spaced apart from one another and extending axially toward the bulk head. Separately, one or more corresponding coupling devices, adapters, fasteners and extenders are mounted to the bulk head, extending towards, and also spaced apart from one another at the same intervals as, the earth anchors. Each earth anchor must then be connected by its trailing end to the leading end of the corresponding extender, i.e., elongated member, such as an extension rod. For that purpose, it is common in the industry for the leading end of the extension rod to have external threads and for the trailing end of the shaft of the earth anchor to have an internally threaded socket or opening sized and shaped to threadedly receive the external threaded leading end therein, forming a secure connection which does not allow either of the earth anchor or extension rod to move axially or transversely, relative to the other. Completion of the tie back assembly requires that the earth anchor and the extension rod be positioned in functional alignment with one another to enable the externally threaded leading end to be screwed into the internally threaded socket or opening. If the earth anchor and extension rod are not functionally aligned, personnel must, if possible, manually reposition one or both of them to permit formation of the intended secure threaded connection.
• With reference now toFIG. 2, a schematic elevational view is shown of a single tie back assembly T, including aconnector assembly10 in accordance with one embodiment of the present invention. The tie back assembly T is shown inFIG. 2 already constructed and supporting a bulk head B. This particular tie back assembly T includes elongated members, including but not limited to, anearth anchor12 and anextension rod14, each having a longitudinal axis (shown inFIGS. 3 and 4).
• Characteristically, theearth anchor12 has ashaft20 with aleading end22 and a trailingend24. The leadingend22 has apoint26 to facilitate insertion into the ground G. A plurality of load-bearing elements, such as twohelical blades28a,28bare attached to, and extend radially outward from, theshaft20 proximate theleading end22. Nonetheless, the leadingend22 may be provided with a semi-spherical or blunt end, as desired. The load-bearing elements28a,28bare typically circular as viewed from either end of theshaft20, however, they may be any shape desired, such as ovular, double pendulum, or some other shape.
• In this embodiment, theshaft20 of theearth anchor12 is hollow and has a square cross-section. However, theshaft20 may be solid or hollow, or a combination thereof, and may have any desired, functional cross-sectional shape including, but not limited to, tetrahedral, polygonal, circular or ovular. Theshaft20 may be of any length and diameter suitable for the particular application.
• Theearth anchor12 must be able to withstand rotational, shearing, driving and other forces that are created as it is screwed and driven into the ground G. It must also resist corrosion over time due to exposure to water and minerals while in the earth. Thus, theshaft20 and load-bearing elements28a,28bshould be constructed of a material capable of providing sufficient strength to withstand those forces and resist corrosion. Many earth anchors12 are constructed of carbon steel, because of its strength and relative low cost, and then hot dipped zinc galvanized for additional strength. Earth anchors12 may also be suitably constructed from any other suitable materials as determinable by persons of ordinary skill depending on the application.
• With reference back toFIG. 2, theextension rod14 has aleading end16 and a trailingend18. Theextension rod14 may be an externally threaded bar with a fairly uniform outer diameter and circular cross section, as shown in the figures. It may also be any suitable elongated shape, including, but not limited to, a partially threaded bar, or a bar with an externally threaded projection (not shown) which extends from the leadingend16 and has a different diameter than the bar. Theextension rod14 may also have any practicable cross sectional shape, as determinable by persons of ordinary skill.
• In the embodiment ofFIG. 2, theearth anchor12 has been driven into the ground G, leadingend16 first. Acorresponding tie rod30 has been affixed directly to the bulk head B with abolt fastener32 and theextension rod14 is connected in end-to-end fashion at its trailingend18 with thetie rod30, using asleeve connector34. It is noted that a quantity of earth E has been removed from adjacent the bulk head B to create a depression D in which installation of theearth anchor12 and tie back assembly T can be performed. At least a portion of the quantity of earth E will be used later to back fill the depression D, covering the completed tie back assembly T and, thus, providing additional security against undesirable movement of the tie back assembly T and the bulk head B.
• FIGS. 3 and 4 provide enlarged front and side views, respectively, of theconnector assembly10 shown inFIG. 2. The back view is substantially a mirror image of the front view ofFIG. 3, and the opposite side view is substantially a mirror image of the side view provided inFIG. 4. Theconnector assembly10 connects the trailingend24 of thehollow shaft20 of theearth anchor12 to theleading end16 of theextension rod14. A first attachment feature, such as a pair of opposing, transversely alignedopenings40a,40bare provided through the trailingend24 of thehollow shaft20, for attachment to theconnector assembly10. The leadingend16 of theextension rod14 is equipped with a first coupling feature which, in this embodiment, comprisesexternal threads42, for connection to theconnector assembly10. Where the extension rod is not a fully threaded bar as shown here, there may be provide an externally threaded projection (not shown) affixed to and extending away from the leadingend16, co-axially with the longitudinal axis44 of saidextension rod14.
• Generally, theconnector assembly10 itself includes abracket50 having abridge plate52 and at least oneside plate54, each of which extends perpendicularly from a side of the bridge plate. As used herein, the term “perpendicularly” is not intended to require a strict 90-degree angle, but rather includes any angle between the bridge plate and each side plate that is from about 80 degrees to about 100 degrees. As will be discussed in further detail hereinafter, a second coupling feature is provided on thebridge plate52 to cooperate with the first coupling feature of theextension rod14. Similarly, a complementary attachment feature is provided on at least one of theside plates54 for cooperating with the first attachment feature of theshaft20 of theearth anchor12.
• As more clearly shown inFIGS. 2,3 and4, thebracket50 may have a U-shaped profile formed by thebridge plate52 and twoside plates54,56, the first of which54 extends perpendicularly from one side of thebridge plate52 and the other of which56 extends perpendicularly from the opposite side of thebridge plate52. While the dimensions of thebridge plate52 andsides plates54,56 may be easily varied and adjusted by persons of ordinary skill in the art, based on the project and application, in this embodiment, thebridge plate52 has a length of about 4 inches, and each of theside plates54,56 has a length of about 6 inches, with the thickness of allplates52,54,56 being about 0.375 inch, and the width of allplates52,54,56 being about 3 inches.
• In this embodiment, shown in greater detail inFIGS. 3 and 4, the second coupling feature is anopening58 through thebridge plate52 which is sized and shaped to loosely receive therethrough the externally threaded leadingend16,42 (i.e., first coupling feature) of theextension rod14. A retaining fastener, such as a threadednut60, is screwed onto the externally threaded leadingend16,42, after its insertion through theopening58 to secure theextension rod14 to thebracket50. Theopening58, the externally threaded leadingend16,42 and the threadednut60 are sized and shaped to cooperate together to form atolerant connection62 capable of accommodating amisaligned earth anchor12 andextension rod14. It is possible that the misalignment of theearth anchor12 andextension rod14 results in the threadednut60 being oriented at an angle relative to thebridge plate52, rather than in flush contact as shown inFIGS. 3 and 4. In such a situation, it is recommended that a beveled washer (not shown) be placed on the externally threaded leadingend16,42 of theextension rod14, in between thebridge plate52 and the threadednut60.
• Thetolerant connection62 comprises atolerance61, which means that there is an annular space between the outer surface of the externally threaded leadingend16,42 and theinner edge64 of theopening58 of thebridge plate52, which allows freer movement of the externally threaded leadingend16,42 when inserted through theopening58. Thetolerance61 is typically between about 0.125 inch and 0.25 inch, measured as the total difference between the inner diameter of theinner edge64 of theopening58 of thebridge plate52 and the outer diameter of the externally threaded leadingend16,42. The outer diameter of theextension rod14 is typically be between about 0.5 inch and 1.0 inch, such as, for example, without limitation, 0.5 inch, 0.625 inch, 0.75 inch or 1.0 inch, and the diameter of theopening58 should, accordingly, be between about 0.875 inch and about 1.25 inch to loosely accommodate insertion of the externally threaded leadingend16,42. For example, where theextension rod14 has an outer diameter of about 0.75 inch, the diameter of theopening58 of thebridge plate52 should, preferably, be about 1 inch. The foregoing dimensions are provided as typical examples of preferred embodiments only, and persons of ordinary skill will readily be able to modify them according to the needs of the project. Furthermore, in the event that thebridge plate52 has anopening58 that is too large for theextension rod14 selected for use, such as, for example, an opening of 1.0 inch for an extension rod of only 0.5 inch outer diameter, one or more oversized washers (not shown), at least one of which has an outer diameter greater than theopening58, may be inserted between thebridge plate52 and the threadednut60 to accommodate the undersized externally threaded leadingend16,42. This and other modifications and adjustments will be easily recognized and developed by persons of ordinary skill in the field, without altering the function and operation of the present invention.
• Furthermore, in the embodiment shown inFIGS. 2,3 and4, the complementary attachment feature includes anaperture70a,70bthrough each of theside plates54,56 of thebracket50. Theapertures70a,70bare aligned with one another and are sized and shaped to align with the pair of opposing, transversely alignedopenings40a,40b(i.e., the first attachment feature) through the trailingend24 of thehollow shaft20. Theapertures70a,70band theopenings40a,40balign and cooperate to receive therethough a fastener, such as the threadedbolt66 andnuts72a,72bshown inFIGS. 2,3 and4, to form a pivotable connection between theearth anchor12 and thebracket50. Theapertures70a,70band theopenings40a,40bmay each be about 15/16 inch to accommodate a threadedbolt66 of about 0.75 or 0.875 inch. Of course, these dimensions are adjustable by persons of ordinary skill in the art based upon the project, the materials available and the structure to be supported.
• FIGS. 5 and 6 provide enlarged schematic front and side views, respectively, of another embodiment of a connector assembly100 in accordance with the present invention. The back view is substantially a mirror image of the front view provided inFIG. 5, and the opposite side view is substantially similar to the side view of the previous embodiment provided inFIG. 4. The connector assembly100 of this embodiment again connects the trailingend24 of theshaft20 of theearth anchor12 with the leadingend16 of theextension rod14. The trailingend24 of theshaft20 still has the first attachment feature comprising a pair of opposing, transversely alignedopenings40a,40b.Similarly, the leadingend16 of theextension rod14 is still equipped with the first coupling feature comprisingexternal threads42. The dimensions of the various elements and features of this embodiment are substantially similar to those provided above in the description of the embodiment shown inFIGS. 2,3 and4.
• More particularly, as shown inFIGS. 5 and 6, the connector assembly100 also includes abracket150. Thebracket150 of this embodiment of the connector assembly100 has an L-shaped profile formed by abridge plate152 and oneside plate154 which extends substantially perpendicularly from a side of thebridge plate152. While the dimensions of thebridge plate152 andside plates154 may be easily varied and adjusted by persons of ordinary skill in the art, based on the project and application, in this embodiment, thebridge plate152 has a length of about 3 inches, and theside plate54 has a length of about 5 inches, with the thickness of allplates52,54,56 being about 0.375 inch, and the width of allplates52,54,56 being about 2.5 inches.
• The second coupling feature is still anopening158 through thebridge plate152 which is sized and shaped to loosely receive therethrough the externally threaded leadingend16,42 (i.e., first coupling feature) of theextension rod14. As above with the first embodiment, a retaining fastener, such as a threaded nut160, is screwed onto the externally threaded leadingend16,42, after its insertion through theopening158 to secure theextension rod14 to thebracket150. Theopening158, the externally threaded leadingend16,42 and the threaded nut160 are sized and shaped to cooperate to form atolerant connection162 capable of accommodating amisaligned earth anchor12 andextension rod14. As described hereinabove in connection with the embodiment shown inFIGS. 3 and 4, thetolerant connection162 of this embodiment comprises atolerance161 between the externally threaded trailingend16,42 and theinner edge164 of theopening158 of thebridge plate152 of thebracket150. Thetolerance161 and theopening158 each have substantially the same dimensions as discussed hereinabove in connection with the first embodiment.
• In this embodiment ofFIGS. 5 and 6, the complementary attachment feature includes anaperture170 through theside plate154 of thebracket150. Theaperture170 is sized and shaped to align with the pair of opposing, transversely alignedopenings40a,40b(i.e., the first attachment feature) through the trailingend24 of thehollow shaft20 of theearth anchor12. Theaperture170 and theopenings40a,40balign and cooperate to receive therethough a fastener, such as the threadedbolt166 andnuts172a,172bshown inFIGS. 5 and 6, to form a pivotable connection between theearth anchor12 and thebracket14. Theaperture170 has the same dimensions as discussed hereinabove in connection with theapertures70a,70bof the first embodiment, shown inFIGS. 2,3 and4.
• Although, in both embodiments presented hereinabove, at least portions of the attachment features and coupling features are integrally formed with the respective portions of the elongated members or the connector bracket, they are not required to be integrally formed with the elongated members to any extent. For example, an externally threaded projection (not shown, but mentioned above) may be separately formed and then securely affixed, such as by welding, apoxy, or cement, to theleading end16 of theextension rod14. Additionally, rather than forming theshaft20 of theearth anchor12 having the pair of opposing, transversely alignedopenings40a,40bintegrally formed therein, an adapter (not shown), such as a sleeve having a transverse opening therethrough and a flange (not shown) for connecting to theshaft20 could instead be formed separately and then securely affixed to the trailingend24 of thehollow shaft20. Furthermore, it will be readily recognized by persons of ordinary skill in the art that many other devices, connectors, adapters, attachments and couplers can be alternatively and successfully employed in connection with the present invention and, the invention is not limited to those particular embodiments shown and discussed herein.
• The present invention also provides a method for connecting misaligned elongated members, without (i.e., in the absence of) repositioning the elongated members into functional alignment. The method of the present invention is essentially the method that is employed when the connector assembly of the present invention is used to connect elongated members, whether misaligned or not. First, the elongated members must be connected to their respective structures, and each of the structures may include the ground, a retaining wall, a bulkhead, a foundation, or some other structure. More particularly, a first elongated member (such as an earth anchor), having a trailing end and a longitudinal axis, is connected to a first structure (such as the ground) and oriented such that the first elongated member extends longitudinally from the first structure and the trailing end is remote from the first structure. A second elongated member (such as an extension rod), having a leading end and a longitudinal axis, is connected to a second structure (such as a bulk head), such that the longitudinal axes of the first and second elongated members extend toward one another but are not parallel, and the leading end of the second elongated member is remote from the second structure and proximate the trailing end of the first elongated member.
• After the first and second elongated members have been connected to the first and second structures, respectively, either the trailing end of the first elongated member, or the leading end of the second elongated member, is pivotably connected to a connector (for example, the bracket of the connector assembly of the present invention).
• Then whichever of the trailing end of the first elongated member and the leading end of the second elongated member was pivotably connected to the connector, the other is now connected to the connector, with a tolerant connection capable of accommodating the misaligned first and second elongated members without repositioning them into functional alignment. The tolerant connection should provide a total tolerance of between about 0.125 inch and 0.25 inch, for allowing movement of at least one of the first and second elongated members relative to the another, in a direction which is transverse, axial, or both.
• In other words, if the first and second elongated members are not misaligned, then the present invention will still accomplish the job of connecting them. If they are misaligned, however, they need not be repositioned into full functional alignment for the present invention to accomplish connecting them with the connector because a tolerant connection as is taught hereinabove, provides some latitude, or wiggle room, to connect them without being totally in functional alignment. Applicant has found that the connector assembly and method of the present invention have resulted in significant time and effort savings by installation personnel, making projects proceed more easily and more quickly.
• The present invention as described hereinabove is well adapted to achieve the purpose and provide the benefits mentioned, as well as others which are inherent. While several presently preferred embodiments of the invention have been given for purposes of disclosure, numerous changes in the details of apparatus and procedures may be made without departing from the spirit of the invention. Some such changes and modifications have already been discussed herein. Such modifications, and others, will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.

Claims (18)

1. A connector assembly for end-to-end connection of misaligned elongated members, said connector assembly comprising:

A) a first attachment feature which is affixed proximate to one end of a first elongated member having a longitudinal axis;

B) a first coupling feature which is affixed proximate to one end of a second elongated member having a longitudinal axis;

C) a bracket for connecting the first and second elongated members to one another, having:

1) a bridge plate with a second coupling feature sized and shaped to cooperate with said first coupling feature on the first elongated member to connect the first and second elongated members to one another with a tolerant connection capable of accommodating misalignment between the longitudinal axes of the first and second elongated members, and

2) at least one side plate, each of which extends from a side of said bridge plate and each of which has a complementary attachment feature sized and shaped for cooperating with said first attachment feature of the first elongated member to form a pivotable connection between the first and second elongated members.

2. The connector assembly according toclaim 1, wherein said tolerant connection between said first and second coupling features comprises a tolerance of between about 0.125 inch and about 0.25 inch between said first and second coupling features for accommodating the ends of the misaligned first and second elongated members.

3. The connector assembly according toclaim 2, wherein, after the first and second elongated members are connected to one another, said tolerance allows movement of at least one of the first and second elongated members relative to the another, in a direction which is transverse, axial, or both.

4. The connector assembly according toclaim 1, wherein said bracket comprises an L-shaped profile formed by one side plate extending perpendicularly from one side of said bridge plate, said second coupling feature comprises an opening provided through said bridge plate, said opening for loosely receiving at least a portion of said first coupling feature therethrough, and said complementary attachment feature comprising an aperture through said side plate, said aperture being sized and shaped to cooperate with said first attachment feature to form a pivotable connection.

5. The connector assembly according toclaim 1, wherein said bracket comprises a U-shaped profile wherein a first side plate extends perpendicularly from one side of said bridge plate, and a second side plate extends perpendicularly from an opposite side of said bridge plate, said second coupling feature comprises an opening provided through said bridge plate for loosely receiving at least a portion of said first coupling feature therethrough, and said complementary attachment feature comprises a first aperture through said first side plate and a second aperture through said second side plate, said first and second apertures being aligned with one another and sized and shaped to cooperate with said first attachment feature to form a pivotable connection.

6. The connector assembly according toclaim 1, wherein at least a portion of each of said first coupling feature, said second coupling feature, said first attachment feature, and said complementary attachment feature, is formed integrally with said first elongated member, said bridge plate of said bracket, said second elongated member, and said at least one side plate of said bracket, respectively.

7. The connector assembly according toclaim 1, wherein said first elongated member comprises an earth anchor having a shaft with a trailing end and said first attachment feature comprises a transverse opening through said trailing end of said shaft and a fastener sized and shaped to be inserted through said transverse opening.

8. The connector assembly according toclaim 7, wherein said shaft of said earth anchor further comprises a pointed leading end and at least one load-bearing element attached to said shaft proximate said leading end.

9. The connector assembly according toclaim 8, wherein each of said load-bearing elements comprises a helical blade.

10. The connector assembly according toclaim 1, wherein said second elongated member comprises an extension rod having a leading end and said first coupling feature comprises external threads on said leading end.

11. The connector assembly according toclaim 10, wherein said first elongated member comprises an extension rod having and a trailing end, and wherein said first attachment feature comprises a transverse opening through said trailing end of said extension rod and a fastener sized and shaped to be inserted through said transverse opening.

12. The connector assembly according toclaim 1, wherein at least one of said first and second elongated members is affixed to another structure.

13. An end-to-end connection between elongated members, which were misaligned prior to being connected and each of which has an end and a longitudinal axis, said connection comprising:

A) a pivotable connection between a first elongated member and a connector; and

B) a tolerant connection between the connector and a second elongated member;

wherein said tolerant connection comprises one or more attachment features affixed to the connector and one or more complementary attachment features affixed to the second elongated member, said attachment features and said complimentary attachment features cooperating together to accommodate and connect misaligned elongated members.

14. The end-to-end connection according toclaim 13, wherein said tolerant connection comprises a tolerance of between about 0.125 inch and about 0.25 inch between at least one of said attachment features and at least one of said complimentary attachment features, which allows movement of at least one of the elongated members relative to the another, in a direction which is transverse, axial, or both.

15. A method for connecting misaligned elongated members, in the absence of repositioning the elongated members into functional alignment, said method comprising:

A) connecting a first elongated member, having a trailing end and a longitudinal axis, to a first structure, wherein the first elongated member extends longitudinally from the first structure and the trailing end is remote from the first structure;

B) connecting a second elongated member, having a leading end and a longitudinal axis, to a second structure, wherein the longitudinal axes of the first and second elongated members extend toward one another but are not parallel, the leading end of the second elongated member is remote from the second structure and proximate the trailing end of the first elongated member;

C) pivotably connecting either the trailing end of the first elongated member, or the leading end of the second elongated member, to a connector;

D) connecting the other of either the trailing end trailing end of the first elongated member, or the leading end of the second elongated member, to the connector, with a tolerant connection capable of accommodating the misaligned first and second elongated members without repositioning them into functional alignment, said tolerant connection comprising a tolerance of between about 0.125 inch and about 0.25 inch for allowing movement of at least one of the first and second elongated members relative to the another, in a direction which is transverse, axial, or both.

16. The method for connecting misaligned elongated members according toclaim 15, wherein the first structure comprises the ground and the first elongated member comprises an earth anchor having a shaft with at least one load-bearing element affixed thereto, wherein said connecting step A) comprises rotating and driving the earth anchor into the ground.

17. The method for connecting misaligned elongated members according toclaim 15, wherein the second structure comprises at least one structure requiring support selected from the group consisting of: a bulkhead, a retaining wall, a foundation and a sea wall, and the second elongated member comprises an extension rod wherein said connecting step B) comprises securely affixing the extension rod to the second structure.

18. The method for connecting misaligned elongated members according toclaim 12, wherein the extension rod is securely affixed to the second structure indirectly with one or more devices selected from the group consisting of: a cable, an additional extension rod, an adapter bar, a connector device, an adapter device, a connector sleeve and a tie rod.

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