IP Library Granted Patent US 12,222,138
Granted Patent B2
US 12,222,138 · App. 17/729,879 · Granted Feb 11, 2025

Free-standing load support system

Inventors: James Mckinion (Austin, TX); Keith Becker (Cedar Park, TX)
Assignee: Helical Solar Solutions, LLC
F24S25/12F24S25/617
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,222,138
App. No.
17/729,879
Granted
Feb 11, 2025
Kind
B2
Abstract

A load support system includes an elongate support member having a first diameter and first and second ends. The elongate support member includes, toward the first end, a first portion for direct earth burial and further includes, toward the second end, a second portion to which the load can be coupled. The system additionally includes a lateral support having a second diameter greater than the first diameter and a second length less than a first length of the first portion. The lateral support is mounted about the first portion of the elongate support member. The lateral support includes a first opening formed therein at a first location relative to a long axis of the elongate support member and a second opening formed therein at a different second location relative to the long axis in order to support a range of embedment depths.

Claims (76)

1. A load support system, comprising:

an elongate support member having a first diameter and a first end and a second end, wherein the elongate support member includes, toward the first end, a first portion for direct earth burial and further includes, toward the second end, a second portion to which the load can be coupled, wherein the first portion has a first length;

a lateral support having a second diameter greater than the first diameter and a second length less than the first length, wherein the lateral support has a substantially cylindrical curved outer wall and is mounted about the first portion of the elongate support member;

a helix formed at least partially about an exterior surface of the substantially cylindrical curved outer wall of the lateral support; and

wherein the substantially cylindrical curved outer wall of the lateral support has a first opening formed therethrough at a first location relative to a long axis of the elongate support member and the elongate support member includes a second opening formed therein at a different second location relative to the long axis of the elongate support member, such that a range of embedment depths of the first portion of the elongate support member is supported.

2. The load support system of claim 1 , and further comprising a pedestal for coupling the load to the elongate support member, wherein the pedestal includes an elongate tube received within the elongate support member.

3. The load support system of claim 2 , wherein:

the second portion of the elongate support member includes a mounting hole;

the elongate tube of the pedestal has an exterior surface and an interior surface, a plurality of spacers distributed along the elongate tube that protrude from the exterior surface of the tube, a plurality of holes through the spacers and the tube, and a respective one of a plurality of threaded nuts fixedly attached to the interior surface of the tube at each of the plurality of holes.

4. The load support system of claim 1 , wherein:

the elongate support includes a series of holes along the second portion for receiving removable steps; and

the load support system further includes at least one removable step configured to be inserted in one of the series of holes and removably coupled to the elongate support.

5. The load support system of claim 1 , wherein the second portion of the elongate support member has multiple sets of load mounting holes formed therein, such that a range of embedment depths of the first portion of the elongate support member is supported.

6. The load support system of claim 1 , wherein an interior volume of the lateral support is selected to determine an embedment depth of the first portion of the elongate support member.

7. The load support system of claim 1 , wherein:

the lateral support includes a top cap coupling the substantially cylindrical curved outer wall of the lateral support to the elongate support member; and

the lateral support encloses a substantially hollow annular interior volume between the substantially cylindrical curved outer wall and the elongate support member.

8. The load support system of claim 1 , wherein:

the substantially cylindrical curved outer wall of the lateral support has opposing first and second ends, wherein the first end of the substantially cylindrical curved outer wall is closer to the first end of the elongate support member, and wherein the second end of the substantially cylindrical curved outer wall is closer to the second end of the elongate support member; and

the helix is formed about the exterior surface proximate to the second end of the substantially cylindrical curved outer wall.

9. A load support system, comprising:

an elongate support member having a first diameter and a first end and a second end, wherein the elongate support member includes, toward the first end, a first portion for direct earth burial and further includes, toward the second end, a second portion to which the load can be coupled, wherein the first portion has a first length;

a lateral support having a second diameter greater than the first diameter and a second length less than the first length, wherein the lateral support has a substantially cylindrical curved outer wall and is mounted about the first portion of the elongate support member to form a hollow interior annular volume between the substantially cylindrical curved outer wall of the lateral support and the elongate support member, said hollow interior annular volume being chosen to select an embedment depth corresponding to a given installation torque; and

a helix formed at least partially about an exterior surface of the substantially cylindrical curved outer wall of the lateral support;

wherein:

the second portion of the elongate support member includes a plurality of sets of load mounting features at respective differing distances from the second end, such that a load can be coupled to the elongate support member at one of the plurality of sets of load mounting features to substantially achieve a desired clearance height for the load despite variability in the embedment depth; and

the substantially cylindrical curved outer wall of the lateral support has a first opening formed therethrough at a first location relative to a long axis of the elongate support member and the elongate support member includes a second opening formed therein at a different second location relative to the long axis of the elongate support member, such that a range of embedment depths of the first portion of the elongate support member is supported.

10. The load support system of claim 9 , wherein:

the elongate support includes a series of holes along the second portion for receiving removable steps; and

the load support system further includes at least one removable step configured to be inserted in one of the series of holes and removably coupled to the elongate support.

11. The load support system of claim 9 , wherein the plurality of sets of load mounting features includes multiple sets of load mounting holes.

12. The load support system of claim 9 , wherein the lateral support includes a top cap coupling the substantially cylindrical curved outer wall of the lateral support to the elongate support member.

13. A load support system, comprising:

an elongate support member having a first diameter and a first end and a second end, wherein the elongate support member includes, toward the first end, a first portion for direct earth burial and further includes, toward the second end, a second portion to which the load can be coupled, wherein the first portion has a first length, and wherein the second portion of the elongate support member includes a plurality of sets of load mounting features at respective differing distances from the second end, such that a load can be coupled to the elongate support member at one of the plurality of sets of load mounting features to substantially achieve a desired clearance height for the load despite variability in the embedment depth;

a lateral support having a second diameter greater than the first diameter and a second length less than the first length, wherein the lateral support has a substantially cylindrical curved outer wall and is mounted about the first portion of the elongate support member to form a hollow interior annular volume between the substantially cylindrical curved outer wall of the lateral support and the elongate support member, said hollow interior annular volume being chosen to select an embedment depth corresponding to a given installation torque;

a helix formed at least partially about an exterior surface of the substantially cylindrical curved outer wall of the lateral support; and

a pedestal for coupling the load to the elongate support member, wherein:

the pedestal includes an elongate tube received within the elongate support member;

the pedestal is coupled to said one of the plurality of sets of load mounting features;

the second portion of the elongate support member includes a mounting hole; and

the elongate tube of the pedestal has an exterior surface and an interior surface, a plurality of spacers distributed along the elongate tube that protrude from the exterior surface of the tube, a plurality of holes through the spacers and the tube, and a respective one of a plurality of threaded nuts fixedly attached to the interior surface of the tube at each of the plurality of holes.

14. The load support system of claim 13 , wherein:

the elongate support includes a series of holes along the second portion for receiving removable steps; and

the load support system further includes at least one removable step configured to be inserted in one of the series of holes and removably coupled to the elongate support.

15. The load support system of claim 13 , wherein the plurality of sets of load mounting features includes multiple sets of load mounting holes.

16. The load support system of claim 13 , wherein the lateral support includes a top cap coupling the substantially cylindrical curved outer wall of the lateral support to the elongate support member.

17. A load support system, comprising:

an elongate support member including a sidewall having a mounting hole therein;

a pedestal for coupling a load to the elongate support member, wherein the pedestal includes an elongate tube received within the elongate support member;

wherein the elongate tube has an exterior surface and an interior surface, a plurality of spacers distributed along the elongate tube that protrude from the exterior surface of the tube, a plurality of holes through the spacers and the elongate tube, and a respective one of a plurality of threaded nuts fixedly attached to the interior surface of the elongate tube at each of the plurality of holes; and

a bolt extending through the mounting hole in the elongate support member, extending through a hole of a spacer among the plurality of spacers, and threadedly engaging a threaded nut among the plurality of threaded nuts.

18. The load support system of claim 17 , further comprising a load coupled to the pedestal.

19. The load support system of claim 17 , wherein the spacer is configured to be deformed by contact with the elongate support member due to a compressive force applied by the bolt and threaded nut.

20. A system, comprising:

a load support system in accordance with claim 1 ; and

a load coupled to the load support system.

21. The system of claim 20 , wherein the load includes at least one solar panel.

22. A system, comprising:

a load support system in accordance with claim 9 ; and

a load coupled to the load support system.

23. The system of claim 22 , wherein the load includes at least one solar panel.

24. A system, comprising:

a load support system in accordance with claim 13 ; and

a load coupled to the load support system.

25. The system of claim 24 , wherein the load includes at least one solar panel.

26. A method of installing a load support system, the method comprising:

providing a load support system, including:

an elongate support member having a first diameter and a first end and a second end, wherein the elongate support member includes, toward the first end, a first portion for direct earth burial and further includes, toward the second end, a second portion to which the load can be coupled, wherein the first portion has a first length;

a lateral support having a second diameter greater than the first diameter and a second length less than the first length, wherein the lateral support has a substantially cylindrical curved outer wall and is mounted about the first portion of the elongate support member;

a helix formed at least partially about an exterior surface of the substantially cylindrical curved outer wall of the lateral support;

wherein the substantially cylindrical curved outer wall of the lateral support has a first opening formed therethrough at a first location relative to a long axis of the elongate support member and the elongate support member includes a second opening formed therein at a different second location relative to the long axis of the elongate support member, such that a range of embedment depths of the first portion of the elongate support member is supported;

forming a bore in the earth having a diameter less than that of the lateral support; and

placing the first end of the elongate support member in the bore and rotationally installing the first portion of the elongate support member and the lateral support in the earth.

27. The method of claim 26 , further comprising stopping rotational installation of the first portion of the elongate support member based on spoils filling a volume of the lateral support.

28. The method of claim 26 , wherein:

the rotationally installing includes rotationally installing until at least one of the first and second openings is below a surface of the earth by at least a predetermined distance.

Assignments (2)
CONFIRMATORY LICENSE Recorded Apr 27, 2023
From: HELICAL SOLAR SOLUTIONS, LLC
To: UNITED STATES DEPARTMENT OF ENERGY
Reel/Frame 063472/0592 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 26, 2022
From: MCKINION, JAMES; BECKER, KEITH
To: HELICAL SOLAR SOLUTIONS, LLC
Reel/Frame 059735/0438 →
Continuity (2)
Provisional Application 63192455 · May 24, 2021
Related Publication 20220373229A1 · Nov 24, 2022
References Cited (71)
US 4875660A · Gagnon et al. · 1989 [cited by applicant]
US 4995377A · Eiden · 1991 [cited by applicant]
US 5002435A · Dupeuble · 1991 [cited by applicant]
US 5066168A · Holdeman · 1991 [cited by applicant]
US 5088681A · Procaccianti et al. · 1992 [cited by applicant]
US 5683207A · Mauer · 1997 [cited by applicant]
US 5730117A · Berger · 1998 [cited by applicant]
US 5833399A · Bullivant · 1998 [cited by applicant]
US 5904447A · Sutton et al. · 1999 [cited by applicant]
US 5919005A · Rupiper · 1999 [cited by applicant]
US 5927905A · Van Halteren · 1999 [cited by applicant]
US 6058930A · Shingleton · 2000 [cited by applicant]
US 6142712A · White · 2000 [cited by examiner]
US 6386295B1 · Suver · 2002 [cited by applicant]
US 6399881B2 · Edelstein · 2002 [cited by applicant]
US 6552257B1 · Hart et al. · 2003 [cited by applicant]
US 6652195B2 · Vickars et al. · 2003 [cited by applicant]
US 6662801B2 · Hayden et al. · 2003 [cited by applicant]
US 6722821B1 · Perko · 2004 [cited by examiner]
US 6761387B2 · Sloss · 2004 [cited by applicant]
US 6814525B1 · Whitsett · 2004 [cited by applicant]
US 6820379B1 · Krinner et al. · 2004 [cited by applicant]
US 6824331B2 · Parker et al. · 2004 [cited by applicant]
US 6942430B1 · Suver · 2005 [cited by examiner]
US 7004683B1 · Rupiper · 2006 [cited by applicant]
US 7413035B1 · Miller · 2008 [cited by applicant]
US 7731454B1 · Watson et al. · 2010 [cited by applicant]
US 7770669B1 · Desrochers et al. · 2010 [cited by applicant]
US 7854451B2 · Davis · 2010 [cited by applicant]
US 8052100B2 · Zante · 2011 [cited by applicant]
US 8371771B1 · Lugo et al. · 2013 [cited by applicant]
US 8407950B2 · Hartelius · 2013 [cited by applicant]
US 8602689B1 · Van et al. · 2013 [cited by applicant]
US 8763601B2 · Doyle · 2014 [cited by applicant]
US 8863450B2 · Anderson et al. · 2014 [cited by applicant]
US 9051706B1 · Ludwig · 2015 [cited by applicant]
US 9068318B1 · Gochis · 2015 [cited by applicant]
US 9231141B2 · Kirchner et al. · 2016 [cited by applicant]
US 9416512B2 · Suver · 2016 [cited by examiner]
US 9422741B1 · Conte · 2016 [cited by applicant]
US 10119291B2 · McKinion · 2018 [cited by examiner]
US 20030159839A1 · Perko · 2003 [cited by applicant]
US 20040076479A1 · Camilleri · 2004 [cited by applicant]
US 20040103599A1 · Keck · 2004 [cited by applicant]
US 20040231257A1 · Brown · 2004 [cited by applicant]
US 20050097833A1 · Campbell et al. · 2005 [cited by applicant]
US 20060001271A1 · Zugaza et al. · 2006 [cited by applicant]
US 20070000187A1 · St. Onge · 2007 [cited by examiner]
US 20070231081A1 · Gantt, Jr. · 2007 [cited by applicant]
US 20100319272A1 · Kellner · 2010 [cited by applicant]
US 20110099923A1 · Ventura et al. · 2011 [cited by applicant]
US 20110194901A1 · Jones · 2011 [cited by applicant]
US 20110297141A1 · Correia et al. · 2011 [cited by applicant]
US 20120114425A1 · Seider et al. · 2012 [cited by applicant]
US 20120213597A1 · Baumsteiger · 2012 [cited by applicant]
US 20130160380A1 · Atchley · 2013 [cited by applicant]
US 20130256246A1 · Tagliamonte · 2013 [cited by examiner]
US 20140069483A1 · Wolter · 2014 [cited by examiner]
US 20140283894A1 · Silver · 2014 [cited by applicant]
US 20140311552A1 · Garrett · 2014 [cited by examiner]
US 20140356075A1 · Hale · 2014 [cited by examiner]
US 20150247336A1 · Bergman · 2015 [cited by applicant]
US 20160069075A1 · Powers, III · 2016 [cited by examiner]
US 20160215519A1 · Bergman · 2016 [cited by applicant]
US 20180238072A1 · Mckinion · 2018 [cited by examiner]
KR 20210077226A · 2021 [cited by examiner]
WO WO2013109186A1 · 2013 [cited by examiner]
WO WO2014162834A1 · 2014 [cited by examiner]
Earth Contact Products, ECP Solar Foundation—ECP “One Step” Solar Foundation, Feb. 17, 2017, 1-2 pp. [cited by applicant]
Maier et al. “Increasing Lateral Capacity of Helical Piles with Lateral Restraint Devices”, Missouri University of Science and Technology, May 26, 10 pages. [cited by applicant]
Terrell Croft, “A Reference Book for Practical Electrical Workers”, First Edition, Second impression-Corrected, 1914, 329, 331 & 332 pp. [cited by applicant]