Connector assembly and method for connecting misaligned elongated members and a connection formed by the connector assembly

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.

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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 8 , wherein each of said load-bearing elements comprises a helical blade. 
   
   
       10 . The connector assembly according to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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 to  claim 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.