Screw anchor with consumable tip

Abstract

Disclosed is a foundation component having an elongated open shaft, an external thread form beginning at a first end and extending along the shaft, a driving coupler at a second end, opposite to the first end, and a cone received by the first end and extending from the first end. The cone is of a material having a lower elastic modulus than the elongated open shaft.

What is claimed is: 
     
         1 . A foundation component comprising:
 an elongated open shaft;   an external thread form beginning at a first end and extending along the shaft;   a driving coupler at a second end, opposite to the first end; and   a cone received by the first end and extending from the first end, the cone comprising a material having a lower elastic modulus than the elongated open shaft.   
     
     
         2 . The foundation component of  claim 1 , wherein the cone is consumable. 
     
     
         3 . The foundation component of  claim 1 , wherein the elongated open shaft is configured to receive a drilling tool therewithin. 
     
     
         4 . The foundation component of  claim 1 , wherein the driving coupler further comprises a ring comprising a plurality of driving teeth. 
     
     
         5 . The foundation component of  claim 4 , wherein the plurality of driving teeth are configured to engage with a chuck of a rotary driver. 
     
     
         6 . The foundation component of  claim 1 , wherein the cone further comprises a conical tip and a male insertion portion opposite the conical tip. 
     
     
         7 . The foundation component of  claim 6 , wherein the male insertion portion is configured to be press fit into the elongated open shaft at the first end. 
     
     
         8 . The foundation component of  claim 6 , wherein the cone has a modulus of elasticity substantially lower than that of the elongated open shaft. 
     
     
         9 . A system comprising:
 a rotary driver;   an open-ended screw anchor foundation component;   a driving coupler at one end of the foundation component;   a drilling tool with an attached drilling rod extending through the rotary driver and into the foundation component; and   a consumable cone received by and extending from an end of the open-ended foundation component, wherein the consumable cone is a made from a material having a lower material strength than the screw anchor foundation component.   
     
     
         10 . The system of  claim 9 , wherein the drilling tool includes an upper portion and a lower portion and a drilling head on a distal end of the lower portion. 
     
     
         11 . The system of  claim 10 , wherein the upper portion is configured to compress into the lower portion when the drilling head encounters resistance. 
     
     
         12 . The system of  claim 10 , wherein the drilling rod further comprises a center channel configured to guide pressurized air through the drilling head such that drilling spoils are urged upwardly around the open-ended screw anchor foundation component around the drilling head. 
     
     
         13 . A method of embedding a foundation component in mixed strata soil comprising:
 inserting a consumable cone tip into a first end of the foundation component;   driving the first end of the foundation component into the soil from an opposing second end with a rotary driver;   while driving the foundation component, operating a drill rod and bit within the foundation component without contacting the cone; and   if continued rotation and downforce applied through the rotary driver fails to result in additional embedment, extending the drill rod and bit through the consumable cone and operating the drill rod and bit ahead of the first end while continuing to drive the foundation component.   
     
     
         14 . The method of  claim 13 , wherein the inserting a consumable cone tip step is accomplished by press fitting the consumable cone tip into the first end of the foundation component. 
     
     
         15 . The method of  claim 13 , wherein the driving the first end of the foundation component step is accomplished by attaching a drill chuck to a driving coupler coupled to a second end of the foundation component and rotating the drill chuck such that the foundation component is driven into the mixed strata soil. 
     
     
         16 . The method of  claim 15 , wherein the drill chuck is attached to a ring of the driving coupler having a plurality of driving teeth. 
     
     
         17 . The method of  claim 13 , further comprising the step of guiding pressurized air through the drilling head such that drilling spoils are urged upwardly around the foundation component around the bit. 
     
     
         18 . A hybrid screw pile for drilling while driving in mixed density soils comprising:
 a tip portion made of a first material;   a shaft portion made of a second material, comprising a section of hollow tube with an external thread form beginning proximate to the tip portion; and   a driving portion, opposite to the tip portion, for engaging with a rotary driver and for interconnecting to an upper foundation component, wherein the first material has substantially lower modulus of elasticity than the second material.   
     
     
         19 . The hybrid screw pile of  claim 18 , wherein the tip portion is consumable. 
     
     
         20 . The hybrid screw pile of  claim 18 , wherein the shaft portion is configured to receive a drilling tool therewithin. 
     
     
         21 . The hybrid screw pile of  claim 18 , wherein the driving portion further comprises a ring comprising a plurality of driving teeth. 
     
     
         22 . The hybrid screw pile of  claim 18 , wherein the plurality of driving teeth are configured to engage with a chuck of a rotary driver. 
     
     
         23 . The foundation component of  claim 1 , wherein the cone further comprises a conical tip and a male insertion portion opposite the conical tip.