Abstract:
A screw-in foundation anchor for traffic, lighting and utility poles and the like. The anchor comprises a shaft with an upper end fixed to a base plate on which the pole base is attachable. A helical blade on the shaft allows the anchor to be driven into the earth by rotation. At least two notches are provided on the edges of the base plate, each notch sized to engage the shaft of an adjacent anchor. Multiple anchors can be strapped together in groups or bundles for storage and shipment, with the notches engaging adjacent anchor. Such an arrangement prevents dislodgement or shifting of the anchors in transit. This reduces the cost of shipping the anchors, decreases the likelihood of damage to the anchors during shipment, and improves the safety of handling the bundles and unloading the individual anchors.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to foundation anchors and more particularly, but without limitation, to screw-in foundation anchors for supporting traffic, lighting and utility poles. 
     BACKGROUND OF THE INVENTION 
     Foundation anchors are used to support various types of vertical poles, such as traffic, lighting and utility poles, along roadways and elsewhere. In most cases, and especially where new roadways are under construction, multiple poles and anchors are required. Typically, foundation anchors are stored and shipped in bundles or rows secured by various means. In most cases, spacers such as wood slats or polystyrene foam racks are used to support a number anchors in a row or in several tiers or layers that are strapped together into a shipping/storage unit. Some expense is involved in the production of the spacers, which are then simply discarded at the job site. In addition to the cost of the materials, significant labor is required to position the anchors on the spacers prior to securing them with the straps. During shipping, the spacers may become dislodged or shift out of proper alignment, allowing the anchors to become damaged as well as difficult and dangerous to handle or unload. 
     Thus, there is a need for a foundation anchor that can be bundled and shipped without spacers of any kind. Such an anchor will eliminate the cost of producing the spacers and the waste associated with their discard at the job site. In addition, anchors that can be bundled without using spacers will reduce the likelihood of damage to the anchors during shipment to the job site. Still further, there is a need for a more secure bundling system, which will in turn improve the safety associated with handling the bundles and unloading the individual anchors. These and other needs are satisfied by the foundation anchor of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of an anchor constructed in accordance with the present invention. 
         FIG. 2  is a plan view of the base plate of the anchor shown in  FIG. 1  with one bolt assembly installed. The pole and pole base have been omitted to clarify the illustration. 
         FIG. 3  is an exploded perspective view of the preferred nut and bolt assembly for attaching the pole base to the base plate of the anchor assembly. 
         FIG. 4A  shows a side elevational view of the bolt used in the preferred embodiment of the anchor of this invention. 
         FIG. 4B  shows a plan view of the bolt in  FIG. 4A . 
         FIG. 4C  shows a plan view of the T-shaped slot in the preferred embodiment of the anchor of this invention. 
         FIG. 5  is a bottom view of one corner of the base plate with the nut and bolt installed. 
         FIG. 6  is a cross-sectional view along line  6 - 6  in  FIG. 2 . 
         FIG. 7  is a cross-sectional view similar to  FIG. 6  but showing the use of a carriage bolt instead of the square-headed bolt shown in  FIG. 6 . 
         FIG. 8A  shows a side elevational view of an L-bolt that can be used in another embodiment of the anchor of this invention. 
         FIG. 8B  shows a plan view of the bolt in  FIG. 8A . 
         FIG. 8C  shows a plan view of the slot for use with the L-bolt in  FIGS. 8A and 8B . 
         FIG. 9  is a perspective, partially cut away view of the pole assembly of this invention. 
         FIG. 10  shows a frontal perspective, partially cut away view of the base of a pole attached to the base plate of the anchor. 
         FIG. 11  shows a fragmented, perspective view of an inside corner of a transformer base connected to the base plate. 
         FIG. 12  shows a side elevational view of a bundle of four foundation anchors secured with metal bands securing the anchors in the stacked position. 
         FIG. 13  shows an end perspective view of the bundle of anchors seen in  FIG. 12 . The bands have been removed to simplify the illustration. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning now to the drawings in general and to  FIG. 1  in particular, there is shown therein an anchor constructed in accordance with the present invention and designated generally by the reference numeral  10 . The anchor  10  is adapted for implantation into a compressible material, such as earth. To that end, the anchor  10  includes a shaft  12 , preferably round in cross-section, and having a first or upper end  14 , a second or lower end  16 , and a body portion  18  therebetween. 
     To facilitate driving the shaft  12  into the earth, one or more blades may be provided on the shaft  12 . In the embodiment shown herein, the blade comprises a helical blade  22  on the body portion  18  of the shaft  12  near the lower or second end  16 . By means of the helical blade  22 , the shaft  12  can be driven into the earth by a rotary motion using a hydraulic drill or some other suitable machine. Where the blade is positioned along the body of the shaft  12 , the lower end  16  may be pointed or beveled as shown, or otherwise adapted to pierce the earth, to begin the driving process. 
     It will be appreciated, however, that the blade need not be helical in form; rather, linear splines could be used where the drive mechanism is a non-rotational impact or percussive system. Further, the position of the blade on the shaft may vary. For example, in some larger diameter anchors, it may be advantageous to place a helical blade at the bottom or lower end of the shaft and to include a pointed rod or “stinger” on the bottom of the blade to assist in the implantation of the anchor. 
     In most instances, the shaft  12  will be tubular having a hollow center. Typically, conduit openings  24  are provided on opposite sides of the shaft  12  for incoming and outgoing wiring, if any, that supplies the traffic signal or other device that will be supported on the pole for which the anchor  10  is being installed. 
     Referring still to  FIG. 1  and now also to  FIG. 2 , the anchor  10  comprises a base plate  26  fixed on the upper end  14  of the shaft  12 . Preferably, the base plate  26  is square, but other shapes will work depending on the pole and pole base with which it will be used. A hole  28  is provided in the center of the base plate  26  for receiving the upper end  14  of the shaft  12 . This joint may be welded or secured in any other suitable fashion. 
     With reference now to  FIGS. 3 ,  4 A, and  4 B, the anchor  10  further comprises at least one and preferably four connectors, such as bolts  30 , for connecting the base plate  26  to the pole base yet to be described. Each bolt  30  has a head  32  with a first dimension D 1  and a stem  34  with a dimension D 2 , the head being wider than the stem in at least a first dimension and preferably centered on the stem. Preferably, the head  32  is square and the stem  34  is threaded for reasons that will become apparent. A nut  36  ( FIG. 3 ) preferably is provided for each bolt  30 , and the stem  34  of the bolt should be threaded to receive the nut. A washer  38  ( FIG. 3 ) also may be included. Further, a corner member  40  may be included for a purpose described hereafter. 
     With continued reference to  FIG. 2  and also now to  FIG. 4C , the base plate  26  defines at least one and preferably four slots, designated generally by the reference numeral  44 , there being one slot for engaging each bolt  30 . More specifically, each slot  44  is sized to permit passage therethrough of the stem  34  of the bolt  30 . Preferably, each slot  44  is sized to permit passage therethrough of the head  32  of the bolt  30  only when the first dimension D 1  of the head is aligned with the slot. More preferably, as seen best in  FIGS. 2 and 4C , each slot  44  comprises a head portion  46  and a stem portion  48 . The head portion  46 , having a dimension W 1 , is sized to allow passage therethrough of the head  32  of the bolt  30  when the edge of the head is aligned with the head portion of the slot  44 . 
     The stem portion  48 , having a width W 2 , is sized to permit passage therethrough of the stem  34  of the bolt  30 , but not the head  32 . Preferably the slots  44  are T-shaped having the elongated head portion  46  at the end of and perpendicular to the narrower, elongated stem portion  48 . More preferably, the slots  44 , or the stem portions  48  of the slots, extend radially from the center of the base plate  26  in each corner thereof, with the head portion  46  between the center of the base plate and the stem portion  48 . 
     Now it can be understood that the bolt  30  can be placed in the slot  44  by first aligning the head  32  (along dimension D 1 ) of the bolt with the head portion  46  (W 1 ) of the slot, and then inserting the head therethrough. Next, the head  32  is moved in the slot  44 , along the length of the stem portion  48  of the slot, until the dimension D 1  is disaligned with the width W 1 , and sliding the head along the stem portion  48  of the slot to the desired location. Thus, the head  32  of the bolt  30  can be placed under the base plate  26  by inserting the head through the slot from above the base plate when the base plate is about flush with the surface of the earth. 
     Now it will be apparent that access to the head  32  of the bolt  30 , when positioned under the base plate  26  will be limited. Where a threaded nut and bolt assembly is used as the connector, it might be difficult to stabilize the bolt  30  against turning as the nut  36  is threaded on the stem  34 . 
     To alleviate this difficulty, the anchor  10  preferably is provided with an elongate member  50  extending from the bottom  52  of the base plate  26  parallel and adjacent to the stem portion  48  of each of the slots  44 , as shown in  FIGS. 5 and 6  to which attention now is directed. As described above, the head  32  of the bolt  30  preferably is square. However, the head  32  may be hexagonal as long as it is polygonal with at least one planar surface parallel to the longitudinal axis of the stem  34 . The elongate member  50  preferably is a narrow bar with at least one planar abutment surface  54 . In this way, as seen in  FIG. 6 , when the head  32  of the bolt  30  is pulled up snugly against the bottom  52  of the base plate  26  with the stem  34  of the bolt extending through the stem portion  48  of the slot  44 , the planar side of the bolt head  32  will engage the abutment surface  54  non-rotatingly so that the nut  36  can be threadedly tightened on the stem  34 . This engagement is released by simply unscrewing the nut until the head  34  of the bolt  30  can be pushed down beneath the elongate member  50 . 
     In the preferred embodiment, where the shaft  12  is driven into the earth by rotation, the elongate members  50  will serve another function. The depending elongate members  50  will serve to excavate an area of soil as the bottom  52  of the base plate  26  scrapes the surface of the earth. Thus, each elongate member  50  may also function as a spacer to provide a space in the soil to receive the head  32  of the bolt  30  under the base plate  26  as the anchor is screwed into the earth. As a result, there is no need to dig into the soil while positioning the head  32  of the bolt  30 . The length of the spacer, that is, the distance it extends down from the bottom  54  of the base plate  26  should be minimized to provide only enough space in the soil to accommodate the head  32  of the bolt  30 . This will allow the head  32  of the bolt  30  to be supported by the soil underneath the base plate. 
     Where the shaft is driven into the earth by a direct impact or percussive system, without rotation, the space may include a surface extending under the slot so that there will be a space beneath the slot to receive the head of the bolt. For example, the spacer could take the form of a member that is L-shaped in cross-section, the vertical surface forming the abutment surface and the horizontal surface creating the cavity for the bolt head and for supporting the bolt in position in the slot. 
     While the preferred connector takes the form of a square headed bolt  30  with a threaded stem  32  and a nut  36  receivable thereon, other types of connectors may be successfully employed. For example, as shown in  FIG. 7 , the connector could a carriage bolt  30 A wherein the head  32 A comprises a cap  60  and a neck  62  between the cap and the stem  34 . As in the conventional carriage bolt, the cap  60  has a greater diameter than the neck  62 . Also, the cap  60  is round and domed and the neck  62  is square. However, the neck could have another shape comprising an equilateral polygon with at least two planar sides parallel to each other and to the longitudinal axis of the stem. 
     For use in this invention, though, the slot  44  should be sized so that one pair of parallel sides of the neck  62  of the bolt  30 A can be non-rotatably received in stem portion  48  of the slot  44 , as illustrated in  FIG. 7 . Thus, when the cap  60  of the bolt head  32 A is beneath the base plate  26 , the neck  62  is received in the slot  44 , and the stem  34  extends above the base plate, then the nut can be tightened on the stem  34 . 
     In still another embodiment of the present invention, depicted in  FIGS. 8A-C , the connector is an “L” bolt  30 B where the head  32 B is an elongated member extending to one side of the stem  34  creating a dimension D 1  which is greater than the dimension D 2  of the stem. As shown in  FIG. 8C , this L-bolt  32 B can be used with a slot  44 B that has a uniform width W along its entire length L. That is, the head  32 B is insertable through the slot  44 A at any point if the head is aligned with the length L of the slot. Then, the stem  34  is rotated until the free end of the head  32 B abuts the abutment surface  54  (not shown in  FIG. 8C ). It will be apparent that a T-bolt or J-bolt may also be substituted for the L-bolt and will function similarly. 
     It will be further appreciated further that a threaded connector is not essential. A non-threaded stem with a latch, bendable joint, clamp, set screw, or cross member could be used. An adjustable telescopic engagement could be utilized. Likewise, a toggle bolt configuration would be operable. 
     Having described the preferred anchor  10 , its use now will be described. With reference again to  FIG. 1 , the shaft  12  and attached base plate  26  first are installed in the earth at the designated location. The shaft  12  is positioned into the earth so that the top of the base plate  26  is about flush with the surface of the earth. Although the shaft  12  can be placed in an open hole which is back filled, in most instances the placement of the shaft will be by a rotary mechanism of some sort utilizing the helical blade  22  on the shaft. In this case, the spacers/elongate members  50  will have formed a shallow cavity in the earth immediately beneath each slot  44 . A bolt  30  is inserted into each slot and positioned in the desired location. 
     Turning now to  FIG. 9 , there is shown therein a pole assembly  68  in accordance with the present invention. The assembly  68  comprises a base  70 , a pole  72  supportable by the base in a known manner, and the above-described anchor  10  supporting the base. In the example shown in  FIG. 9 , a streetlight  74  is shown extending laterally from the top of the pole  72 . However, it will be apparent now that the term “pole” refers to any vertical support member that is supportable by means of an anchor assembly and includes, without limitation, poles that support any type of traffic control device, sign, lighting or electrical fixture. 
       FIG. 10  shows how the pole base  70  is attached to the base plate  26  of the anchor  10 . The base  70  typically is the same shape and size as the base plate  26  of the anchor  10 , and is provided with a holes  76  in each corner aligned with the slots  44  in the base plate  26 . Although not shown in this drawing, all four of the bolts  30  usually would be in position in the slots  44  at the time the pole base  70  is positioned over the anchor base  26 . With the base  70  positioned over the base plate  26 , the stems  34  of the bolts  30  are inserted in the holes  76  of the pole base. Then, washers  38  and nuts  36  are placed on the stems  34  and tightened until the pole base  70  is securely fixed to the anchor base  26 . In the case of an ornamental street light, a decorative base enclosure can be placed around the base  70 . 
     Turning now to the  FIG. 11 , the use of the anchor  10  with a transformer base will be described. The anchor  10  is driven in to the earth as described above, and the bolts  30  are positioned in the slots  44 . Next, the transformer base  70 A is moved into position over the base plate  26 . As is well known, each inner corner of a transformer base is provided with a pair of ears  80  and  82  that form a notch  84  therebetween. Next, the corner member  40  (see  FIG. 3 ) is positioned over the bolt  30  and across the ears  80  and  82  to span the notch  84 . Then, the nut  36  and washer  38  are tightened down against the corner member  40 . This is repeated in each corner of the base  70 A. Finally, the pole  72  is secured to the base  70 A in the conventional manner. 
     In the preferred embodiment of the present invention, the anchor  10  is adapted for convenient, spacer-free stacking with other like anchors to form a bundle of anchors for shipping and storage. To that end, the base plate  26  of each anchor  10  preferably is provided with a plurality of notches spaced equidistantly around its peripheral edge  88 , as seen in  FIG. 2 . In the preferred embodiment where the base plate  26  is square with four sides, designated in  FIG. 2  as  90 ,  92 ,  94  and  96 , a notch may be positioned in center of each of the sides, such as the notches  100 ,  102 ,  104  and  106 . It will be understood, however, that the stacking notches of the present invention can be adapted to base plates having other shapes, such as round, and that the base plates may have as few as two notches, depending on the number of anchors desired in a single bundle. Still further, while the notches  90 ,  92 ,  94  and  96  are shown as generally curved, they may take other forms such as V-shaped. 
     Although, the number, size and shape of the notches  100 ,  102 ,  104  and  106  may vary, generally the notches are sized and shaped to engage a portion of the shaft of an adjacent anchor in the bundle, as seen in  FIGS. 12 and 13 , to which attention now is directed. In this preferred embodiment, four anchors  10 A- 10 D are stacked together to form a single bundle  110  secured by at least one band and preferably a pair of bands  112  and  114 . The bands  112  and  114  shown herein are flat, slender metal straps, such as commercial shipping straps or bands, which are secured end to end by strapping buckles (not shown). It will understood that the term “band,” as used herein, denotes any structure or member capable of securing the assembly of multiple anchors together in the stacked position. Thus, the band may take the form of a wide swath of plastic, or single wide elastic belt of some sort. 
     To make the most compact and stable bundle, the anchors  10 A-D are arranged so that the orientation of each anchor is opposite relative to the adjacent anchors engaged by the notches on its base plate. That is, the upper end of one anchor is adjacent the lower end of the anchor above, below, and to either side of it. In this way, as seen in  FIG. 13  for example, one notch on the base plate  26 A engages the shaft  12 B of the anchor  10 B above the blade  22 B, while another notch engages the shaft  12 C of the anchor  10 C below the blade  22 C. At the same time, a notch on the base plate  26 B engages the shaft  12 A of the anchor  10 A above the blade  22 A, and a notch on the base plate  26 C of the anchor  10 C engages the shaft  12 A of the anchor  10 A below the blade  22 A. This alternating arrangement of the anchors provides a stable and balanced bundle. 
     Returning once again to  FIG. 2 , it may be desirable to include alignment means, such as the point  120  and the indentation  122 , to indicate the sides of the shaft on which the conduit openings  24  are found. In a conventional manner, the indentation  122  may used to indicate the side for the incoming wiring, and the point  120  may be used to indicate the side for the outgoing wiring. The alignment point  120  and indentation  122  are conveniently placed in the center portion of a pair of opposing stacking notches, such as the notches  100  and  104 . 
     Now it will be appreciated that the present invention provides many advantages. The notched base plate allows multiple anchors to be stacked in a bundle and secured with straps for stable transport. The slots in the base plate allow the bolt that connects the pole base to the base plate to be inserted from above. This makes installation of the pole easier and faster. Moreover, the spacers underneath the base plate excavate a sufficient amount of earth under the plate so that the head of the bolt can be easily manipulated into the proper location. This had the added advantage of minimizing the extent to which the soil surrounding the installation must be disturbed. 
     The embodiments shown and described herein are exemplary. Some elements or features of the present invention may be found in the art and, therefore, have not been described in detail herein. The description and drawings are illustrative only, and changes may be made in the combination and arrangement of the various parts and elements described herein without departing from the spirit and scope of the invention as defined in the following claims. The description and drawings do not point out what an infringement of this patent would be, but rather merely provide one example of how to use and make the invention. The limits of the invention and the bounds of the patent protection are measured by the claims.