AU2020101166A4

AU2020101166A4 - A marine pile joiner

Info

Publication number: AU2020101166A4
Application number: AU2020101166A
Authority: AU
Inventors: Daniel Jebbink; David Morris
Original assignee: Marine Composites IP Pty Ltd
Current assignee: Marine Composites IP Pty Ltd
Priority date: 2020-06-26
Filing date: 2020-06-26
Publication date: 2020-08-06
Anticipated expiration: 2028-06-26
Also published as: AU2020101166B4

Abstract

The present invention relates to a marine pile joiner. The joiner includes a protective layer, and a structural layer adjacent the protective layer. Preferably, the joiner is received within a pair of marine piles. The joiner may have a fillet or taper at one or both ends. 4/10 1001 102 1 106 104 (b) 102 1007 (C) (d) Fiaure 5

Description

4/10

1001 1 106 104

102

(b) 102

1007

(C)

(d)

Fiaure 5

AUSTRALIA PATENTS ACT 1990

COMPLETE SPECIFICATION INNOVATION PATENT A MARINE PILE JOINER

The following statement is a full description of this invention:

A MARINE PILE JOINER TECHNICAL FIELD

[0001] The present invention generally relates to a marine pile joiner for joining marine piles.

BACKGROUND

[0002] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0003] Marine piles are upright structural members used for various purposes including: supporting wharves, jetties and boardwalks; restraining marina pontoons and canal pontoons; supporting jetties and floating pontoons at boat ramps; acting as fender piles in marina applications; and construction of navigation beacons around ports and harbours.

[0004] In practice, marine piles are made from concrete, steel or timber so as to withstand extreme pile driving forces when they are driven into the marine bed with a pile driver. The corrosive environment takes its toll on such piles which need to be replaced. Replacement is complicated by the weight of the piles. In practice, it is necessary to join two or more marine piles together.

[0005] The preferred embodiment provides a lighter, stronger and/or more durable alternative to known marine pile joiners.

SUMMARY OF THE INVENTION

[0006] According to one aspect of the present invention, there is provided a marine pile joiner including: a protective layer; and a structural layer adjacent the protective layer.

[0007] The joiner may have a fillet or taper at one or both ends . The joiner may be a cylinder of substantially constant external diameter. The joiner may be received within a pair of marine piles.

[0008] The joiner may include an abutment protrusion for abutting with a marine pile. The protrusion may extend outwardly from the joiner. The protrusion may be of comparable height to the wall thickness of a marine pile so that the protrusion and pile form a flush finish. The protrusion may be a ridge. The ridge may be triangular. The protrusion may be wound. The protrusion may be endless. Alternatively, the protrusion may be localized at a point.

[0009] The protective layer may be an inner protective layer. The joiner may further include an outer protective layer adjacent the structural layer. Advantageously, the structural layer is sandwiched between the protective layers to facilitate durability. The pile joiner may be tubular thereby making it lightweight compared with known solid pile joiners. The pile joiner may be more flexible than concrete, steel or timber alternatives.

[00010] Each layer may be wound. Each layer may include resin. The resin may include vinyl ester or epoxy vinyl ester. Each layer may include filament. The filament may include e-glass or fibre glass

[00011] Each protective layer may be waterproof. Each protective layer may include at least 70% vinyl ester or epoxy vinyl ester resin. Each protective layer may include at most 30% filament. Each protective layer may be at least 0.5 mm thick.

[00012] The outer protective layer may include a ultraviolet stabilizer. The outer protective layer may include a color pigment.

[00013] The structural layer may include at least 70% filament. The structural layer may include no more than 30% vinyl ester or epoxy vinyl ester resin. The structural layer may have a wind angle of between 30 degrees and 60 degrees. The structural layer may have a thickness of between 10 and 30mm. The pile may have a diameter in the range of 100mm to 1200mm.

[00014] The marine pile may include a coating adjacent the outer layer. The coating may resemble existing piles in a structure, when retrofitting the pile.

[00015] According to one aspect of the present invention, there is provided a marine pile assembly including: a pair of marine piles; the joiner for engaging with the marine piles to join the piles together.

[00016] The joiner may be received within the marine pile. The joiner may be concealed within the marine piles. One of the marine piles may have a inner step to accommodate a protrusion of the joiner.

[00017] The assembly may further include adhesive for adhering the joiner to the marine piles.

[00018] According to another aspect of the present invention, there is provided a method for manufacturing a marine pile joiner, the method including: forming an inner protective layer; and forming a structural layer adjacent the inner protective layer.

[00019] The method may further involve forming an outer protective layer adjacent the structural layer.

[00020] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[00021] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[00022] Figure 1 is a sectional view of a wall of a marine pile;

[00023] Figure 2 is a characteristic showing the properties of a structural layer of the marine pile of Figure 1;

[00024] Figure 3 shows exemplary load data for the structural layer of Figure 2;

[00025] Figure 4a is a perspective view of a marine pile joiner A in accordance with an embodiment of the present invention;

[00026] Figure 4b is a side sectional view of a wall of the marine pile joiner A of Figure 4a;

[00027] Figure 4c is a side sectional view of the marine pile joiner A of Figure 4a showing modifications;

[00028] Figure 4d is a side sectional view of a marine pile assembly including the marine pile joiner A of Figure 4a;

[00029] Figure 5a is a perspective view of a marine pile joiner B in accordance with an embodiment of the present invention;

[00030] Figure 5b is a side sectional view of a wall of the marine pile joiner B of Figure 5a;

[00031] Figure 5c is a side sectional view of the marine pile joiner B of Figure 5a showing modifications;

[00032] Figure 5d is a side sectional view of a marine pile assembly including the marine pile joiner B of Figure 5a;

[00033] Figure 6a is a perspective view of a marine pile joiner C in accordance with an embodiment of the present invention;

[00034] Figure 6b is a side sectional view of a wall of the marine pile joiner C of Figure 6a;

[00035] Figure 6c is a side sectional view of the marine pile joiner C of Figure 6a showing modifications;

[00036] Figure 6d is a close up side sectional view of Figure 6c;

[00037] Figure 6e is a side sectional view of a marine pile assembly including the marine pile joiner C of Figure 6a;

[00038] Figure 6f is a close up side sectional view of the marine pile joiner C of Figure 6a;

[00039] Figure 7a is a perspective view of a marine pile joiner D in accordance with an embodiment of the present invention;

[00040] Figure 7b is a side sectional view of a wall of the marine pile joiner D of Figure 7a;

[00041] Figure 7c is a side sectional view of the marine pile joiner D of Figure 7a showing modifications;

[00042] Figure 7d is a side sectional view of a marine pile assembly including the marine pile joiner D of Figure 7a;

[00043] Figure 7e is a close up side sectional view of Figure 7d;

[00044] Figure 8a is a perspective view of a marine pile joiner E in accordance with an embodiment of the present invention;

[00045] Figure 8b is a side sectional view of a wall of the marine pile joiner E of Figure 8a;

[00046] Figure 8c is a side sectional view of the marine pile joiner E of Figure 8a showing modifications;

[00047] Figure 8d is a side sectional view of a marine pile assembly including the marine pile joiner E of Figure 8a; and

[00048] Figure 8e is a side sectional view of a marine pile assembly including a marine pile joiner without a protrusion.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[00049] There is provided a tubular marine pile 100 with a wall cross-section as shown in Figure 1. The pile 100 includes an inner protective layer 102, a load-bearing structural layer 104 adjacent the inner protective layer 102, and an outer protective layer 106 adjacent the structural layer 104.

[00050] Advantageously, the structural layer 104 is sandwiched between the protective layers 102, 106 to facilitate durability. The pile 100 is tubular thereby making it lightweight compared with known solid piles. Furthermore, the pile 100 is more flexible than concrete, steel and timber alternatives.

[00051] Each layer 102, 104, 106 is wound and includes vinyl ester or epoxy vinyl ester resin. Each layer 102, 104, 106 also includes e-glass (or fibre glass) filament.

[00052] Each protective layer 102, 106 includes at least 70% vinyl ester or epoxy vinyl ester resin, and includes at most 30% filament. Each protective layer 102, 106 is at least 0.5 mm thick to ensure waterproofing so that the structural layer 104 is not exposed to moisture.

[00053] The outer protective layer 106 also includes an ultraviolet stabilizer, and can also include include a color pigment.

[00054] The sandwiched structural layer 104 includes at least 70% filament, and includes no more than 30% vinyl ester or epoxy vinyl ester resin. The structural layer 104 can have a wind angle of between 30 degrees and 60 degrees as indicated in Figure 2 to provide the right mix of strength and stiffness. A 30 degree wind produces a stiffer pile 100 than a 60 degree wind. A layer wall thickness of between 10 and 30mm provides loading as indicated in the tables of Figure 3. The pile 100 can a diameter in the range of 100mm to 1200mm.

[00055] In some circumstances, such as retrofitting the pile 100, the marine pile 100 may include a coating 108 adjacent the outer layer 106 which resembles existing piles in a structure. This layer 108 is a traditional marine coating applied post production essentially as an aesthetic enhancement or to match the new pile 100 into an existing structure. Coatings 108 such as Interzone and Marathon can be applied to the composite pile 100 and still exceed manufacturers pull off standards i.e. the paint yields before the surface bond.

[00056] The pile 100 is a far stronger and more durable product than known piles, better suited to the marine environment as it is inert meaning that vessels moored in close proximity will not suffer electrolysis damage to metal components. The structural pile 100 can be driven by means of hammer or vibration in the same way traditional timber, steel and concrete piles are installed. Advantageously, the pile 100 weighs half the weight of a steel pile of comparable strength which allows a pile driving barge of a set lifting capacity to drive bigger or longer piles than was possible before.

[00057] The pile 100 is formed in layers using a filament winding process. This process involves winding the filament under tension over a rotating mandrel. The mandrel rotates around the spindle (Axis 1 or X: Spindle) while a delivery eye on a carriage (Axis 2 or Y: Horizontal) traverses horizontally in line with the axis of the rotating mandrel, laying down the filament in the desired pattern or angle. This process is computer controlled to ensure that the filament is wound onto the mandrel at the correct angle and thickness for the design application. The most e-glass filament is impregnated in a bath with the vinyl ester or epoxy vinyl ester resin as it is wound onto the mandrel. Once the mandrel is completely covered to the desired thickness, the resin is cured. Depending on the resin system and its cure characteristics, often the rotating mandrel is placed in an oven or placed under radiant heaters until the part is cured. Once the resin has cured, the mandrel is removed or extracted, leaving the hollow final product.

[00058] According to the foregoing method, the marine pile is formed by first forming the inner protective layer 102, then forming the structural layer 104 adjacent the inner protective layer 102, and finally forming the outer protective layer 106 adjacent the structural layer 104. The coating 108 can be applied to the finished pile 100 if desired.

[00059] According to an embodiment of the present invention, there is provided a marine pile joiner 100' of types A to E, as shown in Figures 4b to 8b respectively. Each joiner 100' is of similar construction to the pile 100 and manufactured using like techniques and materials. The joiner 100' includes an inner protective layer 102, and a structural layer 104 adjacent the inner protective layer 102.

[00060] Joiner A

[00061] Figure 4 shows Joiner A. The joiner 100' has a fillet or taper 1a at one or both ends to facilitate joining with the marine pile 100. As piles 100 are driven into the ground, the inside of the pile 100 is filled with the ground material that can often be quite solid i.e. stiff ground or rocks etc. The fillet 1a reduces the risk of this material catching on the joiner 100' and applying force on the joiner 100' as it is driven and installed. A square edge which juts out is more susceptible to catching. The joiner 100' is a cylinder of substantially constant external diameter.

[00062] Features shown in Figure 4 are as follows:

1a. Fillet / taper to internal edge of joiner 2a. Consistent diameter external surface 3a. Filament wound joiner 4a. Top and bottom internal edge removed to create fillet / taper a. External surface modified (if required) to create consistent diameter and surface suitable for adhesive. Spaces fixed as required, prior to joining to ensure consistent thickness of adhesive. 6a. Top pile 7a. Bottom pile 8a. Top and bottom piles meet at join 9a. Adhesive at desired thickness between the piles and the joiner, fixing the joiner and the piles

[00063] Joiner B

[00064] Figure 5 shows Joiner B. The joiner 100' includes a wound abutment protrusion 3b for abutting with a tubular marine pile 100. The endless protrusion 3b extends outwardly from the joiner 100'. As can best be seen in Figure 5d, the protrusion 3b is of comparable height to the wall thickness of a marine pile 8b so that the protrusion 3b and pile 8b form a flush outer finish.

[00065] The joiner 100'further includes an outer protective layer 106 adjacent the structural layer 104. Advantageously, the structural layer 104 is sandwiched between the protective layers 102, 106 to facilitate durability. The pile joiner 100' is tubular thereby making it lightweight compared with known solid pile joiners. The pile joiner 100' is more flexible than concrete, steel or timber alternatives.

[00066] Features shown in Figure 5 are as follows: 1b. Fillet / taper to internal edge of joiner 2b. Consistent diameter external surface, of areas to be inserted into the piles 3b. Collar of filament wound pile to match thickness of pies to be joined

4b. Filament wound joiner b. Top and bottom internal edge removed to create fillet / taper 6b. Area of filament wound joiner removed to create both a consistent external joiner surface to insert into required piles and leave a filament wound collar to match the external thickness of the pies to be joined 7b. Top pile 8b. Bottom pile 9b. Top and bottom piles stop at edge of filament wound collar 1Ob. Adhesive at desired thickness between the piles and the joiner, fixing the joiner and the piles

[00067] Joiner C

[00068] Figure 6 shows Joiner C. The collar protrusion 3c is a triangular ridge.

[00069] Features shown in Figure 6 are as follows: 1c. Fillet / taper to internal edge of joiner 2c. Consistent diameter external surface, of areas to be inserted into the piles 3c. Collar of filament wound pile as small ridge, sufficient to stop joiner falling into the pile it is to join 4c. Filament wound joiner c. Top and bottom internal edge removed to create fillet / taper 6c. Area of filament wound joiner removed to create both a consistent external joiner surface to insert into required piles and leave a filament wound small ridge, sufficient to stop the joiner falling into the pile it is to join 7c. Top pile 8c. Bottom pile 9c. Top and bottom piles join above the small ridge at the centre of the joiner 1Oc. Adhesive at desired thickness between the piles and the joiner, fixing the joiner and the piles

[00070] Joiner D

[00071] Figure 7 shows Joiner D. The joiner 100' is completely concealed within the marine piles 7d, 8d as one of the marine piles 8d has an inner step to accommodate the collar protrusion 3d of the joiner.

[00072] Features shown in Figure 7 are as follows: 1d. Fillet / taper to internal edge of joiner 2d. Consistent diameter external surface, of areas to be inserted into the piles 3d. Collar of filament wound pile as thin band or similar, offset from centre of the joiner so the top of the band is at the centre of the joiner 4d. Filament wound joiner d. Top and bottom internal edge removed to create fillet / taper 6d. Area of filament wound joiner removed to create both a consistent external joiner surface to insert into required piles and leave a collar of filament wound pile as thin band or similar, offset from centre of the joiner so the top of the band is at the centre of the joiner 7d. Top pile 8d. Bottom pile 9d. Top and bottom piles join with the bottom pile modified to accommodate the full band on the joiner 1Od. Adhesive at desired thickness between the piles and the joiner, fixing the joiner and the piles

[00073] Joiner E

[00074] Figure 8 shows Joiner E. The protrusion 3e is localized at a point.

[00075] Features shown in Figure 8 are as follows: 1e. Fillet / taper to internal edge of joiner 2e. Consistent diameter external surface, of areas to be inserted into the piles 3e. Sections of filament wound pile are left raised in a specific number of locations around the joiner i.e. 2, 3 or 5 locations and not continuous around the joiner, offset from centre of the joiner so the top of each section is at the centre of the joiner 4e. Filament wound joiner e. Top and bottom internal edge removed to create fillet / taper 6e. Area of filament wound joiner removed to create both a consistent external joiner surface to insert into required piles and leave sections of filament wound pile, raised in a specific number of locations around the joiner i.e. 2, 3 or 5 locations and not continuous around the joiner, offset from centre of the joiner so the top of each section is at the centre of the joiner

7e. Top pile 8e. Bottom pile 9e. Top and bottom piles join with the bottom pile modified to accommodate raised sections on the joiner surface (or unmodified in areas where no raised sections are present) e. Adhesive at desired thickness between the piles and the joiner, fixing the joiner and the piles

[00076] Joiners 100' are cut to the required length, typically from the end of longer sections of pile 100. The external edge of these joiners 100' is removed as required, to create a specific joiner design and external diameter to fit as required into the piles 100 that are to be joined.

[00077] The piles 100 that are to be joined are mechanically modified as required, to accommodate the specific joiner 100' that is to be used. Both of the surfaces of the joiner 100' and the corresponding surface to which it is to be joined are made sufficiently rough to provide a bonding surface for adhesive. All surfaces are cleaned and prepared to be free of dust and any other elements that may inhibit adhesive bond. Spacers are fixed to the external surface of the joiner 100', at a specific height to ensure the adhesive achieves the required thickness as the piles 100 and the joiner 100' are pushed together. These spacers can be screws, adhesive strips and or any other material that will ensure sufficient gap is maintained. Adhesive is then applied to the joining surfaces and the piles 100 and the joiners 100' pushed together.

[00078] A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention.

[00079] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[00080] Reference throughout this specification to 'one embodiment' or'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

Claims

The claims defining the invention are as follows:

1. A marine pile joiner including: a protective layer; and a structural layer adjacent the protective layer.

2. A marine pile joiner as claimed in claim 1, wherein the joiner has a fillet or taper at one or both ends.

3. A marine pile joiner as claimed in claim 1 or claim 2, wherein the joiner includes an abutment protrusion for abutting with a marine pile, the protrusion preferably extending outwardly from the joiner.

4. A marine pile joiner as claimed in claim 3, wherein the protrusion is: of comparable height to the wall thickness of a marine pile so that the protrusion and pile form a flush finish, or of lesser height so as to be concealed by marine piles in use; wound and endless; a ridge, preferably triangular in shape; or is localized at a point.

5. A marine pile joiner as claimed in any one of the preceding claims, wherein the protective layer is an inner protective layer, the joiner further including an outer protective layer adjacent the structural layer.

Dated this 2 6 th day of June 2020

DANIEL JEBBINK AND DAVID MORRIS

by my attorneys

Spruson & Ferguson Patent and Trade Mark Attorneys