CA2479521C

CA2479521C - Modular dock floats

Info

Publication number: CA2479521C
Application number: CA002479521A
Authority: CA
Inventors: Craig L. Lobson
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-23
Filing date: 2004-09-23
Publication date: 2006-12-05
Anticipated expiration: 2024-09-23
Also published as: CA2479521A1

Abstract

A modular dock assembly has floats and connectors to hold them together. The floats are square blocks wider than deep. They are connected at their top and bottom corners by connector plates and bolts. These plates have apertures through which bolts pass through to engage nuts embedded in the block tap and bottom corners. The plate may have a central aperture to receive a cover to provide a continuous surface. Alternatively the plate may incorporate a top cover. A connector can clamp four floats together fairly rigidly. The apertures can be slots, which make for ease of assembly. Both covers and blocks have nonslip surfaces. The resulting float can be used to form a floating dock, which is sufficiently rigid for general use. The floats are rotationally molded from suitable plastic.

Description

MODULAR DOCK FLOATS
This invention relates to a modular dock float together with a system for joining them together. The floats are basically flattened hollow cubes with blindnut inserts embedded in the top and bottom corners. Connectors are attached to the floats by passing flanged bolts through them to engage the blindnuts, which hold the floats together at the corners. 'The connectors are flat;
plates with angularly equispaced apertures or slots for bolts which register with the blindnuts. The shape of the connectors is not critical, they can be circular, or have arms including the apertures, and may have central apertures, additional to the apertures or slots for the bolts. Circular. covers may be present, which may be separate from, or integral with the connector plates.
Circular covers with a c~.ownward central projection can snapfit the apertures of the top connectors. Typically both floats and covers have a nonslip surface pattern. Bolt slot; are preferred to bolt apertures as this makes assembly from components easier. Bolt apertures make the dock harder to assemble, but provide a more 2a rigid join. A top and bottom pair of connectors can clamp two, three, or four floats together rigidly, forming a floating dock.
BACKGROUND
Floating docks, including dry docks are old. Attempts of various sorts. have been made to build such docks of modular units.
None are really satisfactory, what is desired is a single unit, which can be joined together sufficiently strongly to prevent the dock coming apart, forming a rigid unit. It also desired to 30 produce a simple unit, with minimal problems in joining it with others.
PRIOR ART
Applicant is aware of two earlier attempts to provide floating modular docks. Canadian Patent 2,174,705 describes earlier attempts, involving 16 inch hollow cubical floats, linked by tabs projecting from vertical edges about 8 inches (halfway) down, a variant with 16 inch sides, and 10 inch deep again with linking edge tabs about 8 inches down. Canadian Patent 2,174,705 teacher>
assembly of floats substantially similar to those described as prior art. The tabs are joined by fasteners or plastic bolts passed through aligned holes in the float edge tabs. The floats when joined have limited relative angular motion, stated as a few degrees up to 10 or 15°, with the tops having less relative motion than the bottoms. Canadian Patent 2,308,617 teaches larger floats which are hollow but also trap air in inverted troughs in the bottom of the floats. Connectors of specific shape interlock with receiving sockets in which they are secured by bolts.
DESCRIPTION OF THE INVENTION
In one broad aspect the invention is directed to a modular float for docks. The float has a hollow integral shell with opposed top and bottom horizontal surfaces and a plurality of vertical side surfaces. The side surfaces are substantially planar and joined at top and bottom to the top and bottom surfaces of the float and are joined at either side to neighbouring side surfaces, forming vertical corners. The side surfaces all have substantially the same depth, and substantially the same width. The top and bottom surfaces have corners corresponding to the vertical corners.
Each corner of the top a.nd bottom surfaces has embedded therein a blindnut to receive a bolt. Preferably each corner of the top and bottom surfaces has a recess with a horizontal plane. Each plane is recessed the same distance, and each plane has embedded therein a blindnut. Each corner of the top and bottom surface has a circular groove concentric with the corner. Each circular groove has the same radius, and each circular grove is peripheral to the horizontal plane. Typically the circular groove has angled generally planar inner and outer walls separated by a generally planar recess wall. Preferably the top and bottom surfaces are bowed outward. Preferably the top and boti~om surfaces have a

2 nonslip surface pattern. In practice due to the mold both surfaces are nonslip, although only the top surface need be nonslip.
Generally the float is of square horizontal cross section with four vertical side surfaces. Generally the depth of the vertical sides surfaces is less than their width. Sometimes the vertical corners each have a vertical edge cylindrical groove extending from the i~op to the bottom surface, which can form a cylinder when enough floats are pushed together. More preferably each corner of the tap and bottom surfaces has a recess having a hori:7ontal plane, each plane being recessed the same distance, each plane has embedded therein a blindnut. The top and bottom surfaces are bowed outward and have a nonslip surface pattern. Also the float is of square horizontal cross section with four vertical side surfaces, and the depth of the vertical side surfaces is less than their width. In this care each corner of the top and bottom surface has a circular groove concentric with the corner. Each circular groove has the same radius, and each circular grove is peripheral to the horizontal plane, and the groove has angled generally planar inner and outer_-walls separated by a generally planar recess wall. Sometimes thf~
vertical corners each have a vertical edge cylindrical groove extending from top to bottom surface.
In another broad aspect the invention is directed to a dock element. The dock element has in combination at least two connectors and at least two modular dock floats of as indicated above. Each connector ~.s a plate having paired opposed substantially planar surfaces and a plurality of apertures adjacEant the disk edge. Each connector has at leash two flanged bolts passing through adjacent apertures. Each bolt threadably engage:a a blindnut of a dock float. The bolts are dimensioned to fit the apertures snugly. The flanges are dimensioned larger than the apertures so that they cannot pass thereth~__~ough. These bolts and their attached flanges hold the connectors touching the dock floats and the float assembly fairly rigidly. Preferably the connectors are attached in pairs. One of each pair is attached to the top surface of the dock floats, the other to the bottom surface of the

3 dock floats. Preferably each top and bottom corner of the dock floats has a recess having a horizontal plane. Each plane is recessed the same distance, each plane has embedded therein a blindnut and the conneci:ors touch the horizontal planes of the recesses. Preferably each corner of the top and bottom surfaces has a circular groove concentric with the corner. Each circular groove has the same rad_Lus, and is peripheral to the horizontal plane. At least one connector has a flange peripheral to its plate, and this flange registers with the groove when the plate is in contact with the floats. Preferably the connector with the flange has an inner wall containing the apertured plate. An outer wall is spaced apart from the inner wall. The outer wall merges into the flange and the outer wall has therein access apertures aligned with the plate apertures. These access apertures are dimensioned so the flanges of the bolts pass therethrough. The vertical corners of the floats may have a vertical cylindrical groove extending from the top to bottom surface of each float. :In this case the apertured plate of the connector has a central axial cylindrical stem extending toward the float, which registers with the cylindrical grooves of the floats. Preferably both flange and stem are present provid~_ng a solid float join. Generally only top connectors have flange and stem, bottom connectors are plates.
When a mixture of tall and short floats are combined, generally ithe connectors are at the bottom. Regardless of whether the cannector is flange and stem or p7_ate alone the join is solid, although the flange and stem is solider. Typically the dock floats have top <~nd bottom surfaces, which are bowed outward and have a nonslip surface pattern. Usually the floats are of square horizontal cross section with four vertical side surfaces. Commonly the depth of the vertical side surfaces i.s less than their width. Conveniently the connectors have a central circular aperture. This may be used to hold a circular cover in a top connector. The cover may have a planar bottom surface having therein a central projection which engages snapfittingly the central aperture of tap connector.
Preferably the cover surface is bowed upward and has a nonslip surface pattern. Generally each connector engages up to four

4 i floats.
BRIEF L>ESCRIPTION OF THE IaRAWINGS
Fig. 1 shows a top plan view of a float cube of the invention.
Fig. 2 shows a vertical corner to corner cross sectional view of the embodiment of Fig. 1.
Fig. 3 shows a top plan view of another float cube of the invention.
Fig. 4 shows a vertical corner to corner cross sectional vieew of the embodiment of Fig. 3.
Figs. 5 to 7 show t:op plan views of connectors of the invention.
Figs. 8 and 9 show top plan views of connectors connecting float cubes of the invention.
Figs. 10, 11 and 12 show cross sectional sketches of connectors connecting f~_oat cubes of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is illustrated but not restricted by the following description. The invention is now illustrated by reference to preferred embodiments thereof. Numeral 10 (Figs. 1 and 2) indicates a float cube of the invention which has top surface 12, four sides ~_4, bottom surface 16, sides 14 are identical as are top surface 12 and bottom surface 16. Surfaces 12 and 16 each contain blindnut or locknut 20 of ~ inch nominal bore at corners 18. Nut 20 is about 2 to 4 inclh deep and up to 4 inch in diameter and is integrally molded into float 10. Floats 10 <~re approximately 18 inches (46 cms) wide and 13 inches (33 cms) or inches (162 cms) deep. Float 110, (Figs. 3 and 4) similarly has top and bottom surfaces 12 and 168 sides 14, corners 18 and blindnuts 20, it has vertical quarter cylindrical groove 22 of approximately ~ inch radius at corner 18. Blindnuts 20 are in f:Lat corner surface 24 recessed below top surface 12, and above bottom surface 16, with about 32 inch radius. Circular groove 26 which is

5 about 1z inch across separates surface 24 from surface 12 (or surface 16 if on the bottom). Top surface 12 and bottom surface 16 are slightly bowed outward, approximately ~ inch from the flat. In both float 10 and float 110 surfaces 12 and 16 are covered with nonslip pattern 28, although as those skilled in the art would appreciate, it is optional on bottom surface 16. The surfaces are bowed outward as geometrically flat ones have a tendency to oilcan, bow inward under temperature and hence associated pressure changes, especially in the North American winter.
Float cubes are rotationally molded and have a wall thickness from ~ to 4 inch generally to 3/16 inch in the corners.
Originally it was intended to weld or otherwise join two half shells to form the whole shell cube, but this proved impractical, and was rejected in favor of a rotationally molded hollow whole shell cube. Although the float is referred to as a cube, it is a flattened version thereof, with square top and bottom and rectangular sides wider than deep. All edges are molded rounded as otherwise rotational molding can produce razor sharp cutting edges.
A threaded bung hole and threaded bolt (not shown) is provided in one side 14, which allows high pressure to be relieved in summer and low pressure in winter, as the annual temperature range is from 50 to 80°C, it is preferred that the internal float pressure does not allow oil canning.
Also part of the invention are connectors, (Figs. 5, 6 and 7).
Disk plate connector 30 has diameter about 6~ inch, central optional aperture 32 typically has a diameter of from about 1i to 24 inch. Four equispaced slots 34 about ~ inch radially and Z inch across, with rounded ends, are inward about 3/32 inch from the perimeter disk 30. Plate connector 36 of four arms 38, optional central aperture 32 and four equispaced slots 34, dimensions are the same as connector 30 except for shape. Connector 40 has upper surface 42 covered with non slip pattern 28 about 104 inch diameter with lower connector plate 48, apertures 44 in upper surface 42

6 allow access to apertures 46 in plate 48.
Connector 30 (Fig. 8) is secured to four floats 10, by passing flanged or washered ~ inch bolts 50 through slots 34 to engage blind nuts 20 in floats 10, the flange itself being about ~ inch in diameter. This is a top plan view of the connection of four floats 10, but it could just as easily be a bottom plan view of tree connection of four floats. Connector 30 (Fig. 9) is also secured to four floats 110, by passing flanged or washered ~ inch bolts 50 through slots 34 to engage blind nuts 20 in floats 110. This is a top plan view of the connection of four floats 110, but it could just as easily be a bottom plan view of the connection of four floats 110.
Sectional views of connectors and floats 110 are shown (Fig;s.
10 to 12). In general (Figs. 10 and 11) connectors 30 are attached to upper and lower surfaces of floats 110 by flanged bolts 50 engaging blindnuts 20. Cover 52 which has outward bowed upper surface 42 and circular edge flange 56 fitting into grooves 26 o:E
floats 110, and optional recesses 58 for flanged bolts 50. When recesses 58 are apertures 59 receive flanged bolts 50. Cover 52 (Fig. 10) has central bottom cylinder 60 which has protuberances 62, here shown as round,. to snapfit aperture 32 of connector 30.
Cover 52 (Fig. 11) has central bottom truncated cone &4 which has groove 66 to snapfit aperture 32 of connector 30. Cylinder 60 and cone 66 could equally well fit aperture 32 of connector 36.
Vertical corner grooves 22 form a cylindrical void between floats 110. Connector 40 (Fig. 12) has integral lower plate 48, bolts 50 are passed through apertures 44 in outward bowed upper surface 42 then lower apertures 4& in lower plate 48 to engage blindnuts 20.
Cover 42 has bottom cylinder 68 which extends downward snugly filling the void formed by corner grooves 22.
Any of connectors 30, 36 and 40 are satisfactory. Connector can be made in quarter of half circular form with cylinder 68 being half or a quarter of a full cylinder. Quarter cylinders can

7 L

be used as buffers or fenders at outward corners, while half cylinders can be used at straight joins. In general the bottom joins, which are submerged in use, use connectors 30 or 36. Bolts 50 and blindnuts 20 are made of non corrosive metal, bronze being preferred, but brass, or. aluminum can also be used.
Although floats of generally square horizontal section are shown, it should be realized that floats of equilateral triangular and hexagonal horizontal section can be used instead, as these shapes can also fit together to form a continuous area filling surface, as would be understood by those skilled in the art.
Although the depth of the floats is roughly three-quarters of the width, this ratio can be within limits varied without affecting 'the function of the floats as would be understood by those skilled in the art.
The floats, connectors and covers can be manufactured from any suitable plastic, the floats and covers preferably by rotational molding, as would be readily understood by those skilled in the art. Polyethylene is preferred, and high density polyethylene mor preferred, but this must be understood to be indicative and illustrative of the sorts of suitable plastic, rather than restrictive. Linear polyethylene, linear low density polyethylene, low density polyethylene, can be used. High molecular weight polyethylene is preferred for the connector plates. These polyethylenes have properties within the desired range, and are selected for availability and cost. Other similar conventional plastics of like properties can be used as would be understood by those skilled in the art.
As those skilled in the art would realize these preferred described details and materials and components can be subjected to substantial variation, modification, change, alteration, and substitution without affecting or modifying the function of the described embodiments.

8 Although embodiments of the invention have been described above, it is not limited. thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.

9

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A modular float for docks comprises a hollow integral shell having opposed top and bottom horizontal surfaces and a plurality of vertical side surfaces, said side surfaces are substantially planar and joined at top and bottom to said top and bottom surfaces, and joined at either side to neighboring side surfaces forming vertical corners, said side surfaces all have substantially the same depth, and substantially the same width, said top and bottom surfaces have corners corresponding to said vertical corners, and each corner of said top and bottom surfaces has embedded therein a blindnut to receive a bolt.

2. Float of claim 1, wherein each corner of said top and bottom surfaces has a recess having a horizontal plane, each plane is recessed the same distance, and each plane has embedded therein a blindnut.

3. Float of claim 2, wherein each corner of said top and bottom surface has a circular groove concentric with said corner, each said circular groove has the same radius, and each said circular grove is peripheral to said horizontal plane.

4. Float of claim 3, wherein said circular groove has angled generally planar inner and outer walls separated by a generally planar recess wall.

5. Float of claim 1, wherein said top and bottom surfaces are bowed outward.

6. Float of claim 1, wherein said top and bottom surfaces have a nonslip surface pattern.

7. Float of claim 1, wherein said float is of square horizontal cross section with four vertical side surfaces.

8. Float of claim 1, wherein the depth of said vertical side surfaces is less than their width.

9. Float of claim 1, wherein said vertical corners each have a vertical edge cylindrical groove extending from said top to said bottom surface.

10. Float of claim 1, wherein each corner of said top and bottom surfaces has a recess having a horizontal plane, each plane being recessed the same distance, each plane has embedded therein a blindnut and said top and bottom, surfaces are bowed outward and have a nonslip surface pattern and said float is of square horizontal cross section with four vertical side surfaces, and the depth of said vertical side surfaces is less than their width.

11. Float of claim 10, wherein each corner of said top and bottom surface has a circular groove concentric with said corner, each said circular groove has the same radius, and each said circular grove is peripheral to said horizontal plane and said circular groove has angled generally planar inner and outer walls separated by a generally planar recess wall.

12. Float of claim 11, wherein said vertical corners each have a.
vertical edge cylindrical groove extending from said top to said bottom surface.

13. A dock element comprising in combination at least two connectors and at least two modular dock floats of claim 1, and each said connector comprises a plate having paired opposed substantially planar surfaces and a plurality of apertures adjacent said plate edge, and each connector has at least two flanged bolts passing through adjacent apertures and each bolt threadably engages a blindnut of a dock float and, said bolts being dimensioned to fit said apertures snugly and said flanges being dimensioned larger than said apertures so that they cannot pass therethrough so said bolts hold said connectors touching said dock float.

14. Dock element of claim 13 where said connectors are attached in pairs, one of each pair is attached to the top surface of said dock floats, the other to the bottom surface of said dock floats.

15. Dock element of claim 14 where each top and bottom corner of said dock floats has a recess having a horizontal plane, each plane being recessed the same distance, each plane has embedded therein a blindnut and said connectors touch said horizontal planes of said recesses.

16. Dock element of claim 15, wherein each corner of said top and bottom surface has a circular groove concentric with said corner, each said circular groove has the same radius, and each said circular grove is peripheral to said horizontal plane and at least one said connector has a flange peripheral to said plate and said connector flange registers with said groove when said plate is in contact with said floats.

17. Dock element of claim 16, wherein said connector with said flange has an inner wall containing said apertured plate and an outer wall spaced apart from said inner wall, and said outer wall merges into said flange, and said outer wall has therein access apertures aligned with said plate apertures, and said access apertures are dimensioned so said flanges of said bolts pass therethrough.

18. Dock element of claim 16 wherein said vertical corners of said floats have a vertical cylindrical groove extending from said top to said bottom surface of said float and said apertured plate of said connector has a central axial cylindrical stem extending toward said float, and said stem registers with said cylindrical grooves of said floats.

19. Dock element of claim 13, where said connectors have a central circular aperture.

20. Dock element of claim 19, where a circular cover covers a top connector, said cover hawing a planar bottom surface having therein a central projection which engages snapfittingly said central aperture of said top connector.