WO2009026516A2 - Modular dock system and method installation - Google Patents

Abstract

In one embodiment of the present invention there is provided a dock assembly. The assembly includes at least one pair of pylons. A header support is provided and is secured to each pair of pylons. The dock assembly includes at least one dock module secured to the header support. Each module includes a pair of side frame members and a pair of end frame members rigidly connected together. The end frame members include aligned apertures positioned therein to accommodate tubing for providing water or electrical. The underside of the module further includes a pair of channels running along the length of the module. The channels allow for securing bolts to slide there through and attach the module to the header support.

Description

MODULAR DOCK SYSTEM AND METHOD INSTALLATION

CROSS REFERENCE TO RELATED APPLICATIONS

[01] The present invention claims priority to US Patent Application 11/844,009 filed August 23, 2007.

FIELD OF THE INVENTION

[02] The present invention relates to a dock or pier assembly for use over land or a body of water.

BACKGROUND OF THE INVENTION

[03] Docks and piers built over land or bodies of water, such as lakes, rivers, ocean fronts, or the like, are well known. Most such structures are permanent and construction and repair is a tedious difficult time consuming process. In construction of a dock, pylon pairs are driven into the ground to support the dock. A plurality of individual horizontal planks is then secured to the pylon pairs and serves as a foundation to the wooden walkways that are built on top. Lastly, electrical and water lines that run the length of the dock are often attached to the bottom of the dock.

[04] These traditional wooden structures suffer from many disadvantages. The water and electrical lines are too exposed and often fail or break because of wear and tear. Degradation of wooden docks occurs rapidly under the exposure to weather and traffic and requires replacement from time to time. Moreover, if the dock is entirely or partially destroyed by a storm, the removal, clean up, and replacement of the dock is difficult and expensive. There is thus a need to overcome some or all of these disadvantages as well of other disadvantages well known in the industry.

BRIEF SUMMARY OF THE INVENTION

[05] In one embodiment of the present invention there is provided a dock assembly. The assembly includes at least one pair of pylons driven into the ground, either the sea bed or land. Header supports are then secured to each pair of pylons. Each header support has a side section for securing the header support to the pair of pylons and has a top section with apertures defined there through. In additional embodiments a plank is attached between the pylon pairs and the side section of the header support for additional strength.

[06] In addition to the above, at least one dock module is secured to the top section of the header support. Each module is a preassembled frame constructed from at least a pair of side frame members and a pair of end frame members. The ends of side frame members and the end frame members are rigidly connected together to form a module that is a rectangular shape. The end frame members include aligned apertures positioned therein to accommodate tubing for providing water or electrical wires through the module. The underside of the module further includes a pair of channels running along the length of the module. The channels are positioned about the side frame members and include a trough with edges extending towards each other over the trough.

[07] The dock assembly further includes a plurality of securing means to secure the modules to the header supports. The securing means are in one embodiment a T shaped bolt that is defined as having a top portion sized to be received in the troughs and having a center body portion extending away from the top portion and sized to fit between the edges of the channel and the center body is of a sufficient length to extend through the apertures on the top section of the header support. Lastly, a tightening end is threaded onto the center body portion, such that the tightening end is able to secure the module to the header support.

[08] In another embodiment of the present invention each module includes a center frame member positioned intermediately and substantially parallel to the side frame members, hi yet another embodiment of the present invention each module further includes at least one cross member positioned intermediately to the end members and substantially perpendicular to the center frame member. The cross member further includes one or more apertures positioned to align with and correspond to at least one aligned set of apertures positioned in the end frame members.

[09] In accordance with one of the embodiments of the present invention the dock assembly further includes a plurality of planks secured to the side frame members and secured to an upper portion defined by the module. The dock assembly may also include a railing support defined by having lateral posts secured by brackets to the planks that are secured to the side frame members. [10] In yet another embodiment of the present invention each bracket used to attach the lateral posts of the railing support to the module includes a back member, a bottom member, and at least one vertical member. The back member has a first side positioned against the side frame member of the module and has an underside portion. The bottom member is secured to the underside portion of the back member. The bottom member includes a first region that extends behind the back member under the side frame member of the module and is able to be positioned against the bottom section defined by the module. The bottom member also includes a second region that extends forward of the back member for supporting a bottom end defined by the lateral post. The vertical member is secured to the back member to provide support to a lateral side of the lateral post.

[11] In another embodiment of the present invention a preassembled frame module for constructing a dock assembly is provided. The frame module includes a pair of side frame members, and a pair of end frame members, wherein the ends of side frame members and end frame members are rigidly connected together to define a rectangular shape. At least one aligned set of apertures is positioned in the end frame members, to accommodate tubing for providing water or electrical wires through the frame. Lastly, a pair of channels is provided that run along a length of the frame defined by the side frame members. The channels are positioned about the side frame members on an underside portion defined by the module. Each channel is further defined as having a trough with edges extending towards each other over the trough, wherein the channels are utilized for slidably securing the frame module to pylons used in supporting the dock assembly.

[12] This particular embodiment may also include header supports secured to a pair of pylons, each header support has a side section for securing the header support to the pair of pylons and has a top section with apertures defined through the top section, capable of receiving a plurality of means for securing the top section of each header support to a frame module. [13] Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS;

[14] A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:

[15] Figure 1 is a perspective view of the modular dock assembly in accordance with one or more embodiments of the present invention;

[16] Figure 2 A is a bottom perspective view of a dock module in accordance with one embodiment of the present invention;

[17] Figure 2B is a front view Figure 2 A;

[18] Figure 3 is a perspective view of the installation of the modular dock assembly showing the pylons, header planks, and the header supports in accordance with one embodiment of the present invention;

[19] Figure 4 A is a perspective view of the header support shown in Figure 3 ;

[20] Figure 4B is a side view of Figure 4 A;

[21] Figure 5 is bottom perspective view of the dock module secured to the header supports;

[22] Figure 6 is a bottom perspective view of the dock module secured to the header supports further illustrating the ability to utilize one or more aspects of the invention with non-uniformed placed pylons;

[23] Figure 7 is a perspective view of the dock module being fitted with planks in accordance with one embodiment of the present invention;

[24] Figure 8 is a perspective view of the dock module being fitted with planks in accordance with another embodiment of the present invention;

[25] Figure 9 is a perspective view of the modular dock assembly illustrating the hand rails; [26] Figure 1OA is a perspective view of the bracket used to secure the lateral posts of the hand rails to the dock module in accordance with one embodiment of the present invention; [27] Figure 1OB is a side view of Figure 1OA; and [28] Figure 1OC is a front view of Figure 1OA with a partial view of a lateral post.

DETAILED DESCRIPTION OF THE INVENTION:

[29] While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated. [30] Figure 1 illustrates a dock or pier assembly 10 constructed utilizing a series of dock modules 12 made in accordance with the invention. The modules 12 are connected to each other to form any length desired for the dock. Individual planks 14 may be secured to the top and sides of the modules 12. The planks 14 may be wood, plastic, metal, or any other suitable material. Arm railings 16 may also be secured to the sides of the modules 12 or side planks using specialized brackets 18 (discussed in greater detail below). The modules 12 may also be provided with aligned conduit apertures 46 that provide an opening for tubing 22 to run electrical and water throughout the length of the module 12 and spans across multiple modules to run the same throughout the entire dock.

[31] Referring now to Figure 2 A, each module 12 includes a bottom portion 30, a top portion 32, a front end frame member 34, a back end frame member 36, and a pair of side frame members 38. The ends of the side frame members and the end frame members are rigidly connected together to define a rectangular shape.

[32] The bottom portion 30 includes a pair of channels 40. The channels 40 preferably run the length of the module 12 (from the front end frame member 34 to the back end frame member 36) and are positioned substantially near the side end frame members 38. A center member 42 substantially parallel to the side end frame members 38 and positioned substantially along the center region of the module 12 is provided for support. In addition, at least one or more cross members 44, intermediate of the front end frame member 34 and the back end frame member 36, may also be provided and would run between the side frame members 38 at about an angle substantially perpendicular to the center member 42. The front end frame member 34, the back end frame member 36, and any intermediate cross members 44 would include aligned apertures 46 for receiving the tubing 22. As illustrated the size of the apertures 46 may vary. [33] The channels 40 shown in Figure 2B include trough 50 channel openings 54 substantially flush with the front end frame member 34 (and would also be substantially flush with the back end frame member 36). Each channel 40 includes two edges 52 that protrude over the trough 50 towards each other at the bottom portion 30 of the module 12 thereby creating a slightly larger internal spaced region with a narrow channel opening 56 that is defined as substantially flush with the bottom portion 30.

[34] Referring now to Figures 3 through 7 the process of installing a dock in accordance with embodiments of the present invention will be discussed in further detail. As with the construction of almost any dock, pylon pairs 100a, 100b, 100c, 10Od, etc., are first placed in the water W. The pylons (generally referenced as numeral 100) are placed such that one end of the pylon is positioned out of the water. Header planks 105 are attached to either side of the pylon pairs 100. While the prior art would at this point begin attaching cross beams to the header planks and then laying walkway planks on top, one embodiment of the present invention utilizes a unique header support 110 (shown in greater detail in Figures 4A and 4B) attached to each header plank 105.

[35] Referring to Figures 4a and 4b, the header support 110 includes a top section 112 and a side section 114 extending from one edge 116 of the top section 112 to form an L shaped member 120. The top section includes apertures 122. The number, size, and shape of the apertures 122 do not form part of the invention. However, the header support 110, as illustrated, includes a pair of apertures 122 extending through the top section 112 on either end thereof. In addition, the side section 114 includes openings 124 such that the header support can be secured at least to the header plank 105 and possibly to the pylons.

[36] Continuing to refer to Figures 3 and 5, positioned through the apertures 122 on the header supports 110 are T shaped bolts 130 particularly designed for maximizing the attachment of the modules 12 to the header supports 110. The top portion 132 of the T shaped bolts 130 will fit into the trough 50 in the channels 40 on the modules 12. The modules 12 are then able to slide across the header supports 110 to its resting position. A tightening member 134 is threaded onto the T shaped bolts 130 and is used to secure the modules 12 into place. Each module 12 is also able to be secured to one another by bolts or other types of securing members end to end or end to side.

[37] Referring now to Figure 6, another unique aspect of the present invention is the ability for the modules 12 to fit onto and accommodate angled or unaligned pylons 100. It is not uncommon during insertion of a pylon 100 that the pylon becomes angled or unaligned with its corresponding pair. This often causes a problem because the header planks 105 are then angled requiring planks to be cut on site to fit properly or in worse case scenarios leaving openings or spaces between planks because of angled pylons. However, a module 12 positioned and connected unto the angled pylons will still allow a uniform connection between the other surrounding modules because the channels 40 permit one pylon to be positioned or angled differently from its corresponding pair while the module 12 itself is still positioned flatly against the other modules.

[38] Once the modules 12 are positioned and secured onto the pylons the modules 12 may be covered by planks 140, illustrated in Figure 7. The planks 140 may be secured by bolts to the side frame members 38 and top portion 32 of the modules 12. Alternatively as illustrated in Figure 8, the top portion 32 of the modules 12 may further include channels 40b similarly constructed to the channels 40 positioned in the bottom portion 30. In this alternative embodiment, the planks would include the T shaped bolts 30 positioned such that top portion 132 of the bolt 130 extends under the plank and would slide through the channels 40b and the tightening member 134 extends above the plank and would be used to tighten the plank to the module 12.

[39] Referring now to Figure 9, in another embodiment of the present invention, the dock 10 includes hand rails 16. The hand rails 16 are formed by securing lateral posts 150 to the side frame members 38 of the dock module 12. In most instances, the lateral posts 150 are secured to planks 152 which are secured to the side frame members 38. A cross post 154 is then secured to the lateral posts 150 to complete the hand rail 16. However, the aesthetics of the hand rail 16 may be changed without deviating from the scope of the invention. The lateral posts 150 are secured to the dock module 12 by brackets 18, which are secured at least to the planks 152. [40] As illustrated in Figures 10a through 10c, the brackets 18 are of a unique design. The bracket 18 includes a back member 162 that rests against the plank 152. A bottom member 164 is secured to the underside portion 166 of the back member 162 and includes a region 168 that extends under the plank 152 and possibly the module 12. The underside portion 166 will then rest on top of the region 168. This provides for a stable and uniform installation of multiple brackets. A pair of vertical members 170 is secured to the back member 162 and provides support to the lateral posts 150. Holes 172 on the upright members 170 permit bolts, screws, or other securing means to be inserted there through into the lateral posts 150. Holes 172 are also positioned on the back member 162 such that the bracket can be easily attached to the plank 152 and/or module 12.

[41] From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.

Claims

What is claimed is: 1. A dock assembly, comprising: at least one pair of pylons; a header support secured to each pair of pylons, the header support having a side section for securing the header support to the pair of pylons and having a top section with apertures defined through the top section; at least one dock module, each module includes a preassembled frame constructed of: a pair of side frame members, and a pair of end frame members, wherein ends of side frame members and end frame members are rigidly connected together, at least one aligned set of apertures positioned in the end frame members, to accommodate tubing for providing water or electrical wires through the dock module, a pair of channels running along a length of the module defined by the side frame members, the channels being positioned about the side frame members on an underside portion defined by the module, each channel being defined as having a trough with edges extending towards each other over the trough; and a means for securing the dock module to the top section of the header support.

2. The dock assembly as set forth in Claim 1, wherein the means for securing the dock module to the top section of the header support includes a plurality of T shaped members having a top portion sized to be received in the troughs and having a center body portion extending away from the top portion and sized to fit between the edges of the channel and being of a sufficient length to extend through the apertures on the top section of the header support and having a tightening end threaded onto the center body portion, whereby the top portion of the T shaped members permits the dock module to slidably engage the header support until the tightening end secures the module to the header support.

3. The dock assembly as set forth in Claim 1, wherein each dock module further includes a center frame member positioned intermediately and substantially parallel to the side frame members.

4. The dock assembly as set forth in Claim 3, wherein each dock module further includes at least one cross member positioned intermediately to the end members and substantially perpendicular to the center frame member, the at least one cross member further including apertures positioned to align with and corresponding to the at least one aligned set of apertures positioned in the end frame members.

5. The dock assembly as set forth in Claim 1 further includes a plurality of planks secured to the side frame members and secured to an upper portion defined by the dock module.

6. The dock assembly as set forth in Claim 5 further includes a railing support defined by having lateral posts secured by brackets to the planks secured to the side frame members.

7. The dock assembly as set forth in Claim 6, wherein each bracket includes: a back member having a first side positioned against the side section of the dock and having an underside portion, a bottom member secured to the underside portion of the back member, the bottom member includes a first region that extends behind the back member under the side section of the dock and is able to be positioned against the bottom section of the dock, and a second region that extends forward of the back member able to support a bottom end defined by the lateral post, and at least one vertical member secured to the back member to provide support to a side of the lateral post.

8. The dock assembly as set forth in Claim 1 further comprising: a pair of channels running along a length of the module defined by the side frame members, the channels being positioned about the side frame members on a topside portion defined by the module, each channel being defined as having a trough with edges extending towards each other over the trough; and a plurality of planks attached to the topside portion of the module via the pair of channels.

9. The dock assembly as set forth in Claim 8 further comprising a plurality of T shaped members having a top portion sized to be received in the troughs of the channels in the topside portion of the module, the T shaped members further having a center body portion extending away from the top portion and sized to fit between the edges of the channel and being of a sufficient length to extend through apertures defined on the plurality of planks, and the T shaped members having a tightening end threaded onto the center body portion, whereby the top portion of the T shaped members permits the planks to slidably engage the topside portion of the module until the tightening end secures the planks to the module.

10. The dock assembly as set forth in Claim 1 further comprising a plank secured between the header supports and each pair of pylons.

11. A preassembled frame module for constructing a dock assembly, comprising: a pair of side frame members, and a pair of end frame members, wherein the ends of side frame members and end frame members are rigidly connected together to define a rectangular shape of the module; at least one aligned set of apertures positioned in the end frame members, to accommodate tubing for providing water or electrical wires through the frame; and a pair of channels running along a length of the frame defined by the side frame members, the channels being positioned about the side frame members on an underside portion defined by the module, each channel being defined as having a trough with edges extending towards each other over the trough, wherein the channels are utilized for slidably securing the frame module to pylons used in supporting the dock assembly.

12. The frame module as set forth in Claim 11 further comprising: header supports for attachment to a pair of pylons, each header support having a side section for securing the header support to the pair of pylons and having a top section with apertures defined through the top section; and a plurality of means for securing the top section of each header support to a frame module.

13. The frame module as set forth in Claim 12, wherein the plurality of securing means further includes a top portion sized to be received in the troughs and having a center body portion extending away from the top portion and sized to fit between the edges of the channel and being of a sufficient length to extend through the apertures on the top section of the header support and a tightening end threaded onto the center body portion, such that the tightening end is able to secure the frame module to the header support.

14. The frame module as set forth in Claim 11 further including a center frame member positioned intermediately and substantially parallel to the side frame members.

15. The frame module as set forth in Claim 14 further including at least one cross member positioned intermediately to the end members and substantially perpendicular to the center frame member, the at least one cross member further including apertures positioned to align with and corresponding to the at least one aligned set of apertures positioned in the end frames.

16. The frame module as set forth in Claim 11 further comprising a pair of channels running along a length of the frame defined by the side frame members, the channels being positioned about the side frame members on a topside portion defined by the module, each channel being defined as having a trough with edges extending towards each other over the trough, wherein the channels are utilized for slidably securing planks to the frame module.

17. A railing support bracket for securing a lateral post to a dock, the dock having at least a side and a bottom section, the bracket comprising: a back member having a first side positioned against the side section of the dock and having an underside portion; a bottom member secured to the underside portion of the back member, the bottom member includes a first region that extends behind the back member under the side section of the dock and is able to be positioned against the bottom section of the dock, and a second region that extends forward of the back member able to support a bottom end defined by the lateral post; and at least one vertical member secured to the back member to provide support to a side of the lateral post.

18. The bracket as set forth in Claim 17 comprising a second vertical member secured to the back member and positioned to provide support to another side of the lateral post.

19. The bracket as set forth in Claim 18 wherein the back member includes sides extending past the vertical members.

20. The bracket as set forth in Claim 19 wherein the bottom member and the at least one vertical member are perpendicular positioned with respect to one another.