FLOATING DOCK SYSTEM AND DOCK MODULE THEREFOR

Abstract

A dock system is formed from a plurality of interconnected dock modules, with adjacent dock modules connected together by means of at least one coupler. The coupler has a connector having a first end, a second end, and a middle portion which is flexible, compressible, and tensionable. Each dock module is formed from a buoyant float comprised of a plurality of buoyant float members, a decking support, decking mounted to the decking support to form a tread surface for the dock module, and a decking support connector extending between the decking support and the float to secure the decking support to the float. The decking support is formed from a frame made from frame members, at least one first cross member extending across one dimension of said float, and at least one second cross member extending across a second dimension of said float.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. App. No. 61/748,589 filed Jan. 3, 2013.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

This disclosure relates to floating dock systems, and, in particular, a floating dock system in which dock modules for the system are comprised of a plurality of float members which, in combination, define a float over which decking members can be placed.

Numerous types of floating dock systems have been developed over the years. One illustrative, and commercially popular, floating dock system is made and sold by E-Z-Dock, Inc., of Monett, Mo. under the name EZ DOCK®. The basic floatation or dock member is a monolithic 4′×8′ section, which is described in U.S. Pat. No. 5,281,055, which is incorporated herein by reference. A plurality of these dock members can be assembled together using connectors to form walkways, piers, etc. of a dock system. Various ramps/gangways, watercraft lifts, and accessories can be secured to the basic dock member to form complete a dock system. Such a dock system can be as small as a private pier, and as large as a commercial marina.

The dock system described in the U.S. Pat. No. 5,281,055 patent provides for a significant amount of flexibility in designing dock systems. However, the system can be improved upon to, for example, provide greater flexibility in the type of decking surface used with a dock system, and to provide for the ability to replace decking sections should portions of the decking become damaged or worn. Further, it would be desirable to produce a floating dock system which has a reduced area of contact with the water.

SUMMARY

Briefly stated, a dock system is made from a plurality of connected dock modules.

In accordance with one aspect of the invention, the dock modules comprise a buoyant float comprised of a plurality of buoyant float members, a decking support secured to the float by a decking support connector, and decking secured to the decking support to form a tread surface for the dock module. Each float member comprises an upper surface, a bottom surface and at least one wall surface; at least one connector socket formed in said at least one wall. The decking support is comprised of a frame made of frame members, with at least one first cross member extending across one dimension of the float, and at least one second cross member extending across a second dimension of said float. The decking connector extending between the decking support and the float to secure the decking support to the float.

The decking support connector comprises a strap assembly. The strap assembly comprises an upper member, a lower member, and a strap extending between the upper and lower members. The upper and lower members each comprising an attachment member shaped, sized, and adapted to be received in a receptacle in the decking support and float member, respectively. The strap can be an elastic strap. Alternatively, the strap can be a metal (i.e., aluminum) strap which is tightened by means of a tensioning mechanism.

The decking support can comprise an upwardly opening channel which receives an attachment member of the strap assembly. In this instance, the upper member of the strap assembly comprises a hook portion sized and shaped to engage the channel of the frame member.

The lower member of the strap assembly lower member can comprise a plate having a main portion and a neck portion. The float, in turn, comprises a receptacle on a bottom surface thereof which has a first portion and a neck portion extending from the first portion to the wall of the float. The lower member plate and the float member receptacle are shaped complementarily to each other.

The frame member of the decking support comprises a frame body having an upper surface, a lower surface, an outer surface, and an inner surface. When in place, the frame member lower surface is supported by said upper surface of said float member. The frame member further comprises a flange extending inwardly from the inner surface of the frame member body. This flange is spaced above the lower surface of the body and the first cross member is positioned between the flange and the upper surface of the float. The second cross member is positioned on top of the first cross member.

The decking support frame member can further comprise a decking support flange extending inwardly from the frame inner surface below the frame member upper surface. The decking rests on one of the first and second cross members and has an edge resting on the decking support flange of the frame member. The decking support flange is spaced from the upper surface of the frame member body a distance substantially equal to the height of the decking, such that a top surface of the decking will be generally level with the top surface of the frame member.

In accordance with another aspect of the invention, a dock system is comprised of a plurality of interconnected dock modules which are connected together by at least one coupler. Each the dock module having a connector receptacle and the connector receptacles of adjacent dock modules are aligned with each other. The coupler comprises a connector having first and second ends which are shaped complementarily to the dock module receptacles so that they can be received in the receptacles. The connector further including a middle portion extending between the first and second ends of the connector. This middle portion is sized and shaped to space adjacent dock modules apart from each other a determined distance. The middle portion of the connector is capable of withstanding torsional, tensile and compressive forces.

In accordance with one aspect of the connector, the connector can include a first neck portion extending between the first end and the middle portion and a second neck portion extending between the second end and the middle portion. In this instance, the middle portion is enlarged relative to the neck portions and the adjacent dock modules are separated from each other a distance at least the length of the connector middle portion. The connector middle portion can define a hollow. If the connector middle portion defines a hollow, the middle portion of the connector can be generally annular. The coupler can be comprised of a material that includes fibers, and the fibers can include glass fibers, plastic fibers, or carbon fibers.

In accordance with another aspect of the connector, the each connector comprises an upper connector member and a lower connector member with two tie rods extending between the upper and lower connector members; the tie rods being positioned between the middle portion and the opposite end portions of each connector member. The dock modules can each include a channel in a wall thereof, and the tie rods can be positioned on the connector members to be received in the channel.

In accordance with an aspect of the dock system, the decking support of the dock modules can comprise an edge cross-member positioned at an edge of each the dock module, wherein the edge cross-members of adjacent dock modules are joined together by at least one fastener. Preferably, a resilient bushing is positioned on the fastener between the edge cross-members of the adjacent dock modules. Additional outer bushings can be positioned at opposite ends of the fastener.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a top perspective view of a dock module;

FIGS. 2A-2B are side elevational and end elevational views, respectively, of the dock module;

FIGS. 3A and 3B are top and bottom perspective views, respectively, of the dock module with decking removed to show the decking support;

FIG. 4 is a perspective view of a float of the dock module;

FIGS. 4A-I are perspective views of alternative float configurations;

FIGS. 5A-C are top perspective, bottom perspective, and end perspective views, respectively, of a float member from which the float is formed;

FIG. 6 is a fragmentary cross-sectional view taken along line 6-6 of FIG. 3A to show the decking support in detail;

FIG. 7 is a fragmentary cross-sectional view, generally perpendicular to the view of FIG. 6, taken along line 7-7 of FIG. 3A to further show the decking and decking support;

FIG. 8 is an end elevational view of a frame member of the decking support;

FIG. 9 is a perspective view of the frame member showing an outer surface of the frame member;

FIG. 10 is a perspective of the frame member showing an inner surface of the frame member;

FIG. 11A is a perspective view of a flow through decking section;

FIG. 11B is a perspective view of a decking section in the form of a plank having a wooden appearance;

FIG. 11C is a plan view of four decking sections formed to give the decking a concrete surface appearance;

FIG. 12 is a perspective view of a strap assembly used to connect the decking support to the float;

FIG. 13A is a bottom perspective view of a corner member of the dock module;

FIGS. 13B and 13C are fragmentary perspective views showing the connection of the corner member to the frame member;

FIG. 14 is a perspective view of two dock modules (with decking removed) connected together.

FIG. 15 is an enlarged fragmentary perspective view of two dock modules connected together, with the decking removed for purposes of illustration;

FIG. 16 is an enlarged fragmentary perspective view showing the connection between the floats of two dock modules;

FIG. 17 is a perspective view of the coupler for connecting dock module floats together;

FIG. 18A is a fragmentary cross-sectional view taken along line 18-18 of FIG. 15 to show the connection between the decking support of adjacent modules; and

FIG. 18B is an enlarged fragmentary cross-sectional view showing the connection of two dock modules.

Corresponding reference numerals will be used throughout the several figures of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates the claimed invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the claimed invention, and describes several embodiments, adaptations, variations, alternatives and uses of the claimed invention, including what we presently believe to be the best mode of carrying out the claimed invention. Additionally, it is to be understood that the claimed invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The claimed invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

A dock system 10 is comprised of one or more dock modules 12. A single dock module 12 is shown in FIG. 1. As is apparent from FIG. 14 (which shows two dock modules connected together), two or more dock modules can be connected together for form the dock system 10. Although the dock system 10 of FIG. 14 includes two dock modules 12 connected in line or in tandem (to form a long dock section or pier), the dock modules can be connected at right angles to each other or parallel to each other. Additionally, as will be described below, the construction of the dock modules allows for ramps/gangways, watercraft lifts, and accessories to be connected to the dock module. Hence, using the dock module 12, an entire dock system can be formed.

The dock module (which forms the building unit of the dock system) comprises a float 14, decking 16, and a decking support 18. The dock module of FIG. 1 is shown with decking that is generally wood-like in appearance. That is, the decking is formed from a plurality of planks, which can be formed of wood or plastic. The construction of the dock module, however, allows for a plurality of types of decking-types. Hence, the decking can have the appearance of concrete (FIG. 11C) or can be made from perforated members (FIG. 11A) to allow light and air to easily pass through the decking.

The float 14 is formed from a plurality of buoyant float members 20 connected by coupler assemblies 22. The float members 20 are preferably hollow, and can be formed from a plastic, for example, by rotational molding. If desired, the float members 20 can be filled with foam or with floatation enhancing devices such as discreet air filled members, as is disclosed, for example, in co-owned U.S. Pat. No. 7,243,608, which is incorporated herein by reference. The coupler assemblies 22 illustratively comprise the connectors shown and described in the above-noted U.S. Pat. No. 5,281,055, and the description of the coupler assemblies is incorporated herein by reference. Briefly, that coupler assembly each comprises an upper connector, a lower connector, and a single tie rod or bolt extending between the connectors. The connectors each have opposed enlarged ends connected by a narrower neck section. The float members 20 can be connected using any desired type of connector.

The float members from which the float 14, as shown in FIG. 4, can all be identical (i.e., they can all be the same shape and size). However, the float can be formed from float members of different sizes. Illustratively, the float members can be generally rectangular, and can be approximately 8′ long, 2′ deep, and 14″ wide. The float members can be bigger or smaller as may be desired. As seen, the float 14 has end float members 20a, a central float member 20b, and sides defined by two float members 20c and the end faces of the float members 20a and 20b. The float shown in FIG. 4 is thus approximately 8′×19½′×2′. This configuration forms a float 14 having a rectangular perimeter, and an interior open area bisected by a float member. Thus, the rectangular perimeter defines or encloses two generally open rectangular areas 20d. This provides a float in which more than 50% of the float is open. That is, the area of the two open areas 20d is at least 50% of the area defined by the outer perimeter of the float 14. The open area can even be greater than 60% of the area defined by the outer perimeter of the float 14.

The float members 20 can be connected together to form floats that have less open area. For example, the float in FIG. 4A has float members parallel to the float members 2c which bisect the open areas 20d. The float shown in FIG. 4B has the float members connected directly together for form a “solid” float with no void or no open area. As can be appreciated, the greater the number of float members 20 in a single float 14, the greater the buoyancy of the float 14. Other float configurations are shown in FIGS. 4C-4I. For example, as shown in FIG. 4D, a single float can be formed from different sized float members Further, although all the float members are shown to be rectangular, the float members could be square. Additionally, the floats need not be square or rectangular (oblong). The float members could, for example, be trapezoidal, triangular, or any other desired regular or irregular polygonal shape. Preferably, the float members have at least one flat edge or wall to allow for connection of the float member to at least one other float member along aligned adjacent flat edges or walls. The additional float member shapes would allow even greater flexibility in forming dock systems of desired configurations.

The float members 20 can be connected together in different manners. For example, the float members can be connected together such that the float members 20c (which form the elongate side of the float) are connected to the end faces of the float members 20a. This would form a float that is wider (such a float would be about 10½′ wide using the dimensions noted above). For example, FIGS. 4C and 4D). Additionally, the float members 20 can be connected together to form a float that is not rectangular (or even quadrilateral). For example, the float members could be connected together for form an L-shaped or U-shaped float.

Turning to FIGS. 5A-C, each float member 20 has a top surface 24, a bottom surface 26, opposed side surfaces 28 and opposed end surfaces 30. The top surface 24 of the float members can be flat, as shown in FIGS. 4C-4E, and 4G-4I). Alternatively, dips or depressions 32 can be formed in the top surface 24 of the float member. The depressions 32 are shown to be concave and to be arcuate. In the dock member 12, the depressions define passages 34 (FIGS. 2A and 2B) in both the ends and sides of the dock module 12 through which utility-carrying conduits can pass. Thus, water pipes, gas pipes, and electrical conduit can be passed through the openings 34 to provide access to utilities at desired areas in a completed dock system 10.

The float member 20 further includes a plurality of upper and lower sockets 36a,b, each pair of upper and lower sockets connected by a channel 38. The sockets essentially define an oval, with an opening to an end or side wall of the float member. The sockets 36a,b are sized and shaped to receive the upper and lower connectors 22. To this end, the sockets 36a,b each include an enlarged sections 37a which opens to the end or side surface via a narrower neck portion 37b. The channels 38 extend along the end and side surfaces between the neck portions 37b of a pair of upper and lower sockets. The channel 38 receives a rod which extends between, and connects, the upper and lower connectors. In fact, the channels 38 of adjacent float members are aligned to form a passageway through which the bolt or tie rod of the coupler extends. The upper and lower connectors, as shown in U.S. Pat. No. 5,281,055 are generally dumbbell or dog-bone shaped. As can be seen, the connectors and the sockets are shaped complementarily to each other, and the respective shapes of the connector and socket will prevent two connected float members from separating. As can be appreciated, the shape of the connector can be changed, or other types of couplers can be used. For example, the coupler can be one such as shown and described in U.S. Pat. No. 7,243,608, U.S. application Ser. No. 13/932,911 filed Jul. 1, 2013, or U.S. Pub. No. 2013/0152844, all of which are incorporated herein by reference. The use of differently shaped couplers would require alterations in the configuration of the sockets 36a,b.

The decking support 18 rests on, and is secured to, the float 12. The decking support 18 comprises a peripheral frame 40 defined by frame members 42, there being one frame member 42 positioned along each upper outer edge of the float 12. A plurality of spaced apart, generally parallel, trusses 44 extend across one dimension (illustratively the width) of the float 12 and a plurality of spaced apart, generally parallel, braces 46 extend perpendicularly to the trusses (and illustratively extend the length of the float 12). The braces and trusses are illustratively shown to be formed from square stock, but could be formed from stock of any desired shape. Corner members 48 are positioned at the corners of the float 14 where the frame members join together. Additionally, rub rails 50 extend the length of the walls of the float 12 between the corner members. The corner members and rub rails substantially hide the outer surface of the frame member 42.

The frame member 42 is shown in greater detail in FIGS. 8-10. The frame member 42 is preferably formed by an extrusion process, and can be formed from a metal, a plastic, a composite, or any other desired material. The frame member 42 comprises a body 52 having an upper surface 54, a bottom surface 56, an inner surface 58, and an outer surface 60. The upper surface 54 and the outer surface 60 are shown to be textured. The frame member body 52 is shown to be hollow, but could be solid if desired. The corner between the bottom surface 56 and the inner surface 58 is shown to be chamfered. As seen in FIGS. 6 and 7, the bottom surface 56 of the frame member body sits on the upper surface 24 of the float member 20. A lower generally horizontal flange 62 extends inwardly (and generally perpendicularly) from the inner surface 58. The lower surface of the lower flange is spaced above the bottom surface 56 a distance slightly greater than the height of the support truss 44. An upper generally horizontal flange 64 extends inwardly (and generally perpendicularly) from the inner surface 58 above the lower flange 62. The upper flange 64 is shown to be generally parallel to, and longer than, the lower flange 62. The distance between the upper surface of the upper flange 64 and the lower surface of the lower flange 62 is equal to, or slightly greater than, the height of the brace 46. As seen in FIG. 7, the edge of the decking 16 sits on the upper flange 64. The flanges 62 and 64 both extend the length of the frame member 42, but could be defined by a plurality discrete flange portions.

An L-shaped flange or spacer 66 extends along the inner surface 58 of the body at the top of the frame member body 52. This flange 66 has a generally horizontal portion 66a and a generally vertical portion 66b. The generally horizontal portion 66a of the flange 66 is essentially a continuation of the body top surface 54. The generally vertical portion 66b extends downwardly spaced from the body inner surface 58. The flange 66 thus defines a downwardly opening channel 68.

A top channel 70 is formed in the body upper surface 54. This top channel 70 comprises a main portion 70a, which is shown to be generally rectangular, and a smaller access portion 70b. Thus, the channel 70 has the general shape of an upside down T.

An upper side channel 72 is formed in the outer surface 60 of the body. This outer channel is also generally T-shaped, having a stem portion 72a extending inwardly from the surface to a main portion 72b. The stem portion 72a of the channel 72 is shown to be relatively wide (that is, the stem portion has a height greater than 50% of the overall height of the channel 72.

A lower, generally vertical, flange 74 extends downwardly from the bottom of the frame member body. The junction between the flange 74 and the lower surface 56 of the frame member body is generally concavely curved to define a smooth transition between the flower flange 74 and the body bottom surface 56. As seen, the lower flange is a continuation of the body outer surface 60. A spacer 76 extends inwardly slightly above the bottom of the flange 74. The spacer 76 is below, and generally parallel to, the body bottom surface 56. A generally J-shaped portion 78 extends from the end of the spacer 76. The J-shaped portion 78 comprises a back stem 78a, a bottom 78b, and a front 78c. The bottom 78b of the J-shaped portion 78 is below and generally parallel to the spacer 76. The front 78c extends upwardly from the bottom 78b towards the flange 74. The front 78c of the J-shaped portion is co-planar with the flange 74. The upper surface of the front 78c is spaced from the bottom surface of the flange 74. Thus, as seen, the J-shaped portion 78, the spacer 76 and the flange 74, in combination, define a lower side channel 80. This lower channel 80 opens outwardly (i.e., in the same direction as the upper channel 72) and is generally T-shaped like the channels 72 and 70. Finally, the portion of the stem 78a of the J-shaped portion which extends above the spacer 76, in combination with the spacer 76 and the flange 74, defines an upwardly opening back channel 82.

As noted above, the decking support 18 comprises the frame members 42, the trusses 44, and the braces 46. As seen in FIGS. 6 and 7, the bottom surface 56 of the frame member body 56 rests on the upper surface 24 of the float member 20, with the flange 74 extending along the outer surface 28 of the float member. The frame member 42 has a length substantially equal to the length of the edge of the float 12 on which the frame member is placed. More particularly, the frame member 42 has a length substantially equal to the length of the edge along which it is placed. Depending on the dock system configuration, this could be a full length edge of a float 14, or a portion of an edge of a float 14. The frame members can be formed with mitered ends, and are secured together, such as by welding, to form a frame. As seen in FIG. 3A, the frame surrounds the float 12. The trusses 44 extend across the width of the float 12, and as shown, rest on the upper surface 24 of the float member 20. As seen, the ends of the trusses are positioned between the upper surface 24 of the float member 20 and the flange 62 of the frame member. The opposite ends of the trusses are essentially in contact with (or abut) the inner surface 58 of the frame member body. The trusses each have a length, such that when the trusses abut the frame member body, the J-portion 78 is spaced slightly from the wall of the float member 20. The braces 46 are shown to be generally perpendicular to, and lie across, the trusses 44 and extend the length of the float 12. Corner braces 84 extend diagonally between adjacent frame members 42 proximate the ends of the frame members. These corner braces are co-planar with the braces 46, and, as seen in FIG. 3, the braces at the opposite ends of the float 12 extend between the corner braces 84. The illustrative embodiment shows the trusses 44 extending the width of the float, and the braces 46 extending the length of the float. This can be switched if desired.

The braces 46, as best seen in FIG. 7 have a height such that the top of the brace 46 will be generally level with the top of the frame member flange 64. The braces 46 extend a dimension (e.g., the length) of the float 12, and their opposite ends are essentially in contact with (or abut) the edge of the upper flange 64 of the frame member. As noted above, the upper flange 64 of the frame member is longer than the lower flange 62, hence, the braces 46 do not contact the lower flange 62. The braces 46 have a length such that when the braces abut the frame member flange 64, the J-portion 78 is spaced slightly from the wall of the float member 20.

The elements of the decking support 18 (i.e., the frame members 42, the trusses 46 and the braces 48) are fixed together in any convenient manner, such as by welding, riveting, etc. Alternatively, the braces and trusses can be configured to interlock with each other. As seen in FIG. 3A, the braces and trusses form a grid like pattern. As noted above, the float members 20 could have a shape other than as a square or oblong rectangle. Depending on the configuration/shape of the float members 20, the braces 46 and trusses 44 could be oriented relative to each other at other than right angles. This would affect the shape of the grid-like pattern defined by the trusses and braces in the decking support 18.

As seen in FIG. 7, the decking 16 lies over the braces 46. Additionally, the edge of the decking is supported by the upper flange 64 of the frame member 42. Further, the edge of the decking engages the L-shaped flange/spacer 66. The decking can be comprised of decking sections which are secured to the braces 46 by any acceptable means. Preferably, the sections of the decking 16 are secured by means (such as bolts or threaded fasteners) which allow for sections of the decking to be removed and replaced when marred or warn. If the decking sections are plank-like (such as shown in FIGS. 11A and 11B), the plank-like sections of the decking extend generally perpendicularly to the braces 46, and thus, in the drawings, extend between the “side” float members 20c, with the ends of the plank-like sections abutting, or being in close proximity to, the flange 66 of the frame member 42. The plank-like sections can extend the full width of the float, or can be made of shorter portions which either abut or overlap each other.

Examples of the decking sections are shown in FIGS. 11A-C. FIG. 11A shows a decking section for a flow through decking. This flow through decking allows for light and air to pass through the decking surface. As seen, the decking section includes decking having a plurality of perforations, holes, etc. End and side walls depend from the decking section, and the side walls have alternating plug-like projections, and the plug-like projections from one decking section engage or interfit with the plug-like projections from an adjacent decking section to thus prevent adjacent decking sections from moving laterally relative to each other. The flow through decking section can be made from metal, plastic, a composite, or any other desired material. FIG. 11B shows a decking section having the appearance of wood. As seen, the wood-like decking section has the shape and appearance of a wood plank. This section can be made of wood, a wood-plastic composite, a resin, or any other desired material. FIG. 11C is a plan view of four decking sections designed to give the decking a concrete-like appearance. As seen, these sections are formed as squares and rectangles. The sections could have any other desired shape. These sections can also be made from a resin, a composite, or any other desired material. With currently available materials, the decking 16 can be formed from a variety of materials, and can be made to have any other desired appearance.

The decking support 18 is secured to the float by means of a plurality of strap assemblies 90. The strap assemblies 90 (shown best in FIG. 12) include a strap 92 with an upper hook member 94 secured at a top end of the strap 92 and a lower hook member 96 secured to a bottom end of the strap. The strap 92 can be flexible. The upper hook member 94 is generally in the shape of an inverted J, and includes a stem portion 94a, a top surface 94b extending from a top of the stem portion, and a forward portion 94c extending downwardly from the top surface generally parallel to the stem portion. As seen in FIG. 6, the upper hook member is sized and shaped to fit over the upper end of the stem 78a of the J-shaped portion 78 of the frame member 42, such that the hook portion 94c is received in the frame member channel 82. The bottom hook member 96 has a main plate 96a and an attachment section 96b which is generally perpendicular to the main plate 96a. The main plate 96a sized and shaped to be received in a connector socket 36a, as shown in FIG. 2C. Hence, as seen in FIG. 6, the lower hook main plate 96a is received in a main portion 37a of the lower connector socket 36b of the float member, and the attachment portion 96b extends through the connector socket neck portion 37b from the connector socket to extend upwardly along the wall of the float member. As seen in FIG. 12, the main plate of the lower hook member 96 faces the opposite direction of the hook of the upper hook member 94. The strap 92 can be secured to the hook members in any conventional manner. In the illustrative embodiment, the hook members each define a slot through which the strap extends. The strap is then folded back and fastened to itself. The strap is sized so that it is taut when the lower hook member is received in the lower connector socket 36b and the upper hook member engages the channel 82 of the frame member 42. The strap can be made from a material that has at least some elasticity, and will withstand the elements to which it will be exposed. For example, the strap can be a rubber strap. Hence, during positioning of the strap assembly 90, an elastic strap will stretch, and once the strap assembly is in place, the elastic strap 92 will be in a slightly stretched condition. Alternatively, the strap can be, for example, an aluminum strap, and the strap can be tightened using a mechanical tensioning device. The strap assembly will prevent the decking support 18, and hence the decking 16, from lifting off the float 14.

As seen in FIGS. 3A and 3B, there are a plurality of strap assemblies 90 positioned around the exterior of the float. In addition, the dock module 12 can include one or more interiorly positioned strap assemblies 90 (i.e., in the void area 20d). To position the strap assemblies 90 interiorly of the float 12, upwardly opening U-channels 98 are secured to and extend between adjacent trusses 46 or braces 44. The U-channels 98 are positioned to be opposite “interior” connector sockets (i.e., connector sockets that open in to the interior 20d of the float 12), as seen in FIG. 3. The interiorly placed strap assemblies 90 have the lower hook member engaged with the lower connector socket 36b, and the upper hook assembly engaged with the U-channel 98.

The exterior of the frame members 42 is covered with the rub rail 50, and the corners where adjacent frame members are connected or joined are covered with corner members 48. Turning to FIG. 13A, the corner member 48 comprises a pair of walls 100a,b which are connected together along a vertical edge to define a generally right angle. A top or cover 102 extends between the walls 100a,b. The cover has a curved or radiused edge 102a. The walls 100a,b have a height slightly greater than the height of the frame member 42. Thus, when the corner member 48 is positioned at a corner junction of the frame members, the bottom edges of the corner member walls are below the bottom of the J-shaped member 78 of the at frame member 42. Depressions 104 are formed in the top or cover 102 at the edge 102a. The depressions 104 open outwardly to the edge 102a, and are positioned to be aligned with the top surface 54 of the frame member 42, as seen in FIG. 7. A bolt hole is formed in the depression 104 which, when the corner member is positioned on the frame 40, is aligned with (and opens into) the channel 70 in the top surface 54 of the frame member 42. In addition, depressions 106 are formed in the walls 102a,b. The depressions 106 also include bolt holes which extend through the floor of the depression. The depressions 106 open outwardly to the edge of the walls 102a,b and are positioned such that their bolt holes are aligned with the channel 80 at the bottom of the frame member flange 74. The corner member 48 is secured to the frame member 42 by means of bolts 108 which extend through the respective bolt hole of the depression 104, 106 into the respective frame member channel 70, 80. As seen, the bolts have a head 108a and a threaded shaft 108b. As best seen in FIG. 13B, the bolt head is shown to be an elongate hexagon having a width sized to allow the head 108b to pass into the channel 70, 80, and a length greater than the overall width of the channel 70,80. The threaded shaft 108b has a length such that it will pass through the channel 70, 80 and through the bolt hole of the respective depression 104, 106 to receive a nut 110. When the nut 110 is tightened on the bolt shaft 108b, the bolt head 108a will rotate to engage the side walls of the channel 70,80. At this point, the bolt head will no longer be aligned with the entrance to the channel, and cannot be lifted pulled from the channel. As can be appreciated, the top 104 and sides 102a,b of the corner member 48 become sandwiched between the bolt head 108a and the nut 110, and thus will not inadvertently come off. The exposed portion of the bolt shaft 108b and the nut 110 can be covered, for example, with a nutcap.

The rub rail 50 (FIGS. 6 and 7) has a body 120 which, is shown to be generally rectangular. The body has an outer surface, an inner surface, a top surface and a bottom surface. The junction between the outer surface and the top and bottom surfaces is shown to be curved to avoid sharp corners. A generally T-shaped mounting flange 122 extends from the inner surface of the rub rail body 120. This mounting flange 122 is shaped complementarily to the upper channel 72 of the frame member 42, and the rub rail is secured to the frame member by sliding the flange 122 into the frame member channel 72. The mounting flange 122 is positioned on the rub rail body 120 at a position such that the top of the rub rail is generally flush or level with the top of the frame member 42, as seen in FIG. 6. The rub rail body 120 is shown to be hollow with a plurality of internal truss members which provide structural rigidity to the rub rail. However, if desired, the rub rail could be solid. The rub rail can be formed from a metal, a resin, resin composite, or any other desired material. The rub rail can be formed via an extrusion process, or any other desired manufacturing process.

Turning to FIGS. 14-18, a plurality of dock modules 12 can be connected together to form a dock assembly or system 10. FIG. 14 shows two dock modules 12a and 12b connected together in tandem. However, it will be appreciated that a dock system can be comprised of many more than two dock modules connected in tandem. That is, the dock modules can be used to form a pier or walk way that comprises two, three or more dock modules connected in tandem. Additionally, dock modules can be connected such that some dock modules are perpendicular to others, such as a marina where there is a walkway from which a plurality of piers extends. In this instance, these piers can define boat slips. Additionally, the dock modules can be connected to be parallel to each other, to form a walkway, pier, dock area, etc. that has a width of two or more dock modules.

Adjacent dock modules are connected by joining the floats 14a,b of adjacent dock modules 12a,b and joining the decking supports 18 of the adjacent dock modules. As best seen in FIG. 15, the frame members 42 of the decking support 18 are omitted at the juncture between the adjacent dock modules. Thus, the frame member 42 (and the rub rail 80) extend the length of the edges of the float 12 which define edges of the dock system 10. To facilitate connection of the decking supports 18 of adjacent dock modules, the decking support is provided with a second truss 44 extending the width of the dock module at the end of the dock module. If dock modules were connected in parallel, rather than in tandem, then the decking support would be provided with a second brace 46 along the side edge of the dock module.

Turning to FIG. 16, the floats 14a and 14b of the dock modules 12a and 12b, respectively, can be connected together with the same couplers 22 which connect the float members 20 of the two modules. However, the couplers 22 may not be sufficiently flexible, and thus, the connection between the dock modules would be fairly rigid. In this instance, adjacent dock modules would not be able to move relative to each other, in response to, for example, wave action, forces on the dock system from the docking of boats, or activity on the decking, etc. Hence the floats of adjacent dock modules are preferably connected with the coupler 150, which is shown in more detail in FIG. 17. The coupler 150 comprises an upper connector 152a, a lower connector 152b, and two rods 154 extending between, and connecting the upper and lower connectors. The upper and lower connectors are identical. The upper and lower connectors 152a,b each comprise opposed enlarged ends 156 that are sized and shaped complementarily to the size and shape of the connector sockets 36a,b. A neck 158 extends from each of the enlarged ends. The neck 158 is sized and shaped to extend through the neck potion 37b of the connector socket. Bolt holes are formed in the necks 158 to receive the rods 154. The necks 158 of the two ends 156 are joined by a center section 160. The center section is shown to be generally “0” shaped. That is, it is annular with a generally overall oval shape. As seen in FIG. 16, connected dock modules are spaced apart a distance equal to the length of the center section 150. The bolt holes in the necks 158 are positioned such that the tie rods 154 will be received in the rod channels 38 of the connector sockets of the adjacent floats 14a,b, as seen for example in FIG. 18B.

The upper and lower connectors 152a,b are made from a material which will allow the upper and lower connectors to withstand torsional, tensile and compressive forces. For example, they can be made from a rubber or a thermosetting resin. To increase the tensile strength of the connectors, a fiber, such as a nylon fiber, a carbon fiber, or a glass fiber, for example, can be included in the material from which the connectors are made. The ability of the connectors 152a,b to withstand torsional forces will allow the center section will flex or bend slightly, and hence, allow the two adjacent dock sections to pivot slightly relative to each other (for example, from wave action). The ability to withstand tensile stresses will better enable the connectors to withstand forces, for example from storms) which might try to separate adjacent dock modules. Finally, the ability to withstand compressive forces will allow the dock system 10 to absorb impacts, for example, from docking boats. The coupler 150 is designed to be a sacrificial coupler, and will break if compressive, torsional or tensile loads exceeds loads predetermined amounts, namely, the ultimate compressive, torsional and tensile strength of the float members 20 which form the floats 14 (and thus the dock modules 12). Thus, for example, is the dock system is subject to tensile forces which exceed the tensile strength of the float member 20, the coupler will break, and it will break at the center section 160. Similarly, if the compressive or torsional forces to which the dock system (and hence the coupler) is exposed exceeds the compressive or torsional strength of the float module, the coupler will break, and it will break at the center section.

Turning to FIGS. 18A and B, the decking support 18 of the dock modules are provided with a double truss 162 at the end of the decking support where the two dock modules are connected. This double truss is comprised of a pair of trusses 44a,b extending between side frame members 42. As seen, the outermost truss 44b actually is beyond the end wall of the float module. The two double trusses 162 of the two adjacent modules are connected together by means of a shaft 164 (such as a bolt) which extends all the way through the two double trusses. A central rubber bushing 166a is mounted on the shaft 164 between the two double trusses of the two dock modules, and rubber bushings 166b are positioned at the opposite ends of the shaft 164, such that each double truss is positioned between an end bushing 166b and a center bushing 166a. The bushings (and in particular the center bushing 166a) maintain a spacing between the decking supports 18 of adjacent dock modules and reduce the transmission of impact forces between dock modules that may be caused by motion of one dock module relative to an adjacent dock module.

As can be seen in the drawings, there is as small gap between adjacent dock modules. However, this gap will be closed on the tread surface (i.e., decking) by the decking itself or by a piece of decking filler, which will fill in the gap.

The dock module 12, as described above, can be easily constructed, and the formed dock modules can be easily formed into a dock system. The dock module provides for a large degree of freedom and latitude in designing dock systems. Further, the various components of the dock module can be replaced fairly easily should they become marred or damaged without the need to disassembly the complete dock system or even the individual dock module.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. For example, although the dock modules are shown to be formed from float members that are all identical in shape and size, the dock module could be formed from float members of two or more sizes to facilitate forming wider and/or longer dock modules, or even dock modules that have a shape other than quadrilateral. If different couplers 22, 150 are used to connect float members and dock modules, the float members may need separate upper and lower receptacles for the hook members of the strap assemblies 90 which hold the deck support 18 to the float 12. The strap assembly 90 could be formed in other ways. For example, the upper member 94a could include a projection which would then be received in an opening in the frame member 42, or a slot in the U-channel 98. A similar projection could be formed in the lower member 94b which would be received in a slot (such as a T-slot) in the float member 14. The strap 92 need not be elastic. However, in this instance, there would preferably be some type of tightening mechanism, to tighten the strap 92. Although the float members 20 are shown to be connected by couplers 22 to for the float assembly 14, float members 20 could be connected using the coupler 150 (FIG. 17). These examples are merely illustrative.

Claims

1. A dock module for a dock system, the dock module comprising:

a buoyant float comprised of a plurality of buoyant float members; each float member comprising an upper surface, a bottom surface and at least one wall surface; at least one connector socket formed in said at least one wall;

a decking support comprised of a frame comprised of frame members, at least one first cross member extending across one dimension of said float, and at least one second cross member extending across a second dimension of said float;

decking mounted to the decking support to form a tread surface for the dock module; and

a decking support connector extending between the decking support and the float to secure the decking support to the float.

2. The dock module of claim 1 wherein the decking support connector comprises a strap assembly, the strap assembly comprising an upper member, a lower member, and a strap extending between the upper and lower members; the upper and lower members each comprising an attachment member shaped, sized, and adapted to be received in a receptacle in the decking support and float member, respectively.

3. The dock module of claim 2 wherein said strap is elastic.

4. The dock module of claim 2 wherein said frame of said decking support comprise an upwardly opening channel; said attachment member of said strap assembly upper member comprising a hook portion sized and shaped to engage said channel of said frame member.

5. The dock module of claim 2 wherein said attachment member of said strap assembly lower member comprises a plate having a main portion and a neck portion; said float comprising a receptacle on a bottom surface of said float member; said receptacle having a first portion and a neck portion extending from said first portion to said wall of said float; said lower member plate and said float member receptacle being shaped complementarily to each other.

6. The dock module of claim 1 wherein said frame member comprises a frame body having an upper surface, a lower surface, an outer surface, and an inner surface; said frame member lower surface being supported by said upper surface of said float member.

7. The dock module of claim 6 wherein said frame member comprises a flange extending inwardly from said inner surface of the frame member body; said flange being spaced above the lower surface of said body; said first cross member being positioned between said flange and said upper surface of said float; said second cross member being positioned on top of said first cross member.

8. The dock module of claim 6 wherein said frame member comprises a decking support flange extending inwardly from said frame inner surface below said frame member upper surface; said decking resting on one of said first and second cross members and having an edge resting on said decking support flange of said frame member.

9. The dock module of claim 8 wherein said decking support flange is spaced from said upper surface of said frame member body a distance substantially equal to the height of said decking, such that a top surface of said decking will be generally level with the top surface of said frame member.

10. A dock system comprised of a plurality of interconnected dock modules; adjacent dock modules of said dock system being connected together by at least one coupler; each said dock module having a connector receptacle; the connector receptacles of adjacent dock modules being aligned with each other; said coupler comprising a connector having a first end and a second end; said first and second ends being shaped complementarily to said dock module receptacles to be received in said receptacles; said connector further including a middle portion extending between said first and second ends of said connector; said middle portion of said connector being capable of withstanding torsional, tensile and compressive forces.

11. The dock system of claim 10 wherein said connector includes a first neck portion extending between said first end and said middle portion and a second neck portion extending between said second end and said middle portion; said middle portion being enlarged relative to said neck portions; said adjacent dock modules being separated from each other a distance at least the length of said connector middle portion.

12. The dock system of claim 10 wherein said connector middle portion defines a hollow.

13. The dock system of claim 12 wherein the middle portion of the connector is generally annular.

14. The dock system of claim 10 wherein each connector is an upper connector member; said coupler further comprising a lower connector member, and two tie rods extending between said upper and lower connector members; said tie rods being positioned between the middle portion and the opposite end portions of each connector member.

15. The dock system of claim 14 wherein said dock modules each include a channel in a wall thereof; said tie rods being positioned on said connector members to be received in said channel.

16. The dock system of claim 10 wherein each said module of said dock system comprises a float, a decking support secured to said float, and a decking secured to said decking support; wherein the decking supports of adjacent dock modules are secured together.

17. The dock system of claim 16 wherein said decking support of said dock modules comprises an edge cross-member positioned at an edge of each said dock module; the edge cross-members of adjacent dock modules being joined together by at least one fastener.

18. The dock system of claim 16 wherein said dock system includes a resilient bushing on said fastener positioned between the edge cross-members of the adjacent dock modules.

19. The dock system of claim 18 including outer bushings at opposite ends of said fastener.

20. A coupler for joining dock modules of a dock system said coupler comprising a connector having a first end, a second end, and a middle portion; said middle portion being flexible, compressible, and tensionable.

21. The coupler of claim 20 wherein said connector includes a first neck portion extending between said first end and said middle portion and a second neck portion extending between said second end and said middle portion; said middle portion being enlarged relative to said neck portions.

22. The coupler of claim 21 wherein said connector middle portion defines a hollow.

23. The coupler of claim 22 wherein the middle portion of the connector is generally annular.

24. The coupler of claim 20 wherein said connector is a first connector; said coupler further including a second connector and two tie rods extending between said first and second connectors; said tie rods being positioned between said end portions and said middle portion.

25. The coupler of claim 24 wherein said second connector is substantially identical to said first connector.

26. The coupler of claim 20 wherein said connector is comprised of a material that includes fibers.

27. The coupler of claim 26 wherein said fibers are glass fibers, plastic fibers, or carbon fibers.