Abstract:
A dock connector for the connection of dock members with receiving sockets, includes a pair of end members configured to be received in respective receiving sockets of the dock member. Each end member has a pliable expansion member at a bottom thereof adapted for movement between a contracted/relaxed position and an expanded position. The end members are connected by a brace. A wedge is operatively mounted to the end member for axial translational motion relative to the end member. The wedge operates as an actuator to move said expansion member from its relaxed position to its expanded position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not applicable. 
       BACKGROUND 
       [0003]    This application relates to a floating dock system comprised of dock members, such as drive-on watercraft lifts, floating dock segments, and the like, and, in particular, to a connector for assembling floating docks from the dock members. 
         [0004]    Floating dock systems are made from selected dock members (such as rectilinear sections, watercraft lifts, ramps, etc.) which are assembled together by connectors. The rectilinear sections can be used to form deck areas, piers and the like; the watercraft lifts and ramps can be connected to the formed deck areas, piers, etc. Over the years, many different types of connectors have been developed and used. Some require the connector, or a portion of the connector, be installed from below the dock section. It would be desirable to provide a connector which is easy to install and to replace. 
       SUMMARY 
       [0005]    A dock connector is disclosed which comprises at least one end member having a side surface, an upper surface, a bottom, and a brace extending from the side surface of the end member. An expansion member defining a downwardly opening chamber is at a bottom of the end member is adapted for movement between a contracted position and an expanded position. A fastener extends through the one end member from the upper end of the end member through the expansion member. The fastener is threaded at least at a bottom end thereof. A wedge is threadably received on the fastener to be movable by rotation of the fastener between a lowered position in which the expansion member is in the contracted position and a raised position in which the wedge engages the expansion member to urge the expansion member to its expanded position. 
         [0006]    In accordance with an aspect of the connector, the dock connector can include at least one cap attached to the body. The cap can be formed from a different material than the body. The cap can include one of a groove or rib on a lower surface thereof which is slidably received over a rib or a groove, respectively formed on the upper surface of the connector body. The rib and groove are complementarily shaped to each other to permit horizontal motion of the cap relative to the body, but to prevent substantial vertical movement of the cap relative to the body. 
         [0007]    A tool can be provided which is configured for engagement of the at least one cap to facilitate removal of the dock connector from a dock member in which the connector is placed. 
         [0008]    In accordance with an aspect of the dock connector, the end member is generally frustoconically shaped. 
         [0009]    In accordance with an aspect of the dock connector, the wedge comprises at least one anti-rotation tang and the expansion member defines at least one slot configured for receipt of the at least one tang. 
         [0010]    In accordance with an aspect of the dock connector, the connector includes two end member; the end members being positioned on opposite ends of the brace. 
         [0011]    In accordance with an aspect of the dock connector, the body is formed of a material which enables the connector brace to flex about an axis generally parallel to axes of the end members. The brace can, for example, be formed from a rubber, and the rubber can, for example, have a durometer of between about 60 and about 90. 
         [0012]    The dock member in which the connector is received, includes an upper surface, a lower surface, a side surface between the upper and lower surfaces, and at least one receiving socket proximate the side surface. The socket extends downwardly from the upper surface and comprises an upper portion and a lower portion connected at a juncture. The socket lower portion has a dimension, at least in part, greater than a corresponding dimension of the juncture. A channel extends from the socket to the side surface. The socket is sized and shaped to receive the connector end member, and the channel is sized and shaped to receive the connector brace. The upper and lower portions of the receiving socket define a pair of generally truncated cones connected at their frustums. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0013]    In the accompanying drawings which form part of the specification: 
           [0014]      FIG. 1  is a perspective view of a pair of dock members connected to form a dock assembly; 
           [0015]      FIG. 1A  is an end perspective view of a dock member with a connector in a receiving socket of the dock member; 
           [0016]      FIG. 2  is a perspective view of a dock connector configured to connect the dock members, the dock connector being illustratively shown with one end in a position to be inserted into a receiving socket of a dock member and the other end in a “locking” position; 
           [0017]      FIG. 3  is a front elevational view of the dock connector; 
           [0018]      FIG. 4  is a side elevational view of the dock connector, taken from the left side of  FIG. 3 ; 
           [0019]      FIG. 5  is a sectional view of the dock connector taken along line A-A of  FIG. 2 ; 
           [0020]      FIG. 6  is a perspective partially exploded view of the dock connector showing the connection of a cap to the body of the connector; 
           [0021]      FIG. 7  is a top plan view of the dock connector; 
           [0022]      FIG. 8  is a partial sectional view of the dock connector received in the sockets of two adjacent dock members to connect the dock members; 
           [0023]      FIG. 9  of a bottom view of the dock connector; 
           [0024]      FIG. 10  is a partial perspective view of a tool engaged with the connector; and 
           [0025]      FIG. 11  is a partial perspective view of the connector coupled with a dock member and a tool engaged with the connector. 
       
    
    
       [0026]    Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings. 
       DETAILED DESCRIPTION 
       [0027]    The following detailed description illustrates the claimed invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the claimed invention, describes several embodiments, adaptations, variations, alternatives, and uses of the claimed invention, including what is presently believed 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. 
         [0028]    As shown in  FIGS. 1-9 , a connector  10  is provided for assembling a dock system  12  from a plurality of docking members  14  without the need for access to the bottom of the dock members. The dock system  12  includes a plurality of docking members  14 , which can be generally similar to the dock members disclosed in U.S. Pat. Nos. 5,281,055 or 7,069,872, both of which are hereby incorporated by reference. Each generally rectangular docking member  14  is a generally hollow or foam filled self-floating one-piece molded construction that includes a generally level top surface  16 , side walls  18 , and a bottom surface  20 . The docking members  14  can be constructed of any suitable material, such as a plastic, but any suitable material can be used. In alternate embodiments, the dock system  12  can include any number of docking members  14  of any desired shape and size. 
         [0029]    Each docking member  14  defines a plurality of receiving sockets  22  configured to receive the connectors  10  for securing of the docking members  14  together to form the dock system  12 . Generally, the receiving sockets  22  are located along the side walls  18  proximate the edges of the top surface  16  of the docking member  14  so that when docking members  14  are positioned adjacent each other, the respective receiving sockets  22  are aligned with each other. As shown in  FIGS. 1 ,  1 A and  8 , each receiving socket  22  is illustratively shown to be generally shaped as a pair of truncated cones connected at their frustums and defines openings  24  and  26  in the top surface  16  and bottom surface  20 , respectively of the member  14 . In other words, the receiving socket  22  includes a generally conical-frustum upper portion  28  extending downwardly from the opening  24  in the top surface  16  to connect with a generally conical-frustum lower portion  30  extending upwardly from the opening  26  of the bottom surface  20 . The upper portion  28  and lower portion  30  meet at a junction  31  having a diameter (or defining a cross-sectional area) that is smaller than the diameter (or cross-sectional area) of the lower portion  30 . Although the receiving sockets  22  are shown to extend between the top surface  16  and bottom surface  20  of the dock member, so as to be opened at both the top and bottom surfaces, the sockets  22  could be closed at the bottom of the dock member without affecting the operability of the connector. The opening  24  of the top surface  16  defines a countersink  32  and a tapered portion  34  below the countersink  32 . As seen in  FIG. 1A , the countersink  32  opens to the side surface  18  of the dock member. The bottom portion  30  includes a lower cylindrical portion which then leads into the frustoconical portion. A channel  36  extends from the socket  22  to the side wall  18 . The channel  36  is shown to be defined by side walls which taper inwardly toward each other from both the top and bottom to define a point of smallest width. The taper of the channel  36  generally follows the taper of the socket upper and lower portions. Although shown to be tapered, the channel  36  could be defined by generally straight or vertical side walls. 
         [0030]    The connector  10  includes a body  38  shaped and configured to be received in the receiving sockets  22  and channels  36  defined in the docking members  14 . ( FIGS. 2-4 ). To this end, the connector body  38  is shaped generally complimentarily to the dock member socket  22  and channel  36 . The body  10  includes a pair of elongate end members  40 , sometimes referred to as molly-type fasteners, attached together via a brace  42 . The body  38  is preferably made from a rubber which is selected to enable the body to flex at least about an axis extending vertically through the brace  42 . 
         [0031]    A pair of caps  44  is mounted to the top of the body  38  and are sized and shaped to seat within respective countersinks  32  to sit flush with the top surface  16  of the docking members  14 . As such, the top surfaces of the caps  44  form part of the tread or wear surface of the dock assembly. Each cap  44  is generally heel-shaped and defines a bore  46  and an annular countersink  48  sized to receive a fastener  50 , such as bolt. ( FIG. 5 ). The cap  44  is preferably formed from a plastic and is molded to correspond generally to the color and texture of the upper surface  16  of the member  14 . The bottom surface  62  of the cap  44  defines a groove  64  ( FIG. 6 ) shaped and sized to receive a tongue (or rib)  66  formed on the upper surface of the connector body  38 . The groove  64  and tongue  66  are shaped complimentarily to each other, and are shaped such that the cap  44  can slide laterally onto the tongue  66 , but so that the cap cannot be lifted vertically off the connector body  38 . Although the tongue and groove are shown to be generally T-shaped, the tongue and groove could have any desired shape which would prevent the cap from being lifted vertically from the connector body. This slidable connection of the caps to the connector body allows for the caps to be removed and replaced should they be worn out, broken, or otherwise need replacement. Further, it allows for the cap and body to be made from different materials. Other means (such as a snap connection or a friction fit connection) can also be used to removably connect the caps to the body. A removable connection of the caps  44  to the body  38  is preferred. However, the caps  44  can be connected to the connector body  38  fixed to the body, such as by welding, adhesive, etc. Alternatively, the caps  44  can be combined with the connector body  38  into a unitary member. Further, the connector  10  is shown as provided with two caps  44 . The two caps could be formed as a single cap which is then secured to the connector body  38 . 
         [0032]    As shown in  FIGS. 2-5 , the connector body  38  is configured to be received in a pair of aligned receiving sockets  22  of adjacent docking members  14 . The connector body  38  defines a pair of end members  40  connected by the brace  42 . Each end member  40  is shaped complimentarily to the receiving sockets  22 , and is thus illustratively shown to be generally frustoconically shaped. The end members  40  have a length sufficient to extend at least through the junction  31  of the dock member socket  22  into the lower portion  30  of the socket  22 . The end members  40  each have an enlarged tapered portion  72  at their upper end which generally corresponds with the shape and size of the upper tapered portion  34  of the receiving sockets  22 . Each end member  40  defines a generally cylindrical bolt hole  74  which is coaxial with and aligned with the bore  56  of the cap  44 . The brace  42  is a panel that extends almost the entire length of the end members  40 . The brace is generally rectangular is side elevation. As seen in  FIGS. 6 and 9 , the brace  42  has a width less than the diameter of the end members  40 , and is sized to pass through the socket channel  36 . Additionally, the brace tapers from top to bottom, such that it is narrower in width at its bottom than at its top. The brace  42  defines sections of removed material, such as through slots  70  and reduced width areas  71 , to reduce the amount of material needed and to increase the strength the brace  42 . However, the brace  42  can be any shape and size that positions the end members  40  at a fixed distance apart from each other and provides enough strength to withstand the forces exerted on the connector  10  by the docking members  10  during use. For example, the brace  42  can be configured as a lattice, web, ribs, crossbar, truss, or other suitable arrangement. Preferably, the body  38  is a unitary construction; however, the body  38  can also be comprised of multiple portions attached together by a suitable method, such as fastening or welding. Preferably, the connector body  38  is made from a flexible material, such as rubber with a durometer of between about 60 and about 90. This will enable the body to flex about the brace between the end members  40 . However, the body  38  can be constructed of any suitable material. 
         [0033]    The bottom end of each end member  40  includes an expansion member  76  that can move between a contracted position for inserting or removing the connector  10  from the receiving socket  22  (shown on the right side in  FIGS. 5 and 8 ), and an expanded or locking position (shown on the left side in  FIGS. 5 and 8 ). The expansion member is hollow and open at its bottom. The expansion member thus defines a downwardly opening chamber  82 . In the contracted position, the expansion member has a diameter smaller than the diameter of the junction  31  between the upper and lower portions of the dock member socket  22  such that the end member can pass through the socket  22 . In the expanded or locking position, the expansion member  76  has a diameter greater than the junction  31  between the upper and lower sections of the receiving socket so as to prevent the connector  10  from being lifted vertically out of the receiving socket  22 . ( FIGS. 5 , and  8 ). The expansion member  76  includes a plurality of generally rectangular expandable flanges  78  that extend downwardly formed by a plurality of generally triangular shaped slots  80 . The flanges  78  define the downwardly opening chamber  82 . The chamber  82  is generally conical. 
         [0034]    The bolt  50  has a head  52  and flange  54  at the upper end of a shank  56 , which is sized and shaped to be inserted into the countersink  32  of the cap  44 . At least a bottom portion  58  of the shank  56  is threaded. The shank  56  is sized to pass through the cap bore  56  and the end member bolt hole  74 , and has a length such that the shank extends beyond the bottom of the expansion member  76  of the end member. When the bolt  50  is in place, the threaded portion of the bolt is within the expansion member  76 , and extends beyond the expansion member. 
         [0035]    A wedge  60 , having a threaded bore, is received on the threaded portion  58  of the bolt  50 . A pin  55  extends outwardly from the bottom end of the bolt shank  56  to prevent the wedge  60  from coming off the bolt  50 . The wedge  60  is a generally in the shape of truncated cone which is sized, shaped and configured to be received within the expansion member chamber  82 . As seen in  FIGS. 2 and 5 , the expansion member  76  has a sloped side wall, such that it generally defines a truncated cone. The wedge  60  is sized to pass through the junction  31  between the upper and lower portions of the dock member socket  22 . The diameter of the wedge increases towards its bottom, and has a diameter at its top which is less than the inner diameter of the expansion member  76  and a diameter at its bottom which is equal to or greater than the inner diameter of the expansion member. Anti-rotation tangs  84  ( FIG. 2 ) project from the outer surface of the wedge  60  to be received in the slots  80  of the expansion member  76 . Illustratively, the wedge  60  has three tangs  84 , but can be provided with fewer or more, as may be desired. The tangs  84  are generally triangular shaped raised portions that generally correspond to the triangular slots  80  of the expansion member  76 . The wedge defines a threaded bore  86  for coupling with the bolt  50 . 
         [0036]    As shown, the bolt shaft  56  extends below the bottom of the expansion member  76  a distance sufficient to enable a majority of the wedge  60  to be positioned below the bottom of the expansion member. The tangs  84  are of a height such that when the wedge  60  is in its lowered position, the upper end of the tangs will be positioned within the bottom of expansion member slots  80 . In this position (shown on the right side, for example, in  FIG. 5 ), the flanges  78  of the expansion member  76  are in a contracted position to allow the connector end member  40  to be inserted into the receiving socket  22 . When the bolt  50  is rotated, the interaction of the tangs  84  with the expansion member slots  80  will prevent the wedge from rotating with the bolt. Hence, when the bolt is rotated in a first direction, the wedge will ride up the bolt, and when the bolt is rotated in the opposite direction, the wedge will ride down the bolt. As such, the wedge will translate along the bolt shaft vertically within the chamber  82  of the expansion member  76 . As the wedge moves upwardly in the expansion member chamber, the tapered side wall of the wedge engages the inner side wall of the expansion member  76  and the expansion member  76  will expand to a diameter greater than the diameter of the junction  31  between the upper and lower portions of the receiving socket  22 . When the wedge translated downwardly, the expansion member will relax to resume its contracted position. 
         [0037]    Although the embodiment of  FIGS. 1-9  includes an expansion device  76  with flanges  78  actuated by the wedge  60 , other alternative embodiments of the expansion device can also be used. For example, the flanges  78  and wedge  60  can be configured in other shapes and sizes, such as any rectilinear or curvilinear shapes that provide for movement between the contracted and expanded positions. Additionally, alternate arrangements, other than the tang  84  and slot  80  can be used to prevent the wedge from rotating relative to the end member. For example, the wedge can be provided with a rib which is received in an inner groove or channel in the expansion member. Conversely, the wedge can be provided with a groove or channel which receives a rib on the inner surface of the expansion member. 
         [0038]    To assemble the connector  10 , a pair of caps  44  is attached to the top of the connector body  38  using the tongues  66  and grooves  64 . ( FIG. 6 ). A pair of bolts  50  is inserted through the bores  46  of the caps  44 , through the bores  74  of the end members  40 . The wedges  60  are then threaded onto the bottom of the bolt and are arranged such that its tangs  84  are received in the slots  80  of the expansion member  76 . The pin  55  is then placed through a hole extending through the bolt shaft to prevent the wedge  60  from coming off the shaft. The connectors  10  are preferably supplied in this assembled state. 
         [0039]    To secure two dock sections together, an assembled connector, with the wedge  60  in a lowered position (such as shown on the right side of  FIG. 5 ), is inserted into a pair of aligned docking members  14  until the tapered portions  72  of the end members  40  seat against the tapered portion  34  of the sockets  22 . ( FIG. 8 ). In this position, the connector caps  44  are received within the countersinks  32  and are flush with the top surface  16  of the docking members  14 . Thus, as noted above, the top surface of the caps  44  will form part of the wear or tread surface of the dock assembly. Using an appropriate tool, such as a wrench, each bolt  50  is rotated to move the wedge upwardly within the expansion member chamber  82  to expand the expansion member  76  to its expanded position. As the wedge  60  moves upwardly, the tapered outer surface  87  of the wedge engages the inner surface of the expansion member to deform the expansion member flanges  78  outwardly to a position in which the effective diameter of the expansion member  76  is greater than the diameter of the junction  31  between the upper and lower portions of the receiving socket  22  of the dock member  14 . The expansion member  76  can, but need not, expand to a size in which it engages or contacts the walls of the lower portion  30  of the socket  22 . To prevent over tightening of the bolt  50 , the tangs  84  contact a vertex  90  of the slots  80  and prevent any more turning of the bolt  50 . In this way, the connector  10  engages the receiving sockets  22  and couples the docking members  14  together without any need for the installer to have access to the bottom of the dock system  12 . When the wedge  60  is tightly received in the expansion member (i.e., when the top of the wedge tang is urged against the top of the expansion member slot), the bolt  50  will be in tension due and the expanded condition of the expansion member will prevent the end member  40  from being lifted out of the receiving socket  22 . 
         [0040]    To remove the connector  10 , the bolts  50  are rotated in the opposite direction to lower the wedge  60  to their lowered positions which will allow the expansion member to return to its contracted position. The pin  55  prevents of the wedge  60  from coming off the bolt  50 . In fact, when the wedge  60  contacts the pin  55 , the operator will no longer be able to turn the bolt. This will then serve as a signal to the operator that the wedge  60  has been fully lowered. When both wedges are lowered, the connector  10  can be removed from a pair of connected dock members. 
         [0041]    A tool  100  ( FIGS. 10-11 ) is provided to facilitate removal of the connector from the dock members. The caps  44  include channels  102  with indents or holes  104  in an outer surface of the channels  102 . The tool  100  has a handle  104  with arms  105  extending outwardly and terminating in tines  106  which are sized to engage the channel indents  104 . The tool is made of a spring metal, such that the tool can be squeezed slightly to align the tool tines with the channel indents  104 , and then released to engage the tines with the channel indents  104 . With the tool tines  106  engaged with the channel indents  104 , the connector  10  can be lifted and removed from the receiving sockets  22 . Although the tool is provided with tines which engage holes or indents in the cap channels  102 , the tool could be coupled to the cap in other desired ways to facilitate removal of the connector from the dock members. 
         [0042]    As can be appreciated, the connector  10  can be inserted into the receptacles of the dock members from the top of the dock members. There is no need to access the underside of the dock members. Thus, use of the connectors  10  allow for a dock to be assembled completely from the upper surface of the dock. Further, as noted above, the connector body  38  is flexible. The flexibility of the connector brace  42  allows for slight variance in the position of the receptacles of two adjacent dock members, and facilitates insertion of the connector  10  into the receptacles of the adjacent dock members when the centers of the receptacles are slightly offset from each other. Further, the flexibility of the connectors allows for a slight relative motion between adjacent dock section. 
         [0043]    Changes can 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 instance, the connector end members  40  and receiving sockets  22  can be configured with different shapes and sizes, including, but not limited to, pyramidal, or square, as long as the end members and sockets are complementary to each other. Further, the connector end members  40  and receiving sockets  22  need not be tapered, so long expansion member  76  can be enlarged to a size which will prevent the connector end member from being removed vertically from the receiving socket. In addition, the receiving socket  22  should include a lower portion adapted to mate with the expansion member  76 . Although shown with two end members  40 , the connector  10  could be provided with a single end member. The opposite end of the brace could then be configured to attach an accessory to the dock member. Although the bolt  50  is the preferred means to move the wedge  60  relative to the expansion member, other means could be used as well to move the wedge  60  within the expansion member. These examples are merely illustrative.