Abstract:
Metal dock systems of the type wherein the side edges of metal decking pieces are coupled to one another and held between opposing stringers to create a substantially flush walking surface through the use of first and second coupling elements, each associated with a respective one of the decking side edges. The first coupling element including a lengthwise member with a partially cylindrical outer surface, and the second coupling element including a lengthwise cradle with a partially cylindrical inner surface. Using this configuration, the lengthwise member may be hinged into the lengthwise cradle to couple. The associated pieces of decking to one another while allowing a certain degree of pivoting therebetween. In a system wherein the stringers and decking pieces are suspended using vertical poles on the outer sides of each stringer, the vertical poles being coupled to one another through a transverse member disposed beneath the decking pieces, the assembly system further includes a coupler, connector base, stackable bumper sleeves, and other articles and methods.

Description:
REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a continuation of co-pending U.S. patent application Ser. No. 10/910,072, filed Aug. 3, 2004, the entire content of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates generally to metal dock system of the type that use alumin and other decking pieces and, in particular, to components, systems and methods that improve the assembly, use, and/or cost of such systems.  
       BACKGROUND OF THE INVENTION  
       [0003]     In many warm climates, boat docks may be permanently installed and left in the water without concern for ice flows, for example. In colder climates, however, most smaller recreation dock must be removed from the water because freezing conditions and ice movement may destroy the structure. As such, the combination of lightweight and ease of installation are essential. There have been many inventions relating to dock systems, including methods and apparatus for dismantling before the onset of winter and re-assembling in the spring.  
         [0004]     As a first example, U.S. Pat. No. 2,948,121 relates to portable sectional piers, and more particularly to such devices combined with means for installing and removing the pier sections. However the described system is overly complicated, very expensive to manufacture, and cannot accommodate sideways construction.  
         [0005]     In U.S. Pat. No. 3,421,327 a hinge for use with boat docks or the like comprises first and second hinge sections which are secured to the ends of first and second support members. The hinge sections are detachably secured together by pivoting one of the hinge sections with respect to the other hinge section whereby a pair of posts on one of the hinge sections will be received by a pair of slots on the other hinge section. Although this system offers some versatility, it does not allow down ramping.  
         [0006]     U.S. Pat. No. 3,686,876 teaches a removable pier having at least two sections pivotally joined end to end and extending from a footing on a shore into a body of water. The pier sections are removably supported on permanent footings for stability. Booms having cable guides are removably mounted on leg extensions of the inner pier section. Cables, driven by winches, pass through the cable guides on the boom and engage the outer pier section for its removal from the water by rotation about its pivotable connection with the inner pier section. The booms are transferred to mounts on the shore at the sides of the pier for removal of the inner pier section from the water with the outer pier section in overlying position. The outer pier section is preferably slightly shorter than the inner pier section so that both pier sections can be stored in upright position on the shore ready for repositioning in the water.  
         [0007]     Though not dock-related, U.S. Pat. No. 4,048,960 discloses a floor for use in animal husbandry consisting of a number of elongated extruded aluminum floor lengths each of which has a slotted top surface with longitudinally and transversely spaced apart slots, each length having a multiplicity of integral vertical support beams extending from the undersurface of the slotted surface and terminating in footed ends, one longitudinally extending side of the slotted surface having an arcuate male connector configuration and the other longitudinally extending side having a correspondingly dimensioned female connector configuration whereby adjacent lengths are pivotally connectable to one another.  
         [0008]     According to U.S. Pat. No. 4,126,006 a boat dock is assembled from portable sections hingedly connected to each other and provided with foldable and adjustably extensible leg assemblies. Each section is formed from tread retaining decking members made of extruded metal sections interconnected in close parallel spaced relation by interlocking elements. Pivotally separable half-shell foot elements are connected to the leg assemblies for stabilized support of the dock sections. A drawback with this design is that a separate hinge component is required and gaps are created between sections.  
         [0009]     U.S. Pat. No. 4,398,849 is directed to a portable dock and dock sections used therewith, characterized by each of the dock sections have a plurality of frame members forming a rectangular deck frame for supporting a deck assembly, a pair of adjustable legs extending from adjacent one end of the rectangular deck frame and a first coupling unit disposed on a frame member at the other end of the deck frame. Preferably, an additional or second coupling unit, which is adapted to cooperate with a first coupling unit, is arranged either on an end or side frame member or both at the one end to enable connecting sections together to form either a straight line pier or a pier with a “T” or “L” shape. The portable dock also includes an anchor section having an anchor member with a similar coupling unit which co act with the first coupling unit of a first dock section for securing the first dock section to the beach or shoreline. Again, the hinges are separate from the deck, the deck cannot ramp down, and there are gaps between sections.  
         [0010]     The disclosure of U.S. Pat. No. 4,645,380 relates to a dock that is purportedly easily assembled and disassembled. The dock comprises a number of dock sections, each of which is provided with a leg portion that engages the bottom of a lake or body of water. The opposite end of each dock section from the leg portion thereof is engaged with a preceding dock section by a locking system that facilitates erection of the dock system and maintenance thereof in the assembled condition. Again, the deck cannot ramp down, and there are gaps between sections.  
         [0011]     U.S. Pat. No. 4,948,300 resides in a multiple pier section and installation assembly includes a plurality of modular pier sections, a dolly for transporting, installing and removing the individual pier sections, and a dolly locator. The pier sections have a hinged pier section interconnection system which utilizes a dual pin/slot arrangement that resists both lateral and longitudinal as well as vertical movement of the installed pier. Adjustable pier legs which can be raised or lowered from atop the pier to accommodate variations in water depth are mounted to one end of each modular pier section. The dolly includes a chassis and a pivotally mounted pier section support unit, a dolly hold down system and a pier section hold down system. The dolly and dolly locator cooperate to assure proper alignment and positioning of the dolly during installation and removal of the pier sections. Like other prior-art systems, gaps are created between sections such that a ramping up or down would create raised portions that could result in user tripping.  
       SUMMARY OF THE INVENTION  
       [0012]     According to one aspect of the invention, first and second coupling elements are provided, each associated with a respective one of the decking side edges. The first coupling element including a lengthwise member with a partially cylindrical outer surface, and the second coupling element including a lengthwise cradle with a partially cylindrical inner surface. Using this configuration, the lengthwise member may be hinged into the lengthwise cradle to couple. The associated pieces of decking to one another while allowing a certain degree of pivoting therebetween. An important element is the shorter length since a typical 8 foot or 10 foot section using identical new art would be for heavier and the angle of release would require the far end to be lifted very high to assemble. While these sections could be set on the previous section vertically and tilted down, a 8 foot or greater section would require a boom to tilt it in without operator danger.  
         [0013]     In a preferred embodiment, the partially cylindrical inner and outer surfaces are in substantially intimate contact when the associated pieces of decking are coupled to one another. This is achieved with a configuration wherein the first coupling element includes a lower lip spaced apart from a portion of the cylindrical outer surface, thereby creating a partial J-shaped cavity, and the lengthwise cradle forms part of a partial J-shaped lip. This allows the J-shaped lip to be at least loosely retained in the J-shaped cavity when the associated pieces of decking are coupled to one another.  
         [0014]     According to the invention, the first and second coupling elements may be disposed on opposing edges of the same piece of decking pieces, or on opposing edges of different decking pieces coupled to one another using one or more dovetail joints. A different aspect of the invention provides a member adapted for fastening to a stringer providing one of the first or second coupling elements to add transverse decking pieces. A further, patentably distinct aspect of the invention resides in a member adapted for fastening to a stringer to provide a resilient outer bumper.  
         [0015]     In a system wherein the stringers and decking pieces are suspended using vertical poles on the outer sides of each stringer, the vertical poles being coupled to one another through a transverse member disposed beneath the decking pieces, the improved assembly system further includes a patentably distinct coupler having a first bore that clamps onto one of the vertical poles and a second bore that clamps onto one of the transverse members. According to this invention, the first bore is at least slightly larger than the second bore, allowing a vertical pole to be rotated, installed or removed with the second bore clamping a transverse member.  
         [0016]     A different yet patentably distinct invention resides in a connector base having a distal end with a auger and a hollow proximal end with a cut-away portion, allowing the auger end to be positioned into the ground below water and a vertical pole to be breech-loaded into the hollow proximal end. Yet a further patentably distinct invention provides a plurality of stackable bumper sleeves that may be placed on vertical poles above or below the decking pieces to prove cushioning. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1  is a simplified rendition of a prior-art aluminum dock used to introduce inventive concepts disclosed herein;  
         [0018]      FIG. 2  is a cross-sectional view of a piece of decking according to the invention;  
         [0019]      FIG. 3  is a cross-section of a first coupling element, including preferred dimensions;  
         [0020]      FIG. 4  is a cross-section of a mating coupling element, also including preferred dimensions;  
         [0021]      FIG. 5A  is a drawing that shows the way in which the coupling elements of  FIGS. 3 and 4  may be hinged into position;  
         [0022]      FIG. 5B  is a drawing showing the first and second coupling elements joining two pieces of decking to create a substantially flush upper surface for walking;  
         [0023]      FIG. 6  is a drawing which shows two alternative pieces of decking and associated coupling elements providing a partial retrofit to existing systems;  
         [0024]      FIG. 7  is a drawing which shows how preassembled dock sections may be stored in nested fashion during periods of non-use;  
         [0025]      FIG. 8  is a drawing which illustrates an inventive stand-off which allows the dock section of  FIG. 7 , for example, to be stacked with less damage;  
         [0026]      FIG. 9A  is a cross-sectional drawing of a separate piece that may be mounted against the outer surface of a stringer to permit transverse sections of dock for corners, T-configurations, and so forth;  
         [0027]      FIG. 9B  shows the member of  FIG. 9A  mounted to the outer surface of an existing stringer;  
         [0028]      FIG. 10  illustrates an inventive assembly which may be mounted to the sides or ends of a stringer system to provide a bumper cushion;  
         [0029]      FIG. 11  is a drawing which shows an inventive hinge clamp that allows vertical members to be rotated while rigidly coupled to transverse members located under dock sections;  
         [0030]      FIG. 12  is a drawing of an inventive auger connector base that may be left in-ground below water between seasons;  
         [0031]      FIG. 13  is a drawing which shows how the connector base of  FIG. 12  would ordinarily be used; and  
         [0032]      FIG. 14  is a drawing which shows an inventive bumper extension sleeve to protect larger and smaller watercraft from hitting an assembled dock. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]     The reader&#39;s attention is now directed to the drawings,  FIG. 1  in particular, which depicts an existing, prior-art modular dock system which will be helpful in understanding the various improvements and inventions disclosed and described herein. Such a system, depicted generally at  100 , includes one or more dock sections  104  made up of deck pieces  108  held on either side by stringers  106 ,  107 . Though not shown, a decorative trim piece would also be placed at the end of the dock to cover the ends of the side stringers.  
         [0034]     The dock sections are held suspended above the water through vertical posts  120  which, in turn, are coupled to one another transversely utilizing lower poles  130  and clamps  122  having orthongonally oriented bores to fit the vertical members  120  and transverse  130 , respectively.  
         [0035]     Although docks of this kind may accommodate pieces of decking constructed from wood, plastic and other materials, this invention relates more generally to metal decking pieces and extruded aluminum decking pieces, in particular. The inset drawing of  FIG. 1  illustrates the way in which two decking pieces  108  are now joined, that is, through an extruded bead  110  and mating longitudinal groove  112 , thereby forming a dovetail-type coupling. One disadvantage of this arrangement is that each new piece of decking that must be assembled to one or more previous pieces must be carefully aligned so that the bead  110  can slide easily in the groove  112  until the ends are flush. Once a number of decking pieces are assembled in this manner, the stringer pieces  106 ,  107  are disposed on either side, and various fasteners are used in each corner and elsewhere to hold the assembly in a rigid configuration.  
         [0036]     Having described a typical prior-art system, reference is now made to  FIG. 2 , which shows an improved system for coupling pieces of decking. More particularly, as opposed to a dovetail-type joint which must be precisely aligned and slid into position, the improved system utilizes a first coupling member  200  which mates with a second coupling member  201  through a more forgiving hinging process. This not only allows the pieces to be assembled more easily, without sliding, it also allows a certain degree of pivoting between two pieces without coming apart, as may be desired when one level of decking transitions to a different level of decking, as may be the case in going to or from a shoreline, retaining wall, or the like.  
         [0037]     The first coupling mechanism  200 , includes a longitudinal element  202  that runs the length of the piece of decking, and which, in the preferred embodiment, is generally cylindrical in shape, but for extensions  204  from the edge of the piece of decking. Note that the upper surface of the circular cross-section of the member  202  is substantially tangent to the upper, walking surface of the deck piece. Below the member  202  is a spaced-apart lower lip  206 , which also runs the length of the decking piece, thereby creating a generally J-shaped channel  210 .  
         [0038]     The second coupling member  201  includes a longitudinal cradle  212 , preferably with a partial cylindrical cross-section with a cutaway portion below creating a generally J-shaped extension  216 . Members  220 ,  222 ,  224 , though not technically necessary, are preferably provided for strengthening.  FIG. 3  is a cross-sectional view of the first coupling element showing preferred dimensions.  FIG. 4  is a cross-sectional view of a second coupling element also showing preferred dimensions.  FIG. 5A  is a drawing in cross-section which shows the way in which the first and second coupling elements are hinged into position, and  FIG. 5B  shows the coupling elements connected to one another to form a substantial and flush upper walking surface. Although the two upper thick surfaces are shown flush in  FIG. 5B , a certain degree of pivoting is allowable between two pieces of decking while still being coupled to one another. This capability is useful for constructing ramps to transition from an upper deck to a lower deck, or to the shoreline, for example.  FIG. 6  is a drawing in cross-section which shows two additional pieces of decking  602 ,  604  according to the invention which would be useful in retrofitting with existing docks of the type depicted with respect to  FIG. 1 . In particular, according to the invention, a first piece of decking  602  may be provided having, on one edge, a coupling member of the type depicted at  200  in  FIG. 2 , but at the other edge including a groove for the type of prior-art joint shown in  FIG. 1  at  112 . Such a piece of decking  602  would allow one or more existing decking members of the type shown in  FIG. 1  to be used within a section of dock, while allowing one end to utilize the new system depicted herein. An advantage of this capability is that, with the existing prior-art pieces of decking, the groove and bead associated with the dovetail-type joint do not extend sufficiently beyond the ends of the side stingers to permit use of the new system described herein. However, by replacing one or both of the end decking pieces, there is enough single “platy” in the remaining dovetailed pieces to permit the new end decking pieces to be used with the existing decking pieces particularly to respect to transitions in level.  
         [0039]      FIG. 7  is a drawing which shows the way in which sections of dock may be turned upside down and stored with the legs in tact. This would have been far less practical with prior-art systems, which tend to utilize much longer sections of dock which are already very heavy without the legs assembled. According to this invention, however, the length of each dock section is made shorter, and the stand-offs “B” of  FIG. 8  are preferably utilized along the lower edges of the stringer to permit the dock sections t be stacked in a manner shown in  FIG. 7  though on a staggered basis to accommodate the single set of legs which remains attached to each section.  
         [0040]     To accommodate transverse dock sections which might be found in 90 degree turns, “T” configurations, the component shown in  FIG. 9A  is provided according to the invention.  FIG. 9A  also shows the preferred dimensions of the component. The component of  FIG. 9A  is mounted against the outer side wall of an existing stringer, thereby providing a cradle  912  of the type shown as  212  in  FIG. 2 . As such, with the component  904  mounted as shown in  FIG. 9B , a section of dock including one of the first coupling members may be hinged into the component  904  for a change in direction of the dock. Unlike current art, transverse sections are no longer limited to the area between the straight sections. Current art typically requires transverse sections to be mounted near the legs of the straight sections since to do otherwise would require the straight section to bear the load of the transverse section at its weakest point (midspan). The only remedy would be much heavier sections. However, the new sections are much shorter and therefore any transverse section is inherently close to the legs.  
         [0041]      FIG. 10  is a drawing which illustrates a different component  1002 , which enables a bumper  1004  to be easily and conveniently mounted to the outer wall of a stringer, thereby providing a decorative yet functional added value. As with the invention described with reference to  FIG. 8 , the invention of  FIG. 10  is considered patentably distinct, in that such devices may be used with any appropriate stringer, including those now in use. The component of  FIG. 10  preferably includes a C-shaped bracket that fits over the edge of the stringer, and held in position with fastener  1110 , while providing opposed channels into which a resilient member  1004  is journaled. Whereas the component  1002  is preferably extruded aluminum, the bumper member  1004  is a compressible/resilient material such as rubber, synthetic rubber, or the like, and may be replaced.  
         [0042]      FIG. 11  is a drawing which depicts a different patentably distinct idea in the form of a clamp that may also be used with existing dock assemblies. Such a clamp includes two pieces  1102 , which, when properly mated, provide two orthogonal, clampable bores  1104 ,  1106 , one to receive upright members such as  120  shown in  FIG. 1 , and another to receive transverse members such as  130  depicted in  FIG. 1 . While clamps of this kind do exist, as shown at  122  in  FIG. 1 , a distinct disadvantage is that the inner diameter of both bores is substantially the same, such that both clamps must be loosened in order to loosen only one of the members. This is a distinct disadvantage when installing and removing a dock system, since is often the case that the clamps holding the transverse members  130  should be left assembled, while permitting the other clamp to be loosened for auguring, removal, and other operations that ordinarily take place through the installation and/or removal of dock systems of this type.  
         [0043]     According to the clamp of  FIG. 11 , however, the inner diameter of the bore associated with the vertical members is slightly larger than the inner diameter of the bore associated with the transverse members and all corners are radiused. As such, the transverse members may be tightly clamped, and held in place, while the other side of the clamp is loosened, permitting the vertical members to be rotated as necessary for a given operation. Using the preferred dimensions shown in  FIG. 11 , there is enough “springiness” in the metal comprising the clamp to then tighten the clamp associated with the vertical members once the operation is complete.  
         [0044]      FIG. 12  shows yet a different patentably distinct invention, in this case a connector base that may be installed in the ground below water surface, allowing vertical members to be positioned and removed therefrom with a precise positioning left in place for each season. The component of  FIG. 12 , depicted generally at  1202 , includes a distal end  1204  with a cast auger, and a proximal end with a cutout section  1210  in a main pipe  1211  having a bolt hole  1220 . Also included in the main pipe  1211  is an inner pipe  1212  or some other feature creating a stop  1214 .  
         [0045]      FIG. 13  shows the way in which the component of  FIG. 12  may be used. In particular, a section of dock  1300  including a hinge portion  1302 , is assembled to an installed section  1301  through a hinged joint  1302 . This is done with a vertical leg  120  assembled and mounted to the dock section  1300  in advance. With the component  1202  in place under the water, the dock section  1300  may be pivoted into position, since the lower ends of the legs  120  fit into the cutout section of the proximal end of the component  1202 , after which time, with a slight amount of encouragement, the bottom ends of the legs  120  slip into the pipe of the connector base until hitting the stops. A bolt hole is provided if necessary in extreme wave conditions that mates with a hole in the  120  member.  
         [0046]      FIG. 14  is a drawing which shows yet a different patentably distinct invention, in this case an extendable bumper sleeve that may be used to extend existing bumper guards on existing docks, both upwardly and downwardly. This is advantageous since a larger boat might ‘miss’ the covers over the existing clamps, and smaller newer watercrafts such as jet skis and so forth, may be too short. Accordingly, the existing bumpers guards may be extended in either direction through the use of the device shown in  FIG. 14 , which has a flared portion on either or both ends, allowing them to be stacked and nested. Additionally, as these may be provided in multiple colors, an attractive design may be achieved.