Abstract:
An improved joint member, e.g., a gusset, is provided and is formed from a fiber-reinforced pultruded material. The improved gusset is more lightweight and inexpensive to manufacture than conventional gussets. Furthermore, the fiber-reinforced material is strong enough to provide the structural support needed in most platform-type systems.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/871,738, filed Aug. 29, 2013, the contents of which are expressly incorporated herein by reference. 
     
    
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0003]    1. Technical Field of the Invention 
         [0004]    The present invention relates generally to a joint member for use in a structural frame, and more specifically, to an improved gusset formed for a fiber-reinforced pultruded material and configured for use as a structural joint support in a bridge, platform, containment frames, or dock structure. 
         [0005]    2. Description of the Related Art 
         [0006]    It is well-known that docks are man-made structures that generally extend from shore over a body of water. Docks are commonly employed to provide a walkway from the shore to a boat, which may be tethered to a post or piling adjacent the dock. In addition, docks may be used as a location from which to swim or simply relax and enjoy the natural scenery. 
         [0007]    Floating docks are commonly used on bodies of water having fluctuating water levels, such as oceans and reservoirs. An exemplary floating dock system has been developed by Applicant, and is the subject of U.S. Pat. Nos. 7,640,881 and 8,166,901, the contents of which are expressly incorporated herein by reference. Many floating docks, including the aforementioned exemplary floating dock system, as well as bridges, platforms, and cooling towers, include a support frame comprised of a plurality of intersecting frame members. The intersecting frame members may be held together through the use of a joint support. In particular, the joint support may serve a dual purpose of positioning the intersecting frame members relative to each other, while also providing structural reinforcement at the joint. Therefore, the joint support is generally formed from a strong durable material. 
         [0008]    In most cases, the joint support is formed from a metallic material. Consequently, the joint support is one of the heavier and most costly components of the dock system. 
         [0009]    In view of the foregoing, there is a need in the art for an improved joint supporting member which is formed from a lightweight, durable, and cost-effective material. These, as well as other features and advantages of the present invention, will be described in more detail below. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    In accordance with the present invention, there is provided an improved joint member, e.g., a gusset, formed from a fiber-reinforced pultruded material. The improved gusset is more lightweight and inexpensive to manufacture than conventional gussets. Furthermore, the fiber-reinforced material is strong enough to provide the structural support needed in most dock systems. 
         [0011]    The improved gusset is preferably formed from a pultruded beam that is cut into two adjoining segments. The pultruded beam preferably includes a primary wall, and a plurality of webs extending generally perpendicularly from the primary wall. The adjoining segments may be adjoined in several different angular configurations, including 45°, 90°, 135° or other angles which may be used in the art. 
         [0012]    According to one embodiment, there is provided a method of forming a connecting support member, e.g., a gusset, adapted to connect a first structural member to a second structural member such that the first and second structural members collectively define a corner. The method includes forming a pair of beams, wherein each beam is formed from a pultruded material. A slot is formed in each of the pair of beams. The pair of beams are arranged in a non-parallel configuration corresponding to shape of the corner, wherein the slots are formed in the pair of beams such that when the pair of beams are arranged in the non-parallel configuration, the slots are aligned with each other. A common insert is placed within both slots to maintain the pair of beams together in the non-parallel configuration. The insert may be formed of metal or other high strength materials. 
         [0013]    The step of forming the pair of beams may include forming the pair of beams from a common beam. The step of forming the pair of beams may include forming each beam to include a primary wall and at least one web extending in a non-parallel direction from the primary wall. 
         [0014]    Each beam may include opposed inner and outer faces, wherein the step of forming the slot includes forming the slot such that the slot extends only partially between the inner and outer faces. The method may further include the step of adhering the pair of beams to each other using an adhesive. The method may additionally include the step of forming holes in the beams to receive the adhesive. The pair of beams may be arranged in an orthogonal arrangement. 
         [0015]    The insert may be an L-shaped bracket that is completely inserted within the pair of beams. The insert may be placed within both slots to define a captured portion within the slots and an exposed portion outside of slots. 
         [0016]    According to another aspect of the invention, there is provided a dock comprising a dock frame including a pair of frame members defining a corner. The dock further includes a connecting support member coupled to the pair of frame members and including a pair of beams, wherein each beam includes a slot formed therein and formed from a pultruded material. The pair of beams are arranged relative to each other in a non-parallel configuration corresponding to shape of the corner. The slots are aligned with each other when the pair of beams are arranged in the non-parallel configuration. An insert is positioned within both slots to maintain the pair of beams together in the non-parallel configuration. 
         [0017]    The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    These, as well as other features of the present invention, will become more apparent upon reference to the drawings wherein: 
           [0019]      FIG. 1  is an upper perspective view of two beam segments formed from a pultruded beam constructed in accordance with an embodiment of the present invention; 
           [0020]      FIG. 2  is a side sectional view of the pultruded beam; 
           [0021]      FIG. 3  is a side sectional view of the pultruded beam shown in  FIG. 2  with an upper portion of the beam removed therefrom; 
           [0022]      FIG. 4  is a side sectional view of the pultruded beam shown in  FIG. 2 , with a lower portion of the beam removed therefrom; 
           [0023]      FIG. 4A  is a partial side sectional view of the pultruded beam with an insert located within a slot formed within the beam; 
           [0024]      FIG. 5  is an upper perspective view of a dock system utilizing the pultruded beam; 
           [0025]      FIG. 6  is an upper perspective, partial cutaway view of a dock section have support elements formed from the pultruded beam; 
           [0026]      FIG. 7  is an upper perspective view of a gusset formed from the pultruded beam and having a first embodiment of a bracket connecting a pair of beam segments; 
           [0027]      FIG. 7A  is an upper perspective view of a gusset formed from the pultruded beam and having a second embodiment of a bracket connecting a pair of beam segments; 
           [0028]      FIG. 7B  is a top sectional, partial exploded view of the bracket depicted in  FIG. 7A ; 
           [0029]      FIG. 7C  is a top sectional assembled view of the bracket depicted in  FIG. 7A ; 
           [0030]      FIG. 8  is a front view of a support bracket formed from the pultruded beam; and 
           [0031]      FIG. 9  is a perspective view of a cleat support formed from the pultruded beam. 
       
    
    
       [0032]    Common reference numerals are used throughout the drawings and detailed description to indicate like elements. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the present invention only, and not for purposes of limiting the same, there is shown a pultruded beam  10  specifically configured and adapted for use as a structural support member. The pultruded beam  10  is highly adaptable and may be used in one or more capacities as a structural support in several different structural systems, including a dock structure or similar platform-type systems, as well as in other pultruded structural systems, such as a joint support member in a support frame for a cooling tower. The adaptability of the pultruded beam  10  may relate to the ability of the beam  10  to be cut into segments which are then adhered together to form an improved gusset  12 , e.g., connecting support member. A gusset  12  formed from the pultruded beam  10  typically weighs less and may be formed at a lower cost compared to conventional metal gussets, without compromising the strength of performance of the gusset  12 . Therefore, use of pultruded gussets  12  in dock systems and other pultruded structural systems may reduce the overall cost of the system. 
         [0034]    Referring now specifically to  FIG. 2 , there is shown a cross-sectional view of the pultruded beam  10 , which generally includes a primary wall  14  and a plurality of webs  16  extending generally perpendicularly from the primary wall  14  in spaced relation to each other. The primary wall  14  includes a first (upper) end portion  18  and an opposed second (lower) end portion  20 , an outer face  22 , and an opposing inner face  24 . The primary wall  14  includes a first edge  26  at the first end portion  18  and a second edge  28  at the second end portion  20 . The primary wall  14  defines a height, “H” as the distance between the first and second edges  26 ,  28 . In a preferred embodiment, the height H is approximately equal to 7½″, although it is understood that the height H may be varied without departing from the spirit and scope of the present invention. For instance, the height H may vary depending on the particular application of the beam  10 . 
         [0035]    The webs  16  extend from the primary wall  14  in spaced relation to each other. In the exemplary embodiment, the pultruded beam  10  includes four webs  16 , although other beams  10  may include fewer than four webs  16  or more than four webs  16 . Each web  16  includes a proximal end portion  30  coupled to the primary wall  14  and an opposed distal end portion  32  extending away from the primary wall  14 . The distal end portion  32  terminates to define a respective distal edge  34 . The plurality of distal edges  34  are preferably co-axially aligned along a common axis, referred to herein as the distal edge axis  35 . The beam defines a width, “W” as the distance between the outer face  22  of the primary wall  14  and the distal edge axis  35 . In a preferred embodiment, the width W is approximately equal to 2¼″, although the beam  10  may define other widths W without departing from the spirit and scope of the present invention. Each web  16  additionally includes opposed first and second surfaces  36 ,  38  to define a web thickness, “T” therebetween. The web thickness T is preferably equal to ¼″, although other web thicknesses may also be used. 
         [0036]    The cross section of the beam  10  is preferably substantially symmetrical about a transverse symmetrical axis  40  which extends generally perpendicular to the primary wall  14 , and generally parallel to the webs  16 . In this respect, there are preferably an equal number of webs  16  above the symmetrical axis  40  as there are below the symmetrical axis  40 . In the preferred embodiment, a first (upper) pair of webs  42  is disposed on one side of the symmetrical axis  40 , while a second (lower) pair of webs  44  is disposed on the other side of the axis  40 . The first pair of webs  42  includes an outer web  16   a  and an inner web  16   b . Likewise, the second pair of webs  44  includes an outer web  16   d  and an inner web  16   c.  With regard to the first pair of webs  42 , the outer web  16   a  is positioned such that the first surface thereof resides within a plane including the first edge  26 . Furthermore, the outer and inner webs  16   a,    16   b  are spaced from each other such that the first surfaces of the respective webs are spaced by a distance, “D1” which is preferably approximately equal to 1¾″. With regard to the second pair of webs  44 , the outer web  16   d  is positioned such that the second surface thereof resides within a plane including the second edge  28 . Furthermore, the outer and inner webs  16   d,    16   c  are spaced from each other such that the second surfaces of the respective webs are spaced by a distance, “D2” which is preferably approximately equal to 1¾″. 
         [0037]    According to one embodiment, the beam  10  includes a plurality of web support elements  46  disposed between a respective web  16  and the primary wall  14  to enhance the connection between the webs  16  and the primary wall  14 . Each web support element  46  preferably extends between that surface of the web  16  which faces the symmetrical axis  40 , and the primary wall  14 . In particular, the support elements  46  coupled to the first pair of webs  42  extend between the second (lower) surface  38  of the respective web  16  and the primary wall  14 , whereas the support elements  46  coupled to the second pair of webs  44  extend between the first (upper) surface  36  of the respective web  16  and the primary wall  14 . 
         [0038]    The beam  10  preferably includes an exposed, roughened surface to facilitate adhesion with a dock structural element. In the preferred embodiment, the outer surface  22  of the primary wall  14 , the first surface  36  of the first outer web  16   a  and the second surface  38  of the second outer web  16   d  are all roughened. The roughened texture may be achieved by forming serrations in the beam  10  at those surfaces. 
         [0039]    The beam  10  also preferably includes one or more slots  45  formed therein. The slots  45  are sized and configured to receive a bracket or insert  47  (see  FIGS. 4A and 7 ) for aligning and supporting the beams  10   a,    10   b  during assembly of a gusset  12 , or similar structure. The exemplary slots  45  extend into the beam  10  from the outer face  22 , although it is contemplated that in other embodiments, the slots  45  may extend into the beam  10  from the inner face  24 . 
         [0040]    As noted above, the beam  10  may be configured to enable selective configuration of the beam  10  depending on the desired use thereof. For instance, the beam  10  may be used as a structural support in connection with a wide range of pultruded structures, including support frames for docks, cooling towers, and the like. Along these lines, although the following discussion and related figures relate to use of the beam  10  as a support in a dock, it is understood that use of the beam  10  is not limited thereto. 
         [0041]    Referring now specifically to  FIGS. 3 and 4 , various aspects of the invention are related to forming the beam  10  in a manner which allows the beam  10  to be customized according to the intended use of the beam  10 . For instance, the beam  10  may be used in forming a gusset  12 , a support bracket  48 , or a cleat support  50 . As such, the formation of the various support structures may be achieved by cutting the beam  10  into the desired dimensions for forming the various support structures.  FIGS. 3 and 4  illustrate ways in which the beam  10  may be modified to conform to a desired dimensional profile. In particular,  FIG. 3  shows an upper portion of the beam  10  removed therefrom, while  FIG. 4  shows a lower portion of the beam  10  removed therefrom. The portion removed in  FIGS. 3 and 4  includes a web  16  and a portion of the primary wall  14  extending between the removed web and the remaining adjacent web  16 . The process of removing the portion of the beam  10  in  FIGS. 3 and 4  results in a beam  10  having a shorter height than the original beam. 
         [0042]    The beam  10  shown in  FIG. 4  also differs from the beam  10  shown in  FIG. 3  due to the formation of slot  115  within thickened webs  16 . The purpose of the slot  115  will be described in more detail below. 
         [0043]    According to one embodiment, the full height H of the beam  10  is configured to fit inside of a channel defined by a standard 8″×2 3/16″×¼ dock frame member, with approximately 0.025″ clearance on the upper and lower bearing surfaces. However, the beam  10  may be cut along a cut axis to size the beam for use in a 6″ channel. The cut axis is preferably aligned with the second surface of the second inner web  16   c,  or the first surface of the first inner web  16   b.    
         [0044]    An upper perspective view of an exemplary floating dock  51  is shown in  FIG. 5 , while  FIG. 6  shows partial cutaway view of the dock  51  to illustrate the internal support elements or gussets  12 . The dock  51  generally includes a pair of opposed longitudinal frame members  52  and a pair of opposed transverse frame members  54  coupled to the longitudinal frame members  52  to define four corners. In each corner is a gusset  12  which positions the respective transverse frame member  54  relative to the respective longitudinal frame member  52 , and additionally provides structural support to the frame members  52 ,  54 . The dock  51  additionally includes a plurality of support beams  56  extending between the longitudinal frame members  52  for supporting an upper walking plate  58 . The support beams  56  are engaged with support brackets  48 , which are coupled to respective ones of the longitudinal frame members  52 . 
         [0045]    The gussets  12  may be formed using the pultruded beam  10  described above, and as shown in  FIGS. 1 and 7 . The gusset  12  is formed by cutting the beam  10  into two segments  10   a,    10   b,  which intersect at a miter joint  60 . An adhesive may be used to join the two segments together  10   a,    10   b.  The two segments  10   a,    10   b  may be cut at an angle such that when the segments  10   a,    10   b  are joined at the miter joint, the outer faces  22  of the respective primary walls  14  are arranged approximately 90° relative to each other. However, those skilled in the art will appreciate that the segments  10   a,    10   b  may be cut so as to define different angular offsets between the primary walls  14 , i.e., the primary walls  14  may define an angle therebetween that is greater than 90° or less than 90°. Those skilled in the art will also appreciate that the segments  10   a,    10   b  may also be arranged in a generally parallel arrangement without departing from the spirit and scope of the present invention. 
         [0046]    Alignment of the beam segments  10   a,    10   b  may be facilitated through the use of bracket or insert  47 , which may be inserted into corresponding slots  45  formed in the beam segments  10   a,    10   b.  In this regard, the bracket  47  may hold the beam segments  10   a,    10   b  in the preferred position while an adhesive cures. The bracket  47  may remain attached to the gusset  12  after assembly is complete to provide additional structural support. The bracket  12  is preferably formed from a durable, water resistant material, such as metal, although other materials known in the art may also be used. 
         [0047]    According to one embodiment, the gusset  12  includes a corner plate  62  (see  FIG. 7 ) extending between the two segments  10   a,    10   b.  The corner plates  62  may provide reinforcement to the gusset  12  and additionally may be used to position the two segments  10   a,    10   b  during assembly of the gusset  12 . It is contemplated that the corner plates  62  may include an aperture formed therein, which is preferably sized to receive a freshwater piling. The corner plate  62  may be formed from a similar water resistant material, such as metal, although other materials are contemplated and may be adhered to webs  16  of the gusset  12  using an adhesive known in the art. 
         [0048]    Referring now to  FIGS. 7A-7C , there is depicted another embodiment of a gusset  112  having an enlarged, more robust bracket  147  than the bracket  47  shown in  FIG. 7 . The enlarged bracket/insert  147  may be used to provide increased structural support between the adjoining beam segments  110   a,    110   b.  In the embodiment depicted in  FIG. 7A , the gusset  112  includes a pair of beam segments  110   a,    110   b,  wherein each beam segment  110   a,    110   b  includes four webs  116 . The gusset  112  further includes one or more brackets  147  which are inserted into respective slots  115  formed adjacent each web  116 . In this respect, the exemplary gusset  112  includes two brackets  147  attached to two central webs  116 ; however, it is understood that in other embodiments, the gusset  112  may include fewer brackets  147  than webs  116 , or alternatively, more brackets  147  than webs  116 . The brackets  147  are typically formed of the same materials as used for the brackets  47 . 
         [0049]    The slots  115  are formed in each beam segment  110   a,    110   b  at the adjoining end portion of the beam segment  110   a,    110   b  (e.g., in the corner of the resulting gusset  112 ). It is contemplated that the slots  115  may be formed within the webs  116 , or adjacent the webs  116  (e.g., just above the web  116  or just below the web  116 ). When forming the gusset  112 , the beam segments  110   a,    110   b  are arranged such that slots  115  in the pair of beam segments  110   a,    110   b  are aligned so as to allow a bracket  147  to be inserted therein. 
         [0050]    In the embodiment shown in  FIGS. 7A-7C , the bracket  147  is inserted into the slots  115  from the inside of the corner, wherein the bracket  147  extends into the slot  115  so as to define a captured portion  150  (e.g., that portion of the bracket  147  residing within the slots  115 ) and an exposed portion  152  (e.g., that portion of the bracket  147  not residing within the slots  115  and therefore is exposed). In this respect, the bracket  147  may also serve the same function as the corner plate  62  described above (e.g., the bracket and corner plate may be integrated into a single element). As such, the exposed portion  152  may extend between the inner faces  124  of the pair of beam segments  110   a,    110   b.    
         [0051]    In the exemplary embodiment depicted in  FIGS. 7A-7C , the slot  115  extends completely between the inner and outer faces  124 ,  122  of the primary wall  114 , although it is understood that in other embodiments, the slot  115  may extend only partially therebetween. Furthermore, the slot  115  may extend partially from the outer face  122  toward the inner face  124 , or alternatively, partially from the inner face  124  toward the outer face  122 . 
         [0052]    The bracket  147  may be configured to extend substantially completely along the entire width W of the beam segment  110 . In particular, the bracket  147  may extend from the distal edge of the web  116  to the outer face  122  of the primary wall  114 . As noted above, the bracket  147  may be used to initially join the beam segments  110   a,    110   b  together and hold the beam segments  110   a,    110   b  in place while an adhesive is used to more securely join the two beam segments  110   a,    110   b  together. 
         [0053]    Referring now specifically to  FIG. 8 , the pultruded beam  10  may also be used to form a support brackets  48  which may provide support to an upper walking surface of the dock, or alternatively, may provide support to a transverse frame member. In this respect, the support bracket  48  may provide support to the dock frame at a location spaced from the corner of the dock frame. The support brackets  48  include a primary (upper) load bearing wall  66 , an attachment wall  68 , and a vertical edge  70  for aligning the support beam  56  with the support bracket  48 . The pultruded beam  10  may be cut and positioned such that the primary wall  14  functions as the attachment wall  68 , and the first outer web  16   a  functions as the primary load bearing wall  66 . One or more apertures  72  may be formed in the primary wall  66  to allow adhesive to seep through the primary wall  66  for adhering the primary wall  66  to the longitudinal frame member  52 . 
         [0054]    Referring now specifically to  FIG. 9 , in addition to being used in forming a gusset, the pultruded beam  10  may further be used as a support member for coupling a cleat  50  to the dock  51 . A conventional cleat  50  includes a cleat arm  74  having two opposed end portions  76 ,  78 , and a pair of legs  80 ,  82  having apertures formed therein. Cleat bolts  84  extend through respective ones of the leg apertures and through corresponding apertures formed in the webs  16  of the pultruded beam  10 . A pair of compression tubes  86  may extend around the bolts  84  and between a pair of webs  16  to provide strength to the webs  16 . 
         [0055]    As noted above, the pultruded beam may be used in a wide variety of applications, and is not limited to use as a structural support member in a dock. In this respect, the pultruded support structure may be implemented into any pultruded structure, including, but not limited to a support structure for a cooling tower. 
         [0056]    This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by these exemplary embodiments. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure.