MODULAR DOCK SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No. 63/691,036 filed Sep. 5, 2024 which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to the field of marine structures and docks, and more particularly to a modular dock system, dock assemblies including one or more dock modules, and an E-channel extrusion member for attachment of decking to a dock module or other structure.

BACKGROUND

Marine structures such as docks are commonly used for securing and accessing boats, for water access from land, and for various activities on or around oceans, lakes, rivers and other bodies of water. Docks may be fixed in position, for example rigidly mounted to pilings; or may be floating, whereby the dock rises and falls with the tide or other fluctuations in water level.

Traditional docks are typically large and heavy, making installation and shipping difficult and expensive, and/or requiring custom design and construction, and are often not very flexible in design, especially in the field. Many typical docks also attach the decking or walk surface of the dock by welding to the frame or support structure. Docks utilizing fasteners for attachment of the decking often have fastener heads that project above or stay proud of the decking surface, which can present a tripping hazard, or require countersinking which involves time-consuming extra steps in construction.

Accordingly, it has been found that needs exist for improved dock structures and components. It is to the provision of improved dock structures and components meeting these and other needs that the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides improved dock structures and components including modular dock components that can be assembled into dock structures of various shapes, sizes, and configurations. In particular embodiments, the dock modules are relatively lightweight and interchangeable making installation, repair and reconfiguration easier and more flexible in design.

In further example embodiments, the present invention includes an E-channel extrusion member for attachment of decking to a dock module or other structure, for example using screws, bolts or other fasteners or attachment means. In particular embodiments, the E-channel member is a lightweight aluminum channel that hides the cut edge of the decking and does not require welding. Example decking materials may include metal, plastic, wood, fiberglass, cementitious, and/or other materials.

In one aspect, the present invention relates to a modular dock component including a frame and decking supported by the frame. The frame preferably includes at least one peripheral frame member configured for attachment to a cooperating peripheral frame member of another modular dock component to form a dock assembly structure.

In another aspect, the present invention relates to a dock assembly structure comprising a plurality of such modular dock components coupled to one another.

In still another aspect, the present invention relates to an E-channel member for a modular dock frame. The E-channel member preferably includes a main panel and a bottom flange, an intermediate flange, and a top flange. The bottom flange, the intermediate flange, and the top flange preferably extend generally perpendicular from one side of the main panel in the same direction and generally parallel to one another.

In yet another aspect, the present invention relates to a dock assembly including at least two modular dock components. Each of the at least two modular dock components include a frame comprising an E-channel member having a main panel, a bottom flange, an intermediate flange, and a top flange. The modular dock components preferably also include decking supported by the frame and engaged between the intermediate flange and the top flange. The modular dock components preferably also include a float attached to the bottom flange with a first of the at least two modular dock components attached to a second of the at least two modular dock components by at least one through-bolt engaged between an E-channel member of the first modular dock component and an E-channel member of the second modular dock component.

In further aspects, the invention relates to methods of assembly of a dock assembly structure or system wherein two or more modular dock components or modules, and/or at least one E-channel member as described herein are assembled into a dock assembly structure or system.

These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure can be better understood with reference to the following figures. The components in the figures are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the concepts of the disclosure. Moreover, repeated use of reference characters or numerals in the figures is intended to represent the same or analogous features, elements, or operations across different figures. Repeated description of such repeated reference characters or numerals is omitted for brevity.

FIG. 1 illustrates a perspective view of an example dock system according to various aspects and embodiments of the present disclosure.

FIG. 2 illustrates a perspective view of another example dock system according to various aspects and embodiments of the present disclosure.

FIG. 3A illustrates a perspective view of an example modular dock component according to various aspects and embodiments of the present disclosure.

FIG. 3B illustrates a top view of the modular dock component shown in FIG. 3A according to various aspects and embodiments of the present disclosure.

FIG. 3C illustrates a cross-sectional side view of the modular dock component designated A-A in FIG. 3B according to various aspects and embodiments of the present disclosure.

FIG. 3D illustrates a cross-sectional perspective view of the modular dock component designated B-B in FIG. 3C according to various aspects and embodiments of the present disclosure.

FIG. 4A illustrates a perspective view of an example structural support frame according to various aspects and embodiments of the present disclosure.

FIG. 4B illustrates an exploded or assembly perspective view of the structure support frame shown in FIG. 4A according to various aspects and embodiments of the present disclosure.

FIG. 5A illustrates a perspective view of an example E-channel member according to various aspects and embodiments of the present disclosure.

FIG. 5B illustrates a cross-sectional view of the example E-channel member shown in FIG. 5A according to various aspects and embodiments of the present disclosure.

FIG. 5C illustrates a cross-sectional view of the E-channel member shown in FIG. 5A engaged with example decking according to various aspects and embodiments of the present disclosure.

FIG. 6 illustrates a front view of an example end backing bar according to various aspects and embodiments of the present disclosure.

FIG. 7 illustrates a perspective view of an example center stringer according to various aspects and embodiments of the present disclosure.

DETAILED DESCRIPTION

Floating structures such as dock structures are often designed for a particular application or location and they are typically constructed mostly or entirely on-site at such a location. Components and materials involved with constructing dock structures are often heavy, costly, and require use of specific tools or skills for assembly. In many instances, this limits users'access to some or all dock structures utilizing existing components, materials, and construction methods.

The example embodiments described herein provide a solution to the aforementioned problems associated with existing floating structures such as dock structures in the form of modular dock components that can used individually or collectively to assemble and form various dock structures. The modular dock components can be assembled to form a frame and decking supported by the frame. Each of the modular dock components is relatively light-weight and can be configured in different sizes and shapes to allow easy transport, storage, design, and on-site assembly of multiple such modular dock components together with standard tools and without welding to form dock assemblies having various shapes, sizes, and configurations.

For context, FIG. 1 illustrates a perspective view of an example dock system 5 according to various aspects and embodiments of the present disclosure. The dock system 5 is illustrated as a representative example of a modular floating structure such as a modular dock system formed in part from a collection of individual modular dock components. The concepts described herein can be extended to use with a range of floating structures of different types, styles, components, and configurations, however. For instance, the embodiments described herein can be extended to use with various types of floating platforms or vessels (e.g., floating homes, offshore oil rig platforms), watercraft, infrastructure (e.g., bridges), or other floating structures. In further example applications, the modular docking components and associated features and methods may be utilized to construct fixed dock, pier, walkway, and/or other assembled structures or systems.

The dock system 5 includes modular dock components that can be assembled to form a frame and decking supported by the frame. Each of the modular dock components is relatively light-weight and can be configured in one or more sizes and shapes to allow easy transport, storage, design, and assembly of multiple such modular dock components together to form dock assemblies having various shapes, sizes, and configurations. In some example embodiments, the modular dock components can be carried and assembled manually by one or two persons, and multiple modular dock components may be transported in a standard delivery vehicle. In example embodiments, the modular dock components can be individually and collectively assembled, disassembled, and configured or reconfigured on-site with standard hand and/or power tools and without welding. For instance, the modular dock components allow for the dock system 5 and other modular dock systems in examples herein to be assembled, disassembled, and configured or reconfigured on-site with standard tools and without welding.

The dock system 5 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, component quantity, and other characteristics of the dock system 5 can vary as compared to that shown. For example, the dock system 5 can accommodate modular dock components that are larger (e.g., longer, wider), smaller (e.g., shorter, narrower), a different number, or a different configuration (e.g., L-shaped, U-shaped) compared to that shown, and other variations are within the scope of the examples described herein. Additionally, one or more of the parts or components of the dock system 5, as illustrated in the drawings and described herein, can be omitted in some cases. The dock system 5 can also include other parts or components that are not illustrated.

Referring to FIG. 1, among other components the dock system 5 in the example shown includes a dock assembly structure 10, dock mounts 11, 12, 13 (or “dock mounts 11-13”), a walkway or gangway 15, and posts 16, 17, 18 (or “posts 16-18”). The dock assembly structure 10 can be rigidly (e.g., fixed in place) or dynamically (e.g., moveably, slidably) coupled to the posts 16-18 by way of the dock mounts 11-13, respectively. The dock assembly structure 10 can also be rigidly or dynamically coupled to land or a landing structure 19 by way of the gangway 15.

In some cases, each of the dock mounts 11-13 can be rigidly coupled to or at least partly integrated with a different side or region of the dock assembly structure 10 relative to one another. In other examples, one or more of the dock mounts 11-13 can be removably (e.g., detachably) coupled to the dock assembly structure 10. In still other examples, one or more of the dock mounts 11-13 can be dynamically (e.g., moveably, slidably) coupled to the dock assembly structure 10.

In some examples, each of the dock mounts 11-13 can be rigidly coupled to or at least partly integrated with the posts 16-18, respectively, to secure the dock assembly structure 10 in a fixed horizontal plane or elevation relative to a vertical axis or centerline (℄) of the posts 16-18. In other examples, one or more of the dock mounts 11-13 can be removably coupled to the posts 16-18, respectively. In still other examples, one or more of the dock mounts 11-13 can be dynamically (e.g., moveably, slidably) coupled to the posts 16-18, respectively, and with hinged or otherwise dynamically coupled connection or engagement between the dock, gangway and/or landing structures, to allow the dock assembly structure 10 to travel between different horizontal planes or elevations relative to the vertical centerline ℄ of the posts 16-18 (e.g., in response to rising and falling water level due to tides, seasonal water level variations, boat wakes, or other changes in water level).

The dock system 5 in the example shown further includes a plurality of modular dock components 20 (or “modular dock components 20”) coupled to one another to collectively form the dock assembly structure 10. The modular dock components 20 are coupled to one another to collectively form the dock assembly structure 10 as a T-shaped platform in the example shown, although they may be configured to form the dock assembly structure 10 as another configuration in other examples (e.g., U-shaped, L-shaped, etc.).

In some examples, the dock assembly structure 10 shown in FIG. 1 can be embodied and implemented at least in part as a floating dock assembly having a T-shaped, L-shaped, U-shaped, or otherwise configured platform that can be supported on a surface of a body of water by floats such as the float structure 90. In some cases, the dock assembly structure 10 can be dynamically (e.g., moveably, slidably) coupled to one or more posts, piles, pilings, or other structure to maintain horizontal positioning of the dock assembly structure 10 as it rises and falls with changing water levels (e.g., due to tides, seasonal water level variations, or other changes in water level). In some examples, the dock assembly structure 10 can be at least one of rigidly, removably (e.g., detachably), or dynamically coupled to land or another structure such as the landing structure 19 by way of the gangway 15. For instance, the gangway 15 can be at least one of rigidly, removably, or dynamically coupled to one or both of the dock assembly structure 10 (e.g., to the decking 70) or the landing structure 19. For example, the gangway 15 can be removably and dynamically coupled to or positioned on each of the decking 70 and the landing structure 19. In alternate embodiments, the dock assembly structure 10 shown in FIG. 1 can be embodied and implemented at least in part as a fixed dock assembly that can be supported at a fixed elevation by one or more posts, piles, pilings, or other structure such as the posts 16-18.

FIG. 2 illustrates a perspective view of another example dock system 5′ according to various aspects and embodiments of the present disclosure. The dock system 5′ is an example alternative embodiment of the dock system 5 described herein with reference to FIG. 1. The dock system 5′ includes at least one of the same or similar components, structure, material, and functional ability as that of the dock system 5. The dock system 5′ is illustrated as another representative example of a modular floating structure such as a modular dock system formed in part from a collection of individual modular dock components. The dock system 5′ includes modular dock components that can be assembled to form a frame and decking supported by the frame. Each of the modular dock components is relatively light-weight and can be configured in one or more sizes and shapes to allow easy transport, storage, design, and assembly of multiple such modular dock components together to form dock assemblies having various shapes, sizes, and configurations. The modular dock components can be individually and collectively assembled, disassembled, and configured or reconfigured on-site with standard tools and without welding. For instance, the modular dock components allow for the dock system 5′ and other modular dock systems in examples herein such as the dock system 5 to be assembled, disassembled, and configured or reconfigured on-site with standard tools and without welding.

The dock system 5′ is not drawn to any particular scale or size in the drawings. The shape, size, proportion, component quantity, and other characteristics of the dock system 5′ can vary as compared to that shown. For example, the dock system 5′ can accommodate modular dock components that are larger (e.g., longer, wider), smaller (e.g., shorter, narrower), a different number, or a different configuration (e.g., T-shaped, L-shaped, U-shaped) compared to that shown, and other variations are within the scope of the examples described herein. Additionally, one or more of the parts or components of the dock system 5′, as illustrated in the drawings and described herein, can be omitted in some cases. The dock system 5′ can also include other parts or components that are not illustrated.

Referring to FIG. 2, among other components the dock system 5′ in the example shown includes a dock assembly structure 10′. The dock assembly structure 10′ is an example alternative embodiment of the dock assembly structure 10 described herein with reference to FIG. 1. The dock assembly structure 10′ includes at least one of the same or similar components, structure, material, and functional ability as that of the dock assembly structure 10. The dock assembly structure 10′ shown in FIG. 2 includes a plurality of the modular dock components 20 coupled to one another to collectively form the dock assembly structure 10′ as a rectangular shaped platform in this example, although the modular dock components 20 may be configured to form the dock assembly structure 10′ as another configuration in other examples (e.g., T-shaped, U-shaped, L-shaped).

FIGS. 3A-3D illustrate different views of an example modular dock component 20 according to various aspects and embodiments of the present disclosure. FIGS. 3A and 3B illustrate a perspective view and a top view, respectively, of the modular dock component 20 according to various aspects and embodiments of the present disclosure. FIG. 3C illustrates a cross-sectional side view of the modular dock component 20 designated A-A in FIG. 3B according to various aspects and embodiments of the present disclosure. In particular, FIG. 3C illustrates a cross-sectional side view of the modular dock component 20 with a peripheral or side frame member removed from view. FIG. 3D illustrates a cross-sectional perspective view of the modular dock component 20 designated B-B in FIG. 3C according to various aspects and embodiments of the present disclosure. Specifically, FIG. 3D illustrates a cross-sectional perspective view of the modular dock component 20 with an end frame member removed from view.

The modular dock component 20 is illustrated as a representative example of a modular dock component that can be used individually or together with at least one other modular dock component to form a modular floating structure or modular dock system such as the dock systems 5, 5′ described herein with reference to FIGS. 1 and 2, respectively. The modular dock component 20 includes modular frame, deck, and float components that can be assembled to form a structural support frame and a support platform or deck supported by the frame. The modular dock component 20 and each component thereof is relatively light-weight and can be configured in one or more sizes and shapes to allow easy transport, storage, design, and assembly of multiple modular dock components 20 together to form dock assemblies having various shapes, sizes, and configurations. The modular dock component 20 can be assembled, disassembled, and configured with other modular dock components 20 on-site with standard tools and without welding. For instance, the modular dock component 20 allows for the dock systems 5, 5′ and other modular dock systems to be assembled, disassembled, and configured or reconfigured on-site with standard tools and without welding.

The modular dock component 20 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, component quantity, and other characteristics of the modular dock component 20 can vary as compared to that shown. For example, the modular dock component 20 can accommodate modular frame, deck, and float components that are larger (e.g., longer, wider), smaller (e.g., shorter, narrower), a different number, or a different geometry or configuration (e.g., T-shaped, L-shaped, U-shaped) compared to that shown, and other variations are within the scope of the examples described herein. Additionally, one or more of the parts or components of the modular dock component 20, as illustrated in the drawings and described herein, can be omitted in some cases. The modular dock component 20 can also include other parts or components that are not illustrated.

Referring to FIGS. 3A-3D, among other components the modular dock component 20 in the example shown includes a structural support frame 40 (or “frame 40”), a support platform or decking 70, and a float structure 90. The frame 40 can be at least one of positioned on, supported by, or coupled to the float structure 90, and the decking 70 can be at least one of positioned on, supported by, or coupled to the frame 40.

The frame 40 in some cases can be at least partly embodied as or include a rectangular, square, or otherwise configured peripheral or perimeter frame including an E-channel extrusion member or E-channel member for attachment of the decking 70 and the float structure 90 as described further herein. The E-channel member in the frame 40 further allows for assembly and attachment of multiple modular dock components 20 into various floating structures such as the dock assembly structures 10, 10′ in some cases.

In some examples, the decking 70 can be at least partly embodied as or include a solid or through-flow decking panel or planks of aluminum or other metal, plastic, wood, natural or synthetic lumber, composites, fiberglass grating such as Eco62, fiberglass, cementitious, perforated metal, and/or other materials. The float structure 90 can be at least partly embodied as or include one or more floating bodies such as one or more rotomolded polymer floats, drums or pontoons, or other floating components in some examples.

The frame 40 can include at least one peripheral frame member that is embodied and configured for attachment to a cooperating peripheral frame member of another modular dock component 20 to form a dock assembly structure such as the dock assembly structures 10, 10′ described herein. In the example shown, the frame 40 includes a peripheral frame member such as an E-channel extrusion member 110 (or “E-channel member 110”) that forms a side of the frame 40. The E-channel member 110 is embodied and configured for attachment to a cooperating peripheral frame member of another modular dock component 20 to form a dock assembly structure such as the dock assembly structures 10, 10′. For instance, the E-channel member 110 is embodied and configured for attachment to a cooperating E-channel member 110 of another modular dock component 20 to form a dock assembly structure such as the dock assembly structures 10, 10′.

As shown in FIG. 3D, the E-channel member 110 in this example includes a main panel or upright flange portion 120, a lower or bottom flange 130, an intermediate or middle flange 140, and an upper or top flange 150. The bottom flange 130, the intermediate flange 140, and the top flange 150 can each extend generally perpendicular from one side of the upright flange portion 120, in the same direction and generally parallel to one another as shown.

The frame 40 is positioned on, supported by, and coupled to the float structure 90 in this example by way of one or more fasteners such as a through-bolt or other fastener 200. For instance, the bottom flange 130 of the E-channel member 110 is positioned on, supported by, and coupled to the float structure 90 by way of one or more fasteners 200.

The modular dock component 20 in the example shown further includes multiple panels coupled to the frame 40 such as a fascia panel 240, although one or more of such panels 240 can be omitted in some cases. The fascia panel 240 can be coupled to the frame 40 by way of one or more fasteners such as a through-bolt or other fastener 235 in this example. For instance, as shown in FIG. 3D, the fascia panel 240 can be coupled to the upright flange portion 120 of the E-channel member 110 by way of one or more fasteners 235.

In example embodiments, each of the fascia panels 240 can be at least partly embodied as or include one or more of a waterproof or water-resistant composite or polymeric material, or a resilient material such as natural or synthetic rubber, or other material. The fascia panel 240 provides a bumper to prevent damage to boats bumping or rubbing against a floating structure such as the dock assembly 10, 10′.

FIGS. 4A and 4B illustrate a perspective view and an exploded perspective view, respectively, of the structure support frame 40 according to various aspects and embodiments of the present disclosure. The frame 40 is illustrated as a representative example of a structure support frame that can be used to form a modular dock component such as the modular dock component 20 described herein with reference to FIGS. 1-3. The frame 40 includes modular frame components that can be assembled to form a structural support frame that can support a platform or deck such as the decking 70. The frame 40 and each modular frame component thereof is relatively light-weight and can be configured in one or more sizes and shapes to allow easy transport, storage, design, and assembly of multiple modular dock components 20 together to form dock assemblies having various shapes, sizes, and configurations. The frame 40 can be assembled, disassembled, and configured with other frames 40 in different modular dock components 20 on-site with standard tools and without welding. For instance, the frame 40 allows for the dock systems 5, 5′ and other modular dock systems to be assembled, disassembled, and configured or reconfigured on-site with standard tools and without welding.

The frame 40 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, component quantity, and other characteristics of the frame 40 can vary as compared to that shown. For example, the frame 40 can accommodate modular frame components that are larger (e.g., longer, wider), smaller (e.g., shorter, narrower), a different number, or a different geometry or configuration compared to that shown, and other variations are within the scope of the examples described herein. Additionally, one or more of the parts or components of the frame 40, as illustrated in the drawings and described herein, can be omitted in some cases. The frame 40 can also include other parts or components that are not illustrated.

Referring to FIGS. 4A and 4B, among other components the frame 40 in the example shown includes two peripheral or side frame members such as two of the E-channel members 110 and two end frame members such as an end backing bar 210. Each of the end frame members is coupled to and extends between respective ends of the side frame members. For instance, the end backing bar 210 is coupled to and extends between respective ends of two E-channel members 110. In the example shown, the frame 40 further includes a center stringer 220 coupled to and extending between the end frame members of the frame 40 such as between two end backing bars 210. The center stringer 220 in this example is positioned approximately midway between each of the side frame members of the frame 40 such as midway between two E-channel members 110 to create additional structural support for the frame 40 and the decking 70 in some cases. However, in other examples the center stringer 220 may be omitted from the frame 40.

FIGS. 5A-5C, 6, and 7 illustrate different views and further details of the E-channel member 110, the end backing bar 210, and the center stringer 220 of the frame 40 according to various aspects and embodiments of the present disclosure. In particular, FIGS. 5A and 5B illustrate a perspective view and a cross-sectional view, respectively, of the E-channel member 110, and FIG. 5C illustrates a cross-sectional view of the E-channel member 110 engaged with the decking 70. FIG. 6 illustrates a front view of the end backing bar 210, and FIG. 7 illustrates a perspective view of the center stringer 220.

Referring among FIGS. 4A, 4B, 5A-5C, 6, and 7, the E-channel members 110 in these examples can further include one or more welded or otherwise attached end plates at one or both of its ends such as an end plate 160 for attachment of at least one of the end backing bars 210 by bolts, welding, or other attachment means. The center stringer 220 in these examples can also include one or more welded or otherwise attached end plates at one or both of its ends such as an attachment plate 260 for attachment to the end backing bars 210 by bolts, welding, or other attachment means.

The E-channel members 110 and the end backing bars 210 can be pre-drilled with one or more holes 230 in some cases for the fasteners 190, 200, 235, to allow for assembly of a single modular dock component 20 or for multiple modular dock components 20 to be assembled together to form other floating structures such as the dock assembly structures 10, 10′. For example, one or more holes 230 can be pre-drilled through any or all of the upright flange portion 120, the bottom flange 130, the intermediate flange 140, or the top flange 150 on the E-channel member 110. In another example, one or more holes 230 can be pre-drilled through at least one of the end plates 160 on the E-channel member 110 or the attachment plates 260 on the center stringer 220. In a particular example, one or more holes 230 can be pre-drilled through at least one of the end backing bars 210. In another example, one or more holes 230 can be pre-drilled through portions of at least one of the decking 70 or the float structure 90.

In some embodiments, one or more fascia panels 240 can be attached around the external perimeter of a single modular dock component 20 or another floating structure such as one or both of the dock assembly structures 10, 10′. For example, one or more fascia panels 240 can be coupled to an external perimeter of at least one of the E-channel members 110 or the end backing bars 210 by engagement of the fasteners 235 through one or more holes 230 along or through the exterior perimeter of the E-channel members 110 and/or end backing bars 210.

As seen in FIG. 5C, the spacing between the intermediate flange 140 and the top flange 150 can be configured to receive the decking 70 therebetween, with a close fit in some cases to minimize the transition along the upper walking surface of the decking 70 and reduce tripping potential. In some examples, the top flange 150 can have a grated, ridged, corrugated, or otherwise textured or non-slip upper surface, and a radiused or chamfered distal edge to minimize the transition between the top flange 150 and the upper walking surface of the decking 70. The decking 70 can be attached to the frame 40 in some examples by way of one or more screws, bolts, or other fasteners 190 engaged with at least one of the upright flange portion 120, the intermediate flange 140, or the top flange 150, or by welding, adhesive, close-fitting engagement, and/or other attachment means. The float structure 90 can be attached to the frame 40 in some cases by way of one or more screws, bolts or other fasteners 200 engaged with at least one of the upright flange portion 120, the bottom flange 130, or the intermediate flange 140, or by welding, adhesive, close-fitting engagement, and/or other attachment means.

The E-channel member 110 in many examples can be embodied as a single, unitary body with each of the upright flange portion 120, the bottom flange 130, the intermediate flange 140, and the top flange 150 being integral portions or integrated components of such a single, unitary body. For example, each of the upright flange portion 120, the bottom flange 130, the intermediate flange 140, and the top flange 150 can be formed as an extrusion, casting, or molding of aluminum, steel, or other metal(s), plastic or polymer, composite, or other substantially rigid materials having a material strength selected for an intended load and structure.

The dimensions and configuration of the E-channel member 110 may vary depending on an intended application. In one embodiment, the upright flange portion 120 can have a height ranging from about 4 inches (″) to about 8″, for example about 6″, and a thickness ranging from about 3/16″ to about ¼″, for example about 3/16″. In another embodiment, the bottom flange 130 can have a width ranging from about 2″ to about 3″, for example about 2″, and a thickness ranging from about 3/16″ to about ¼″, for example about 3/16″. In still another embodiment, the intermediate flange 140 can have a width ranging from about 2″ to about 3″, for example about 2″, and a thickness ranging from about 3/16″ to about ¼″, for example about 3/16″. In yet another embodiment, the top flange 150 can have a width ranging from about 1″ to about 1-½″, for example about 1- 3/16″, and a thickness ranging from about ⅛″ to about ¼″, for example about ⅛″. In example embodiments, spacing between the bottom flange 130 and the intermediate flange 140 can range from about 4″ to about 6″, for example about 4-¼″, and spacing between the intermediate flange 140 and the top flange 150 can range from about 1″ to about 1.5″, for example about 1-¼″. In some cases, the intermediate flange 140 may be thicker or otherwise reinforced to provide additional support for the decking 70, depending on anticipated loads and applications.

FIGS. 2, 3A-3D, 4A, 4B, 5A-5C, 6, and 7 show additional details and features of the dock assembly structures 10, 10′ including one or more modular dock components 20, and assembly components, features, configurations, and modular assembly methods of dock design and construction or assembly, according to further embodiments and aspects of the invention.

In example embodiments, the modular dock components 20 can be optimized to reduce the weight of the individual sections for ease of handling and transport, so they can be shipped in pieces and bolted or otherwise assembled together on a remote site. An example weight range for a single assembled frame 40 is from approximately 50 pounds (lbs.) and to approximately 150 lbs. when the decking 70, the fascia panels 240, and the float structure 90 are attached. For compound dock embodiments, each modular dock component 20 can include the decking 70 but in some cases the float structure 90 or the fascia panel 240 may be omitted. Example weights for an assembled 9 feet (′)×30′ compound float or dock system made of 18 individual modular dock components 20 bolted together are approximately 1100 lbs. with the decking 70, 1500 lbs. with the decking 70 and the fascia panels 240, and 2200 lbs. with the decking 70, the fascia panels 240, and the float structures 90 assembled. The weights are most subject to change depending on how the float structures 90 are utilized in a particular example embodiment, so for example, a range of 1800-2400 lbs. may be expected for an assembled 9′×30′ compound float.

In use, one or more modular dock components 20 are provided, for example pre-assembled at the factory and delivered to the dock site or delivered in parts and assembled on-site. Two or more modular dock components 20 may then be assembled, for example by placement of the dock components adjacent or against one another in a desired assembly configuration, and engaging bolts or other fasteners 235 through holes 230 along the sides and/or ends of the modular dock components 20 (e.g., holes 230 through the E-channel members 110 and/or the end backing bars 210. Various dock assembly configurations can be implemented, including for example T-shaped docks, L-shaped docks, U-shaped docks, rectangular, polygonal, or other shapes, as desired. In some examples, additional structures may be utilized in combination with the modular dock components 20, such as walkways or gangways, roofs or awnings, winches, boat mooring cleats, lifts, and/or other marine structures or equipment.

The features, structures, or characteristics described above may be combined in one or more embodiments in any suitable manner, and the features discussed in the various embodiments are interchangeable, if possible. In the above description, numerous specific details are provided in order to fully understand the embodiments of the present disclosure. However, a person skilled in the art will appreciate that the technical solution of the present disclosure may be practiced without one or more of the specific details, or other methods, components, materials, and the like may be employed. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the present disclosure.

Combinatorial language, such as “at least one of X, Y, and Z” or “at least one of X, Y, or Z,” unless indicated otherwise, is used in general to identify one, a combination of any two, or all three (or more if a larger group is identified) thereof, such as X and only X, Y and only Y, and Z and only Z, the combinations of X and Y, X and Z, and Y and Z, and all of X, Y, and Z. Such combinatorial language is not generally intended to, and unless specified does not, identify or require at least one of X, at least one of Y, and at least one of Z to be included. The terms “about” and “substantially,” unless otherwise defined herein to be associated with a particular range, percentage, or related metric of deviation, account for at least some manufacturing tolerances between a theoretical design and manufactured product or assembly, such as the geometric dimensioning and tolerancing criteria described in the American Society of Mechanical Engineers (ASME®) Y14.5 and the related International Organization for Standardization (ISO®) standards. Such manufacturing tolerances are still contemplated, as one of ordinary skill in the art would appreciate, although “about,” “substantially,” or related terms are not expressly referenced, even in connection with the use of theoretical terms, such as the geometric “perpendicular,” “orthogonal,” “vertex,”“collinear,”“coplanar,”and other terms.

Although the relative terms such as “on,” “below,” “upper,” and “lower” are used in the specification to describe the relative relationship of one component to another component, these terms are used in this specification for convenience only, for example, as a direction in an example shown in the drawings. It should be understood that if the device is turned upside down, the “upper” component described above will become a “lower” component. When a structure is “on” another structure, it is possible that the structure is integrally formed on another structure, or that the structure is “directly” disposed on another structure, or that the structure is “indirectly” disposed on the other structure through other structures.

In this specification, the terms such as “a,” “an,” “the,” and “said” are used to indicate the presence of one or more elements and components. The terms “comprise,” “include,” “have,” “contain,” and their variants are used to be open ended, and are meant to include additional elements, components, etc., in addition to the listed elements, components, etc. unless otherwise specified in the appended claims.

The terms “first,” “second,” etc. are used only as labels, rather than a limitation for a number of the objects. It is understood that if multiple components are shown, the components may be referred to as a “first” component, a “second” component, and so forth, to the extent applicable. Further, if a component is described as there being “at least one” of said component, it is understood that this may mean “one or more” of said component. Conversely, if a component is described as there being “one or more” of said component, it is understood that this may mean “at least one”of said component.

As referenced herein in the context of quantity, the terms “a” or “an” are intended to mean “at least one” and are not intended to imply “one and only one. ” As referred to herein, the terms “include,” “includes,” and “including” are each intended to be inclusive in a manner similar to the term “comprising. ” As referenced herein, the terms “or” and “and/or” are generally intended to be inclusive, that is (i.e.), “A or B” or “A and/or B” are each intended to mean “A or B or both. ” As referred to herein, the terms “first,” “second,” “third,” and so on, can be used interchangeably to distinguish one component or entity from another and are not intended to signify location, functionality, or importance of the individual components or entities. As referenced herein, the terms “couple,” “couples,” “coupled,” and/or “coupling” refer to chemical coupling (e.g., chemical bonding), communicative coupling, electrical and/or electromagnetic coupling (e.g., capacitive coupling, inductive coupling, direct and/or connected coupling), mechanical coupling, operative coupling, optical coupling, fluid coupling, thermal coupling, and/or physical coupling.

It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.