Modular Float Bodies and Floating Logs for Floating Structures and Method of Manufacturing

Description

REFERENCES TO RELATED APPLICATIONS

This utility patent application is based on U.S. provisional patent application (Application No. 63/722,514), filed on Nov. 19, 2024.

FIELD OF INVENTION

This invention pertains to floats manufactured using rotational molding and used to make floating structures, such as docks and rafts, which include integrally formed mounting slots and brackets that connect to the floating structure's frame.

BACKGROUND OF THE INVENTION

Rotational molding, also known as roto-molding, offers several advantages over conventional molding processes like injection molding and blow molding. Rotomolding uses molds that are more cost-effective to produce, making it ideal for small production runs. This method is well-suited for creating hollow and complex structures, ensuring uniform wall thickness, and incorporating additional features, such as threaded and non-threaded bores or mounting nuts, directly into the structure.

As discussed in U.S. Pat. No. 12,097,937 (Knapp), floats made by roto-molding are common. One issue with roto-molded tubs is that they have flat top surfaces, which trap water and cause it to become stagnant. As a result, twigs, blue-green algae, and fecal matter floating in the water get caught on the top surface, leading to unpleasant odors and making them hard to wash off.

Another issue with roto-mold tubs is that they offer little or no structural support for the frame. As a result, the frame must be constructed with stronger, heavier materials and equipped with special brackets and hangers to connect the frame members.

Additionally, building floating structures with traditional methods is often slow and labor-intensive. It generally involves extensive measurements, cutting, and pre-assembly on land before installation in water, which raises costs and adds complexity.

SUMMARY OF THE INVENTION

The issues mentioned earlier are addressed by a modular, foam-filled, rotomolded float body designed to be aligned end-to-end with one or more float bodies to create an elongated floating log. Two float bodies are positioned parallel and connected using joists that fit into integrated cutouts on the top surface of each float body. Each cutout features a vertical connecting flange with mounting holes for bolts or threaded connectors, which attach to joists extending into the cutout and connect to the flange. The joists extend perpendicularly from the float bodies'longitudinal axis to join the two float bodies. Each float body is a rectangular box with a curved top, a flat bottom, two sides, and two end surfaces.

The modular design allows flexibility in size: varying the number of float bodies creates floating logs of different lengths. These logs can then be arranged to build floating structures of various dimensions, such as docks, walkways, or platforms, tailored to specific site requirements. This modular approach also simplifies construction, reducing the need for precise measurements and cutting, making assembly faster and less labor-intensive.

To assemble a floating structure, two or more float bodies are aligned longitudinally to create elongated floating logs. The floating logs are spaced apart to a desired distance and positioned parallel to each other, and joists extend between the float bodies on each floating log. The floating bodies are identical so that the joists, when inserted into opposite cutouts, are parallel and evenly spaced apart. Connectors are then used to securely attach the ends of the joists to the float bodies. The ends of each joist extend beyond the cutouts, remaining exposed and connected to one or two rim beams. Decking is then installed over and attached to the joists.

In lakes or ponds with little wake action or minimal water depth variation, using joists, rim beams, and decking provides adequate structural support and rigidity. In larger bodies of water, additional components may be needed to hold the float bodies together and form a floating log. To accommodate this need, each float body can include a plurality of threaded inserts that receive compatible threaded connectors. Tie beams may be longitudinally aligned and attached to the bottom surface of adjacent float bodies. These tie beams provide structural support and serve as replaceable rub surfaces that protect the bottom of the floats when the bottom of the floating structure contacts a subsea or submerged object.

If extra support is needed, multiple cross-members may be attached to the bottom surface of the float bodies, linking float bodies on one side of the floating structure. The cross-members may be attached to threaded inserts embedded into the bottom surfaces of the float bodies, or to a tie beam attached to the bottom of the floating structure.

An optional ladder may be attached to one side of the floating structure. The ladder includes two vertical side rails with multiple steps or rungs. Attached to the lower section of each side rail is a lower support beam that connects to connector pads or to the bottom tie beams.

In another embodiment, one or more vertical hangers may be attached to the joists. The hangers are positioned so that their tops are beneath the decking. One or more utility conduits may be attached to the vertical hangers to supply utilities, such as clean water, wastewater, or electricity, across the floating structure.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a top perspective view of a float body described herein.

FIG. 2 is a bottom perspective view of the float body.

FIG. 3 is a top plan view of the float body.

FIG. 4 is a bottom plan view of a float body.

FIG. 5 is a side elevational view of a float body.

FIG. 6 is a perspective view of a floating structure made of two floating logs, each floating log comprising two float bodies aligned parallel to each other and attached to a deck.

FIG. 7 is an end-elevational view of the floating structure shown in FIG. 6.

FIG. 8 is a top perspective view of the floating structure shown in FIG. 6 with the deck partially removed, thereby showing the frame extending over the floating logs and made up of side beams and end and middle joists covered by decking.

FIG. 9 is a bottom plan view of the floating structure shown in FIG. 8.

FIG. 10 is a perspective view of the floating structure similar to the floating structure shown in FIG. 6 with two bottom ties beams attached to the bottom of each floating log.

FIG. 11 is an end-elevational view of the floating structure shown in FIG. 10.

FIG. 12 is a bottom plan view of the floating structure shown in FIG. 10.

FIG. 13 is a top perspective view of the floating structure similar to the floating structure shown in FIG. 10, with four support legs attached to and extending downward from the ends of the floating logs.

FIG. 14 is an end-elevational view of the floating structure shown in FIG. 13.

FIG. 15 is a bottom plan view of the floating structure shown in FIG. 13.

FIG. 16 is a top perspective view of a floating structure similar to the floating structure shown in FIG. 10 with a ladder attached to one side of the floating structure.

FIG. 17 is an end-elevational view of the floating structure shown in FIG. 16.

FIG. 18 is a top perspective view of a floating structure similar to the floating structure shown in FIG. 10, with bottom joists extending transversely between the two floating logs.

FIG. 19 is an end-elevational view of the floating structure shown in FIG. 18.

FIG. 20 is a bottom plan view of the floating structure shown in FIG. 18.

FIG. 21 is a partial perspective view of a corner of a floating structure with the decking removed showing a vertical hanger attached to a joist with three utility conduits attached to the vertical hanger.

FIG. 22 is an end elevational view of the floating structure shown in FIG. 21.

FIG. 23 is a side elevational view of the floating structure shown in FIG. 21.

DETAILED DESCRIPTION OF THE INVENTION

The modular design float body 22 can be used to easily manufacture different sizes of floating structures. The float bodies 22 can be easily attached to make different lengths of floating logs. These logs can then be arranged to build floating structures of various dimensions, such as docks, walkways, or platforms, tailored to specific site requirements. This modular approach also simplifies construction, reducing the need for precise measurements and cutting, making assembly faster and less labor-intensive.

FIGS. 1-5 show various views of a float body 22 described herein. The float body 22 is a closed, sealed, rotomolded structure designed for use when constructing floating structures 70 shown in FIGS. 8, 10, 16, and 18. The float body 22 may be empty or partially or filled with foam 58.

The float body 22 includes a curved top surface 24, two side surfaces 26, 28, a bottom surface 30, and two end surfaces 32, 34. Formed on the side surfaces and end surfaces 32 are recessed channels 40 that provide greater support. Also formed on the bottom surface 30 are transversing and diagonal channels 50, 52, and 54, respectively.

Formed on the curved top surface 24 are several transversely aligned cutouts 42 and 43, each designed to receive a transversely aligned joist 88. Formed on one side of each cutout 42, 43 is an integrally formed vertical connecting flange 46. Each connecting flange 46 extends above the top surface of the float body and includes at least two mounting holes 48 that receive bolts or threaded connectors (not shown) that attach the end of the joist 88 that extends into the cutout 42, 43. This way, joists 88 extending between float bodies 22 on opposite sides of a floating structure (shown in FIGS. 8, 10, 16 and 18) can be structurally connected. The spacing of the cutouts 42, 43 and the locations of the connecting flanges 46 in the cutouts 42, 43 are adjusted so that the joists 88, when inserted into the cutouts 42, 43 and attached to the connecting flanges 46, are uniformly spaced apart. In the embodiments shown, the cutouts 42, 43 are spaced apart at 16 to 24 inches, and the joists measure 2×4 to 2×6 inches. Other spacing and joist sizes may be used. The orientation of the cutouts 42, 43 may also vary. For example, FIG. 3 shows a wide cutout 42 with the connecting flange 46 facing the end surface 32 and a narrow cutout 43 with the connecting flange 46 facing in the opposite direction towards the opposite end surface 34.

Because the end surfaces 32, 34 of the float bodies 32 are flat and vertically aligned, two or more float bodies 22 can be arranged end-to-end to form an elongated floating log 65. FIGS. 6-9 show a floating structure 70 composed of two parallel floating logs 65, each made up of two float bodies 22. The floating log 65 is not limited to just two float bodies 22. During assembly, the two floating logs 65 are spaced apart and kept parallel. Joists 88 extend between the floating logs 65, with their ends reaching beyond cutouts 42, 43 and exposed, then attached to one or two rim beams 82 that run longitudinally over outside surface of the floating log 62. Decking 75 is placed over and connected to the joists 88. In the embodiment shown, the deck 75 is ‘grated decking’ commonly used, which allows sunlight penetration to support shore habitat. The rim beams 82 cover the exposed edges of the decking 75. In lakes or ponds with minimal wake action or water depth changes, the combination of joists 88, rim beams 82, and decking 75 provides sufficient structural support and rigidity. When additional support is needed, two end rim joists 88 may attached to the two ends of the rim beams 82 as shown in FIG. 7.

FIG. 8 is a top perspective view of another embodiment of the floating structure 60 shown with the deck 75 partially removed, thereby showing the joists 88 extending over the top surfaces of the two floating logs 62 and showing two rim beams 82 (with spacers between them) extending longitudinally over the floating logs 62 and two rim joists 86 attached to the two rim beams 82.

FIG. 9 is a bottom plan view of the floating structure shown in FIG. 8.

While the embodiment of the floating structure 60 shown in FIGS. 6-10 that use of side beams 82, end joists 86, and middle joists 88 and decking 75 may be adequate for small lakes and ponds, additional components may be needed to couple the float bodies 22 together and to securely join two floating logs 62 in parallel alignment. Formed on the bottom surface of each float body 22 are a plurality of threaded inserts 36, shown more clearly in FIG. 4, that receive compatible threaded connectors (not shown). In one embodiment, as shown in FIGS. 10-12, one or more bottom tie beams 90 extend longitudinally over the bottom surfaces of two adjacent float bodies 22 in a floating log 62. Threaded connectors (not shown) are used to attach the tie beams 90 to the threaded inserts 36 in the bottom surfaces of adjacent float bodies 22. The tie beams 90 not only provide structural support but also act as replaceable rub surfaces that protect the bottom surfaces 30 of the float bodies 22 in the event the bottom surfaces 30 of the floating bodies 22 contact subsea or submerged objects.

In another embodiment shown in FIGS. 13-15, two or more vertical legs 100 may be attached to the bottom surface of one or more float bodies 22. The vertical legs 100 include a mounting flange 102 that may connect to the threaded inserts using threaded connectors 104. Alternatively, the vertical legs 100 may be attached directly to the bottom surface of the float body 22, to a tie beam 90.

FIGS. 16 and 17 show a ladder 100 attached to one side of the floating structure 60. The ladder 100 includes two vertical side rails 112 with multiple steps or rungs 114. Attached to the lower section of each side rail 112 is a lower support beam 116 that connects to connector pads 118 or to the bottom tie beams 90.

In another embodiment shown in FIGS. 18-20, multiple bottom cross-members 120 may extend transversely from one floating log 62 to the opposite floating log 62 that provide additional support and rigidity. Compatible connectors (not shown) attach to the threaded inserts 36 embedded in the bottom surfaces of the float bodies 22, securing the ends of the cross-members 120 to the bottom surfaces. In should be understood, that the floating structure 60 may include both the tie beams 90 and the cross-members 120.

FIGS. 21-23 show a floating structure 60 with the deck 75 removed with one or more vertical hangers 150 attached to a joist 88. One or more utility conduits 152, 154, and 156 may be attached to the vertical hanger 150 to supply utilities, such as clean water, wastewater, or electricity, across the floating structure 60. Also shown is a raised cleat board 89 located on the perimeter edge of the floating structure 60.

In addition to the float bodies, the floating logs, and the float structures described above, a method of manufacturing a floating structure is also described using the following steps:

• • (a) roto molding a plurality of hollow float bodies, each having a curved top surface, a flat bottom surface, and integrated transverse cutouts each with a vertical connecting flange;
  • (b) filling each float body with foam and sealing the float body to form a buoyant unit;
  • (c) forming threaded inserts in the bottom surface of each float body during molding to enable attachment of optional components;
  • (d) aligning two or more of the float bodies end-to-end to create an elongated floating log;
  • (e) positioning at least two floating logs in parallel and inserting joists into the cutouts of opposing floating logs;
  • (f) securing the joists to the connecting flanges and attaching rim beams to the joist ends;
  • (g) installing decking over the joists to complete the floating structure; and
  • (h) optionally attaching tie beams, cross-members, or vertical legs to the threaded inserts for added stability.

In compliance with the statute, the invention described has been described in language more or less specific as to structural features. It should be understood, however, that the invention is not limited to the specific features shown, since the means and construction shown comprises the preferred embodiments for putting the invention into effect. The invention is therefore claimed in its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted under the doctrine of equivalents.