Dock Segment Coupling Assembly and Method for Using

Dock construction and installation is often expensive and time consuming. In some regions of the country docks are put in the water every spring and pulled out of the water every fall before the water freezes. Larger organizations, such as a marinas and dock companies, often have many docks to install and service. The need for efficient dock building solutions increases with the number of docks. Docks are typically assembled by connecting individual preconstructed dock segments until a desired dock size and shape is achieved. A variety of dock making kits exist on the marketplace comprising dock segments and the tools required to assemble them. Kits may vary in price from hundreds of dollars to thousands of dollars. It would be advantageous to have a device or dock component that can reduce the amount of time needed to assemble a dock or the cost associated with it.

Dock segments are typically connected to one another using a connection assembly which may include brackets, clamps, hinges, and bolts. Typically, a bracket is combined to each dock segment, then the brackets of adjacent segments are connected to each other. Connection assemblies come in a variety of shapes and sizes depending the dock's design. When connecting repeating dock segments with predefined dimensions, connection assemblies should be in the same location on each segment to ensure the segments are aligned and fitted properly. Connection assembly components are typically combined with the dock segment using a jig to help ensure proper alignment and placement. The installer is required to hold the jig in place while trying to align the dock connection assembly components with the jig. One disadvantage of these types of connection assemblies is that each dock design typically requires a unique jig. An installer may need to carry dozens of jigs and determine which one is correct for each job. Further, if the dock manufacturer ever modifies their dock's shape or dimensions, they may need to create a new jig to match the new design specifications. Creating custom tools is not efficient for those who may only need a single dock, or for those who need a large number of different docks. Still further, different sections of the same dock may require different jigs.

There is therefore a need for an improved dock connection assembly which overcomes these and other drawbacks in the prior art.

One aspect of the invention includes a dock coupling assembly for connecting multiple segments of a dock. The dock coupling assembly comprises a female connecting bracket having a base portion and an offset portion that is connected to the base portion and that is out of alignment with the base portion. The female connecting bracket has an outer surface, an inner surface, a top edge that travels the length of the base portion and the offset portion, a bottom edge that travels the length of the base portion and the offset portion, a proximal edge on the offset portion, and a distal edge opposite to the proximal edge on the female connecting bracket. The offset portion has a first receiving channel and a second receiving channel. The female connecting bracket has a first alignment flange on the inner surface that travels from the top edge to the bottom edge and may be generally perpendicular to the inner edge in some embodiments. The first alignment flange may be generally vertical in some embodiments allowing it to extend around the end of the dock section. The dock coupling assembly also includes a male connecting bracket having a base plate. The base plate has a base plate inner surface, a base plate outer surface, a base plate top edge, a base plate bottom edge, a base plate proximal edge, and a base plate distal edge. The male connecting bracket further includes a first outwardly extending engagement member and a second outwardly extending engagement member located on the base plate outer surface along the proximal edge. The second outwardly extending engagement member is below the first outwardly extending engagement member. The male connecting bracket includes a second alignment flange that travels from the base plate top edge to the base plate bottom edge and is perpendicular to the base plate inner surface. The first receiving channel in the female attachment bracket receives the first outwardly extending engagement member of the male attachment bracket and the second receiving channel of the female attachment bracket receives the second outwardly extending engagement member of the male attachment bracket.

Another aspect of the present invention includes a dock coupling assembly for a dock comprised of multiple dock segments. The dock coupling assembly has a first bracket attached to a first dock segment having a base portion and an offset second bracket connecting portion that is connected to the base portion and is out of alignment with the base portion. The first connecting bracket has an outer surface, an inner surface, a top edge that travels the length of the base portion and the offset second bracket connecting portion, a bottom edge that travels the length of the base portion and the offset second bracket connecting portion, a proximal edge on the offset second bracket connecting portion, and a distal edge opposite to the proximal edge on the first connecting bracket. The first bracket comprises a first alignment flange on the inner surface that travels from the top edge to the bottom edge and is perpendicular to the inner edge. A second bracket is attached to a second dock segment. The second bracket has a base plate having a base plate inner surface, a base plate outer surface, a base plate top edge, a base plate bottom edge, a base plate proximal edge, and a base plate distal edge. The second bracket also includes at least one first bracket engaging member that engages with the second bracket connecting portion of the first bracket. The second bracket further includes a second alignment flange that travels from the base plate top edge to the base plate bottom edge and that is perpendicular to the base plate inner surface.

Another aspect of the present invention a method for attaching a first dock segment to a second dock segment using a dock coupling assembly. The method comprises taking a female connecting bracket and taking a male connecting bracket. The female connecting bracket has a base portion and an offset portion that is connected to the base portion and that is out of alignment with the base portion. The female connecting bracket has an outer surface, an inner surface, a top edge that travels the length of the base portion and the offset portion, a bottom edge that travels the length of the base portion and the offset portion, a proximal edge on the offset portion, and a distal edge opposite to the proximal edge on the female connecting bracket. The offset portion has a first receiving channel and a second receiving channel. The female connecting bracket has a first alignment flange on the inner surface that travels from the top edge to the bottom edge and is generally perpendicular to the inner edge. The first alignment flange and the inner surface of the female connecting bracket form a generally right angled surface that hugs a corner of the first dock segment. The male connecting bracket comprises a base plate having a base plate inner surface, a base plate outer surface, a base plate top edge, a base plate bottom edge, a base plate proximal edge, and a base plate distal edge. The male connecting bracket further includes a first outwardly extending engagement member and a second outwardly extending engagement member located on the base plate outer surface along the proximal edge. The second outwardly extending engagement member is below the first outwardly extending engagement member. The male connecting bracket also includes a second alignment flange that travels from the base plate top edge to the base plate bottom edge and is perpendicular to the base plate inner surface. The second alignment flange and the base plate inner surface form a generally right angled surface that hugs a corner of the second dock segment. The method comprises attaching a female connecting bracket to a first dock segment and attaching a male connecting bracket to a second dock segment. The female connecting bracket is attached to the first dock segment by first aligning the first alignment flange and the inner surface over a corner of the first dock segment. The inner surface contacts a side of the dock segment, and the first alignment flange contacts the second end of the dock segment and prevents the female connecting bracket from sliding backwards along the side of the dock segment. The top edge aligns with the top surface of the dock segment. Likewise, the male connecting bracket is attached a second dock segment by first aligning the second alignment flange and the plate inner surface over a corner of the second dock segment. The plate inner surface contacts the side of the dock segment and the second alignment flange contacts the first end of the dock segment, such that the male connecting bracket is prevented from sliding along the side of the second dock segment. The top plate edge is aligned with the top surface of the dock segment. Both the male connecting bracket and the female connecting bracket are secured to the dock segments by fasteners that pass through their respective receiving openings and into the sides of the dock segments. To attach the dock segments, a dock assembler starts by lowering the second dock segment towards the first dock segment at an angle with the first end lower in height than the first end. The first end of the second dock segment is facing the second end of the first dock, and the second end of the first dock segment has two female connecting brackets and the first end of the second dock segment has two male connecting brackets. Each dock segment should have a male/female connecting bracket on both the right and left sides so that the dock segments are locked together in a stable manner. As the dock segment is lowered, setting the first outwardly extending engagement member into the first receiving channel until the first outwardly extending engagement member reaches the end of the first receiving channel. Swinging the second dock segment axially about the first outwardly extending engagement member, and eventually inserting the second outwardly extending engagement member into the second receiving channel. Once the top surface of the second dock segment is level with the top surface of the first dock segment, the swing motion of the dock segment is stopped. The assembly can be disassembled by reversing these steps.

These and other aspects, objects, and features of the present disclosure and claimed invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure and claimed invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

To the extent that the terms “includes” or “including” or “have” or “having” are used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A” or “B” or both “A” and “B”. When the Applicant intends to indicate “only A or B but not both” then the term “only A or B but not both” or similar structure will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” In this specification and the appended claims, the singular forms “a,” “an” and “the” include plural reference unless the context clearly dictates otherwise.

The invention generally relates to a dock segment coupling assembly. The dock segment coupling assemblyallows for simple assembly and disassembly of adjacent dock segments. The dock segmentsare typically rectangular and have angled or sharply rounded corners. Most dock segmentshave corners at right angles. Typical docks and dock segmentsare made of wood or a metal such as aluminum. Docks are not limited to just those materials, and may be made out of a combination of different materials. Dock segmentsare connected end after end to form a generally linear structure that begins on the shore of a body of water such as a river or lake and extends outward over the body of water. The dock segmentsmay be attached instead to the right and left sides of other dock segmentsin order to create differently shaped docks (e.g., an “L” shaped dock). The dock segmentsare held above the body of water so that people using the dock as well as the material making up the dock segmentsstay dry.

The dock segment coupling assemblyis made up of a male connecting bracket, or first bracket, and a female connecting bracket, or second bracket. The dock segmentswill typically have male connecting bracketsnear a first endof the dock segmentand female connecting bracketsnear the second endopposite of the first end. The connecting brackets,are on both the right or first sideof the dock segmentas well as the left or second sideof the dock segment, such that the dock segmentis securely locked to the adjoining segment on both of its sides. The different dock segmentshave generally the same width so that the brackets,on adjacent segments are aligned, but the lengths of the segments may vary. Brackets,on opposite sides of the dock segments, namely the right and left sides, should be mirrored from one another. Parts of a bracket that are found on one surface of a bracket should be inverted and set to the opposite surface depending on what side of the dock segmentit is attached to. For example, the female connecting brackethas a vertical pole gripattached to the surface not engaged with the side of the dock as shown in. The vertical pole gripon the right-side bracket will be opposite the vertical pole gripon the left side bracket so it is not between the female connecting bracketand the side of the dock.

As shown in, the female connecting bracketcomprises a base portionand an offset portionthat is connected to the base portionwith an angled connecting portion. The base portionhas an inner surfaceand an outer surface. The offset portionhas an offset inner surfaceand an offset outer surface. The offset portionis out of alignment with a vertical plane defined by the base portionsuch that the offset inner surfaceis aligned with the outer surfaceof the base portionas shown in. The offset inner surfaceis separated from the inner surfaceof the base portionby a distance about the thickness of the base portionand the male connecting bracket. The female connecting brackethas an upper edgeand a lower edgethat span the length of the base portion, and continue through the offset portion. The female connecting bracketgenerally has a longitudinal axis running in parallel to the upper edgeand the lower edgeon the base portion. The female connecting bracketalso has a distal edgeand a proximal edgethat is opposite the distal edgeand located on the offset portion. The angled connecting portionis formed integrally with the base portionand the offset portion. The angled connecting portionis angled compared to the longitudinal axis of the base portionand the offset portionis offset, but parallel to the longitudinal axis of the base portion. The angled connecting portionmay be perpendicular with the base portion, or it may have any angle smaller than 90 degrees and greater than 0 degrees with the base portion. The offset portionhas a first receiving channeland a second receiving channel. Both channels cut all the way through the offset portionfrom the offset inner surfacethrough the offset outer surface. The first receiving channelbegins at the top edge, and moves straight downward for a distance that is at least as long as the width of the channel. The second receiving channelbegins at the proximal edgeof and moves towards the base portionbefore terminating directly below the first receiving channel. The second receiving channelis slightly arcuate and it starts around a midpoint of the proximal edge. The base portionalso comprises a plurality of receiving openingsto allow fastenerssuch as screws or bolts to secure the female connecting bracketto a dock segment.

A first alignment flange, as shown in, is positioned on the inner surfaceof the base portionalong the proximal edgeand the angled connecting portion. The first alignment flangeforms an angle with the inner surfaceof the of the base portionsuch that a corner of the dock segmentmay be cupped or received by the flange and the inner surface. In some embodiments the first alignment flangeis generally perpendicular with the inner surfaceof the base portion. The flange helps keep the female connecting bracketin the correct location relative to the end of the dock segmentwhile it is being fastened to the dock segment. The female connecting bracketmust be positioned correctly on the corner so that the offset portionof the female connecting bracketreaches past the end of the segment by a predetermined amount. The predetermined amount is decided by the alignment flangewhen the it catches on the end of the dock segment. The inner surfacein combination with the alignment flangecups the corner of the dock segmentand cannot move further along either side of the dock segment. This ensures that the connection of the female and male connecting bracketsoccurs far enough away from the two dock segmentsthat there is a small gap between the dock segmentsafter the dock segmentsare combined with each other. If the brackets,are attached to the dock segmenttoo close to the end of the dock segment, then the segments could contact one another and prevent proper attachment. In addition, if the brackets,are attached to the dock segmenttoo far from the end of the dock segment, then the outwardly extending engagement members,on the male connecting bracketmay not reach the receiving channels,in the female connecting bracket. The first alignment flangemay be any length from its end to where it connects to the female connecting bracketso long as the length is less than the width of the dock and does not interfere with the flange on the corresponding female connecting bracketon the opposite side of the dock segment. The first alignment flangeis preferably around ¼ inch to about 1 inch.

In some embodiments the female connecting bracketalso includes a vertical pole grip. The vertical pole grip can be seen in. The vertical pole gripis attached to the base portionof the main body and having a first sideand a second side. The first and second sides are may be curved, such that they form a generally c-shaped grip. The vertical pole griphas a generally cylindrical channelwithin the first and second sides. A grip openingis positioned about halfway along the first sideof the vertical pole grip. The grip openingis typically threaded, and allows for the insertion of a fastenersuch as a screw or bolt.displays a support poleengaged to the vertical pole grip. The support poleis allowed to be “side loaded” into the vertical pole gripthanks to the c-shape of the vertical pole grip. In other dock assembly systems, a post would be passed downward through a cylindrical grip, where the cylindrical grip only has opening at the top and bottom of the grip. In effect, previous dock assembly systems could only attach the posts by moving them down through the grips from above. The vertical pole gripmay instead be pipe clamp, ring clamp, sheet metal clamp, or another gripping means. In other embodiments, such as floating docks, the vertical pole gripsare not necessary.

In some embodiments, after a dock segmenthas been placed, it is attached to support poles. A plurality of support poleskeeps the dock suspended above the body of water. Due to the general c-shape of the vertical pole grip, there is a gap between the first and second sides that opens directly to the channel inside. A support poleis loaded into the vertical pole gripthrough the gap. Then the support poleis moved downwards while still being held within the grip until it contacts the bed of the body of water. Once the pole is at the proper height, a dock assembler screws a fastener, such as a screw, bolt, or pin, into the opening. The fastenermay be attached with tools or by hand. The end of the fastenerwill pass through the opening and contact the support pole. As the fasteneris tightened, it will push the support poleinto the second sideof the vertical pole grip. The fastenershould be tightened enough such that the frictional force between the vertical pole gripand the support poleprevents relative movement between the two. The plurality of receiving openingsis usually evenly spaced around the vertical pole grip. For example, there could be four total receiving openingswith a pair of receiving openingson either side of the vertical pole grip.

show a female connection bracketattached to a dock segment. To install the female connecting bracket, a dock assembler places the female connecting bracketagainst either side of a dock segment. The base portionis held flat against the side of the dock segment, while the first alignment flangereaches past the side and cups the corner and second endof the segment. The first alignment flangecatches the end of the dock segmentso that the female connecting bracketdoes not slide backwards along the length of the side. The first alignment flangealso ensures that the offset portioncan reach the male connecting bracketon a separate dock segmentwithout the two dock segmentshitting one another. The upper edgeof the female connecting bracketis aligned with the top surface of the dock segment. This ensures that the female connecting bracketsare aligned with one another which keeps both sides of the dock segmentsat the same height. The male connecting bracketsare similarly aligned such that there are no differences in height between dock segments. If the upper edgeof the female connecting bracketis not aligned correctly and does not match the alignment of top sideof the male connecting bracketthen the dock segmentmay not be completely horizontal and the surface of the overall dock will be uneven. An uneven dock is dangerous to users because they may trip over a dock segmentor slip and fall. If the dock is wet, the danger of injury increases.

The male connecting bracket, as shown in, comprises a flat, typically rectangular, platehaving a top side, a bottom side, a proximal side, and a distal side. The platehas a dock facing plate inner surfaceand a plate outer surface. The plateincludes a pair of engagement memberreceiving openingsalong the proximal sideof the plate. A first engagement member receiving openingis located near the upper corner where the proximal sidemeets the top side, while a second engagement member receiving openingis positioned further below the first engagement member receiving opening, about midway along the length of the proximal side. A pair of outwardly extending engagement membersare inserted into the receiving openings,. There is a first outwardly extending engagement memberfor the first receiving openingand a second outwardly extending engagement memberfor the second receiving opening. The outwardly extending engagement members,are cylindrical and allow the male connecting bracketand female connecting bracketto interlock with one another by fitting into the receiving channels of the female connecting bracket. The outwardly extending engagement members,may instead be formed integrally with the plateas opposed to being inserted. In this case, the platedoes not include the first and second receiving openings. The platealso includes a plurality of fastener receiving openings, preferably four fastener receiving openings. Fasteners, such as screws or bolts, pass through the fastener receiving openingsand into a dock segmentwhich couple the male connecting bracketto the dock segment. The platehas a second alignment flangeon the inner surfaceof the platealong the proximal side, as shown in. The second alignment flangeforms an angle with the inner surfaceof the platesuch that a corner of the dock segmentmay be cupped by the second alignment flangeand the inner surface. The angle may be about 90°, but may vary depending on the shape of the corner of the dock. The second alignment flange is typically around ¼ inch to about 1 inch similar to the first alignment flange.

The receiving channels of the female connecting brackethave a width of at least the diameter of the outwardly extending engagement members,. The outwardly extending engagement members,are able to fit within the receiving channels without becoming stuck or caught anywhere along the length of the receiving channels. The receiving channels may have different widths depending on the width of the outwardly extending engagement members,. The first and second outwardly extending engagement members,themselves may also differ in diameter from one another so long as the outwardly extending engagement members,on the opposite side of the dock segmenthave the same shapes. The distance that the outwardly extending engagement members,reach out from the platecan vary. It is preferred that the distance is equal to or greater than the thickness of the offset portionof the female connecting bracket.

To secure the male connecting bracketto a dock segment, a dock assembler first holds the male connecting bracketflat against the side of the dock segmentwith a portion of the platereaching past the corner of the dock segment. The portion of the platereaching past the corner includes the proximal sideand the second alignment flange, and only extends far enough for the flange to rest against a first endof the segment. The second alignment flangeand the plate inner surfaceform a generally right-angled surface that fits over the corner of the dock segment, and helping to securely hold the plateto the dock segmentand prevent it from sliding backwards along the side of the segment. The top sideof the plateshould be aligned with the top surface of the dock. As with the female connection bracket, if the top sideof the plateis not aligned correctly and does not match the alignment of upper edgeof the female connecting bracket, then the dock segmentmay not be completely horizontal and the surface of the overall dock will be uneven. Aligning the top sidewith the top surface of the dock segmentis an easy way for a dock assembler to accurately assemble the dock and ensure that the dock is safe.

As shown inConnecting the dock segmentsto one another requires a dock assembler to interlock the male connecting bracketsof a new segment to the female connection bracketsof a dock segmentalready in place. A first dock segmentis in position its second enddirected outwards towards the body of water. The second endof the dock has a right-side female connecting bracketon its right side and a left side female connecting bracketon its left side. A second dock segmentis lowered into position next to the fist dock segmentwith its first enddirected towards the second endof the first dock segment. The second dock segmentis lowered at an angle relative to the first dock segment. The first endhas a right male connecting bracketon its right side and a left male connecting bracketon its left side to correspond to the female connecting bracketson the first dock segment. The second dock segmentis lowered while at an angle with respect to the first dock segment. The first outwardly extending engagement memberson the bracketsof the second dock segmentslide into the first receiving channelsof the first dock segment, as shown in. Once the outwardly extending engagement membersreach the end of the first receiving channelsand prevent further downward movement, the second dock segmentperforms a swinging motion with the first outwardly extending engagementmembers as an axis of rotation. The rotational movement of the second segment brings the second outwardly extending engagement membersinto the second receiving channels. The second receiving channelsact as a guide for the outwardly extending engagement membersand limit the range of motion of the dock segmentto a particular path. The second dock segmentcontinues its rotational motion until it is aligned with the first dock segmentas shown in. The second receiving channelsmay terminate at such a length as to prevent the dock segmentfrom swinging further down and out of alignment with the first dock segment. The first receiving channelonly allows the first outwardly extending engagementmember to move vertically, and therefore prevents horizontal movement of the dock segment. The second receiving channelonly allows the outwardly extending engagement memberto move in the direction of its path, therefore preventing the dock segmentfrom moving vertically. Together, the receiving channels restrict movement in most directions.

The dock segmentmay only be removed by performing the inverse of the rotational motion that initially interlocked the male and female connecting brackets. The second dock segment is rotated upwards with the first outwardly extending engagement member as an axis of rotation. The second outwardly extending receiving member is thereby moved along the pathway defined by the second receiving channel until it exits the second receiving channel. Once the second outwardly extending engagement member is free, the second dock segment may now be moved in a vertical direction. The dock segment is lifted upwards until the first outwardly extending engagement member is free of the first receiving channel. The dock segment can be moved away from the location of the dock and set aside or stored.

The female connecting bracketmay optionally include a second offset portion. The second offset portionis set perpendicular to the original first offset portion, and is engaged to the rest of the female connecting bracketvia the connecting portion. The second offset portionis directed away from the dock segmentthat the female connecting bracketis engaged to. In this embodiment, two male connecting brackets, and by extension, two dock segments, may be connected to a single female connecting bracket. For example, in a dock having three dock segments, the first dock segmentis set up overlapping the shore, and the second dock segmentis attached to the first by the male and female connecting brackets,as usual. The third dock segmentengages to the female connecting bracketwith its own male connecting bracket, but the first endof the third dock segmentfaces a side of the second dock segment. This arrangement of dock segmentsforms an L-shape. A fourth dock segmenton the side opposite of the third dock segmentwould form a T-shape. A dock assembler may use this embodiment of the female connecting bracketto create any number of dock configurations with shapes other than a line.