U.S. patent application number 10/997025 was filed with the patent office on 2005-05-26 for rod-reinforced cushion beam.
Invention is credited to Barmakian, Andrew.
Application Number | 20050108980 10/997025 |
Document ID | / |
Family ID | 46303353 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050108980 |
Kind Code |
A1 |
Barmakian, Andrew |
May 26, 2005 |
Rod-reinforced cushion beam
Abstract
A reinforced cushion beam includes a rigid frame having a
plurality of interconnected elements; a plastic body encapsulating
and substantially solidly filling the frame, and one or more panel
members connected to the plastic body with a plurality of recessed
fasteners that extend through the panel(s) and into the plastic
body to form a scuff-resistant load-bearing surface. Also disclosed
is a method for forming the cushion beam.
Inventors: |
Barmakian, Andrew; (Rialto,
CA) |
Correspondence
Address: |
SHELDON & MAK, INC
225 SOUTH LAKE AVENUE
9TH FLOOR
PASADENA
CA
91101
US
|
Family ID: |
46303353 |
Appl. No.: |
10/997025 |
Filed: |
November 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10997025 |
Nov 22, 2004 |
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10927569 |
Aug 25, 2004 |
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10927569 |
Aug 25, 2004 |
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10346204 |
Jan 15, 2003 |
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10346204 |
Jan 15, 2003 |
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10278754 |
Oct 22, 2002 |
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Current U.S.
Class: |
52/831 |
Current CPC
Class: |
E04C 5/065 20130101;
E04C 2003/0491 20130101; E04C 5/166 20130101; E04C 3/291 20130101;
E02B 3/28 20130101; E04C 3/28 20130101; E04C 5/07 20130101; E04C
5/06 20130101; E04C 5/165 20130101; E04C 2003/0495 20130101 |
Class at
Publication: |
052/720.1 |
International
Class: |
E04C 003/30 |
Claims
What is claimed is:
1. A composite beam having a longitudinal axis and a
cross-sectional area of at least 50 square inches, comprising: (a)
a frame comprising a plurality of interconnected members; (b) a
resilient plastic body member substantially encapsulating the
frame; (c) a panel member spaced from the frame, a portion of the
resilient body filling space between the panel member and the
frame, the panel member forming a load-bearing outside surface
portion of the beam; and (d) a spaced plurality of fasteners
extending through the panel member in recessed relation thereto,
through portions of the plastic body, and into engagement with the
frame.
2. The composite beam of claim 1, wherein the panel member
comprises a resilient material.
3. The composite beam of claim 2, wherein the panel member
comprises ultra-high molecular weight (UHMW) polymer.
4. The composite beam of claim 2, wherein the panel member
substantially consists of an ultra-high molecular weight (UHMW)
polymer.
5. The composite beam of claim 2, wherein the plastic body
comprises a resilient material having a first rigidity, the
material of the panel member having a second rigidity being greater
than the first rigidity.
6. The composite beam of claim 1, further comprising an attachment
structure defining a spaced plurality of attachment elements
connected to plural spaced apart locations of the frame.
7. The composite beam of claim 6, wherein the attachment structure
comprises a plurality of transverse members bonded at spaced
locations along the frame, each of the transverse members having at
least one receptacle for engagement by a corresponding one of the
fasteners.
8. The composite beam of claim 7, wherein at least some of the
fasteners are threaded fasteners, the receptacles being threaded
openings.
9. The composite beam of claim 1, wherein the frame comprises: (a)
a plurality of longitudinal main rod members, at least three of the
main rod members being spaced laterally in different corresponding
directions relative to the longitudinal axis; and (b) a plurality
of transverse elements, each transverse element being rigidly
connected between a spaced pair of the main rod members, at least
three of the main rod members being connected to at least two
others of the main rod members by at least some of the transverse
elements.
10. The composite beam of claim 9, wherein at least some of the
transverse elements are shear panels.
11. The composite beam of claim 10, wherein the shear panels
comprise laterally spaced first and second sets of longitudinally
spaced shear panels, the panels of each set being bonded between a
pair of the main rod members.
12. The composite beam of claim 10, wherein at least some of the
shear panels have openings and/or notches formed therein, the body
member having portions external to the cage frame integrally joined
through the openings and/or notches with portions of the body
member within the frame for enhanced structural integrity of the
body member.
13. The composite beam of claim 9, wherein at least one pair of the
main rod members is connected by some of the transverse elements
being transverse rod segments such that diverging pairs of the
transverse rod segments are connected in proximal relation at
spaced intervals along each main rod member of the pair, whereby
the pair of main rod members and the diverging pairs of transverse
rod segments form a truss.
14. The composite beam of claim 9, wherein the main rod members and
the transverse elements are each spaced at least 0.5 inch within an
outside contour of the plastic body.
15. The composite beam of claim 9, wherein the main rod members are
selected from the group consisting of formed steel reinforcing
bars, formed nickel alloy reinforcing bars, fiberglass reinforcing
bars, and carbon fiber reinforcing bars.
16. The composite beam of claim 15, wherein at least some of the
transverse elements are selected from the group consisting of
formed steel reinforcing bars, formed nickel alloy reinforcing
bars, fiberglass reinforcing bars, carbon fiber reinforcing bars,
plastic dowels, wooden dowels, steel plates, and fiberglass
panels.
17. An installed fender assembly comprising a plurality of
composite beams according to claim 1.
18. A method for forming a scuff-resistant composite beam,
comprising the steps of: (a) providing a frame comprising a
plurality of interconnected members; (b) encapsulating the frame in
a plastic body; (c) providing a one or more scuff-resistant panel
members; (d) providing a plurality of headed fasteners; and (e)
connecting each of the one or more panel members to the plastic
body with at least two of the fasteners projecting through each
panel member in recessed relation thereto, and through portions of
the plastic body to provide a scuff resistant load bearing surface
on the resulting composite beam.
19. The method of claim 18, wherein the step of connecting further
comprises the steps of: (i) affixing a plurality of attachment
members at spaced locations along the frame; and (ii) engaging the
fasteners with corresponding ones of the attachment members,
thereby anchoring the one or more panel members to the frame.
20. The method of claim 19, wherein the step of affixing further
comprises the step of positioning the attachment members at
sufficiently greater spacing along the frame to compensate for
thermal extension of the frame at ambient temperature following the
step of encapsulating.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application
Ser. No. 10/927,569 filed Aug. 25, 2004, which is a
continuation-in-part of application Ser. No. 10/346,204, now U.S.
Pat. No. ______, which is a continuation-in-part of application
Ser. No. 10/278,754, filed on Oct. 22, 2002, now U.S. Pat. No.
______, each of these applications being incorporated herein by the
respective references.
BACKGROUND
[0002] The present invention relates to elongated structural
members such as pilings, columns, wales, planks, and beams,
particularly for used in marine environments, and methods for
making such members.
[0003] Concrete, steel, and wood are conventionally used for
pilings, telephone poles, beams and the like. However, each of
these materials has disadvantages. Concrete and steel pilings are
heavy and awkward to maneuver. Neither concrete nor steel pilings
make good fender pilings because neither is "forgiving" when
impacted. Under impact steel bends and buckles and concrete
shatters. Both concrete and steel pilings are expensive to repair.
Furthermore, steel, either standing alone or as a reinforcement in
porous concrete, is subject to corrosion.
[0004] Wood pilings, planks, and beams are plagued by wear and tear
and, particularly in marine environments such as in piers and ship
moorings, are attacked by wood-boring marine organisms. Wood
pilings, wales and planks are typically treated with creosote, but
even this material can be ineffective against modern marine borers.
These marine borers can only be stopped by wrapping the wood
pilings in plastic coverings. However, these plastic coverings
cannot withstand much wear and tear, especially abrasion from
normal vessel contact. So in addition to a thin plastic wrap,
wooden fender piles and planks often require thick plastic
wrappings, which are expensive to put in place, being also subject
to separation.
[0005] Composite pilings are also known, being disclosed for
example in U.S. Pat. No. 5,180,531 to Borzakian, that document
being incorporated herein by this reference. The '531 patent
discloses a plastic pipe having an inner pipe core or mandrel being
6 inches or less in diameter, and a substantially homogenous
coating being at least two inches thick. The thick plastic coating
provides the bulk of the mechanical strength, being formulated with
a desired combination of flexibility, brittleness, and impact
resistance for use as pilings including fender pilings of docks,
telephone poles, light standards, etc.
[0006] U.S. Pat. No. 5,766,711 to Barmakian, which is incorporated
herein by this reference, discloses a composite camel structure
including a pipe mandrel and a thermally bonded plastic cushion
surrounding the mandrel. A mold having the mandrel centered therein
is filled with molten plastic, the plastic being cooled and
solidified by feeding water into the mandrel for progressively
solidifying the cushion member along mandrel for producing a
thermal bond without excessive tensile strain in the plastic
material, thereby to achieve a substantially unbroken outside
surface.
[0007] U.S. Pat. No. 6,244,014 to Barmakian, which is incorporated
herein by this reference, discloses a composite piling having a
welded cage including a circular array of parallel spaced main rod
members that are welded about a helically formed secondary rod
member, the cage being encapsulated in a plastic body.
[0008] U.S. Pat. No. 6,412,431 to Barmakian et al., which is also
incorporated herein by this reference, discloses a composite fender
having a cage frame encapsulated in a plastic body, the cage frame
having an attachment structure connected to plural spaced apart
locations of the frame.
[0009] Notwithstanding the above, it is believed that there is a
need for further improvements in structural components to be used
as beams in moorings, piers, and the like that are contemplated to
be used in marine environments, that such components have high
bending strength and high resistance to impact loading, and that
they have long life, are easily installed, environmentally sound,
and durable in use.
SUMMARY
[0010] The present invention meets this need by providing a
reinforced cushion beam of high bending strength, being
particularly suitable for a variety of marine applications. In one
aspect of the invention, a composite beam having cross-sectional
area of at least 50 square inches includes a frame having a
plurality of interconnected members; a resilient plastic body
member substantially encapsulating the frame; a panel member spaced
from the frame, a portion of the resilient body filling space
between the panel member and the frame, the panel member forming a
load-bearing outside surface portion of the beam; and a spaced
plurality of fasteners extending through the panel member in
recessed relation thereto, through portions of the plastic body,
and into engagement with the frame. Preferably the panel member
includes a resilient material for cushioned contact with objects
coming into contact with the beam. Preferably the panel member
includes ultra-high molecular weight (UHMW) polymer for providing a
desired combination of cushioning, strength and scuff resistance.
More preferably the panel member substantially consists of the
ultra-high molecular weight (UHMW) polymer. It is also preferred
that the plastic body include a resilient material having a first
rigidity, the material of the panel member having a second and
greater rigidity for withstanding localized impact loading.
[0011] The composite beam can include an attachment structure
defining a spaced plurality of attachment elements connected to
plural spaced apart locations of the frame. Preferably the
attachment structure includes a plurality of transverse members
bonded at spaced locations along the frame, each of the transverse
members having at least one receptacle for engagement by a
corresponding one of the fasteners for facilitating spacing the
threaded openings to match a predetermined spacing of the
fasteners. The fasteners can be threaded fasteners such as cap
screws, the receptacles being threaded openings.
[0012] The frame can include a plurality of longitudinal main rod
members, at least three of the main rod members being spaced
laterally in different corresponding directions relative to the
longitudinal axis; and a plurality of transverse elements, each
transverse element being rigidly connected between a spaced pair of
the main rod members, at least three of the main rod members being
connected to at least two others of the main rod members by at
least some of the transverse elements. At least some of the
transverse elements can be shear panels. The composite beam of
claim 10, wherein the shear panels comprise laterally spaced first
and second sets of longitudinally spaced shear panels, the panels
of each set being bonded between a pair of the main rod members.
Preferably at least some of the shear panels have openings and/or
notches formed therein, the body member having portions external to
the cage frame integrally joined through the openings and/or
notches with portions of the body member within the frame for
enhanced structural integrity of the body member.
[0013] Alternatively (or additionally) at least one pair of the
main rod members is connected by some of the transverse elements
being transverse rod segments such that diverging pairs of the
transverse rod segments are connected in proximal relation at
spaced intervals along each main rod member of the pair, whereby
the pair of main rod members and the diverging pairs of transverse
rod segments form a truss.
[0014] Preferably the main rod members and the transverse elements
are each spaced at least 0.5 inch within an outside contour of the
plastic body for enhanced cushioning and isolation of the frame
from harmful contamination. The main rod members can be selected
from the group consisting of formed steel reinforcing bars, formed
nickel alloy reinforcing bars, fiberglass reinforcing bars, and
carbon fiber reinforcing bars. The at least some of the transverse
elements can be selected from the group consisting of formed steel
reinforcing bars, formed nickel alloy reinforcing bars, fiberglass
reinforcing bars, carbon fiber reinforcing bars, plastic dowels,
wooden dowels, steel plates, and fiberglass panels.
[0015] A plurality of the composite beams can be assembled to form
a fender assembly.
[0016] In another aspect of the invention, a method for forming a
scuff-resistant composite beam includes the steps of: (a) providing
a frame comprising a plurality of interconnected members; (b)
encapsulating the frame in a plastic body; (c) providing a one or
more scuff-resistant panel members; (d) providing a plurality of
headed fasteners; and (e) connecting each of the one or more panel
members to the plastic body with at least two of the fasteners
projecting through each panel member in recessed relation thereto,
and through portions of the plastic body to provide a scuff
resistant load bearing surface on the resulting composite beam. The
step of connecting can further include the steps of (i) affixing a
plurality of attachment members at spaced locations along the
frame; and (ii) engaging the fasteners with corresponding ones of
the attachment members, thereby anchoring the one or more panel
members to the frame. Preferably the step of affixing includes the
further step of positioning the attachment members at sufficiently
greater spacing along the frame to compensate for thermal extension
of the frame at ambient temperature following the step of
encapsulating.
DRAWINGS
[0017] These and other features, aspects, and advantages of the
present invention will become better understood with reference to
the following description, appended claims, and accompanying
drawings, where:
[0018] FIG. 1 is a fragmentary sectional side view of a reinforced
cushion beam structure according to the present invention, the
section being taken on line 1-1 of FIG. 2;
[0019] FIG. 2 is a fragmentary sectional top view of the beam
structure of FIG. 1 taken on line 2-2 therein;
[0020] FIG. 3 is an oblique perspective view of a cage truss
portion of the beam structure of FIG. 1;
[0021] FIG. 4 is a lateral sectional view of a the beam structure
of FIG. 1;
[0022] FIG. 5 is a flow chart for a process of forming the piling
structure of FIG. 1;
[0023] FIG. 6 is a fragmentary sectional side view showing the beam
structure having an alternative configuration of the cage truss of
FIG. 3;
[0024] FIG. 7 is an oblique perspective view showing an another
alternative configuration of the cage truss of FIG. 3;
[0025] FIG. 8 is a lateral sectional view as in FIG. 4, showing an
alternative configuration of the beam structure of FIG. 1; and
[0026] FIG. 9 is an end elevational view of a fending panel
incorporating beam structures of the present invention and fastened
on stationary structure;
[0027] FIG. 10 is a front elevational view of the fending panel of
FIG. 9; and
[0028] FIG. 11 is an oblique perspective view showing a cage frame
as another alternative configuration of the cage truss of FIG.
3;
[0029] FIG. 12 is a side view as in FIG. 6, showing the beam
structure having an alternative cage frame configuration of the
cage truss of FIG. 3;
[0030] FIG. 13 is a lateral phantom view of the beam structure of
FIG. 12;
[0031] FIG. 14 is a side view as in FIG. 12, showing an alternative
configuration of the cage frame;
[0032] FIG. 15 is an oblique perspective phantom view of a cushion
beam structure having another alternative configuration of the cage
frame of FIG. 12;
[0033] FIG. 16 is a side view as in FIG. 1 showing another
alternative configuration of the beam structure;
[0034] FIG. 17 is a plan view of the beam structure of FIG. 16;
[0035] FIG. 18 is a fragmentary lateral sectional view of the beam
structure of FIG. 17; and
[0036] FIG. 19 is a partially exploded detail sectional view within
region 19 of FIG. 18.
DESCRIPTION
[0037] The present invention provides a novel reinforced plastic
cushion beam that is particularly effective as a sheathing plank,
wale, or other structural element of a wharf facility. With
reference to FIGS. 1-4 of the drawings, a cushion beam 10 according
to the present invention includes an elongate cage structure 11 in
the form of a cage truss 12, and a resilient plastic material
forming a cylindrical plastic body 14 and encapsulating the cage
truss 12. As used herein, a "resilient material" is one that can be
compressed significantly in volume under load, yet will return to
substantially the same volume when the load is released. The
relative "rigidity" of resilient materials as used herein is
proportional to the amount of compressive loading required to
effect a given change in volume.
[0038] As best shown in FIGS. 1, 2, and 4, an exemplary
configuration of the cushion beam 10 is generally rectangular in
cross-section, having an outside width W and an outside depth D
which can be the same as the width W, and an overall length L that
can be from approximately 10 feet to approximately 60 feet, or even
longer. In one specific exemplary configuration the width W and the
depth D are each approximately 12 inches. Also, the plastic body 14
as shown in the drawings is cylindrical, having a uniform
cross-section between opposite end extremities of the cushion beam
10. As used herein, the term "cylindrical" means having a surface
that is generated by a straight line that moves parallel to a fixed
line. Thus, although the body 14 is shown in the drawings as
rectangularly cylindrical, other cross-sectional shapes such as
circular, elliptical, polygonal, and rounded polygonal are also
contemplated within the scope of the present invention. Moreover,
it is also contemplated that the cushion beam 10 can be curved
and/or have a non-uniform cross-section within the scope of the
present invention.
[0039] The cage truss 12 includes a plurality of longitudinal main
rod members 16 that are rigidly interconnected by transverse
elements 17 that can include a multiplicity of transverse rod
segments 18, opposite end portions of each segment 18 being
connected between a pair of the main rod segments 16. As best shown
in FIG. 4, the main rod segments 16 are spaced laterally in plural
directions relative to a longitudinal axis 19 of the truss 12, with
each of the main rod members having transverse rod segments
projecting in plural directions having components perpendicular to
the longitudinal axis 19 (the plane of FIG. 4 being generally
perpendicular to the longitudinal axis 19). Preferably at least
some of the transverse rod segments 18 are diagonal segments 20, as
shown in FIGS. 1 and 3, so as to impart primarily tension and
compression loads on the main rod members 16 and the transverse rod
segments 18 in response to bending and shear loading of the cage
truss 12 as a whole. In the exemplary configuration shown in FIGS.
1-4, the cage truss 12 is adapted for transmitting bending and
shear loading primarily in the plane of FIG. 1. In particular, the
cage truss 12 has at least one additional transverse rod segment 18
connected in coplanar relation proximate each end portion of the
diagonal rod segments 20. As shown in FIG. 1, there are two such
additional coplanar transverse rod segments 18 proximate each
diagonal rod end extremity, (one being another of the diagonal rod
segments 20, the other being a lateral rod segment, designated
column rod segment 22) except at opposite ends of the cage truss
12, where there is one such additional transverse segment (a column
rod segment 22) at each connection location. Other lateral rod
segments, designated tie rod segments 24, extend perpendicularly
between opposite sides of the cage truss 12 as best shown in FIGS.
2-4.
[0040] In another aspect, the cage truss 12 includes a spaced pair
of generally planar truss units 26 that are connected in generally
parallel-spaced relation by the tie rod segments 24. In one
preferred form, the cage truss 12 is a weldment of steel
reinforcing bars having ribbed contours as indicated in FIG. 4 for
enhanced gripping and adhesion by the plastic body 14, weldable
steel reinforcing bars (ASTM 706) being commercially available from
a variety of sources. More particularly, a first truss unit 26A
includes a first pair (16A and 16B) of the main rod members
connected proximate opposite ends of one subset 18A of the
transverse rod segments 18, and a second pair 16C and 16D of the
main rod members connected on opposite ends of another subset 18B
of the transverse rod segments 18, one subset 24A of the tie rod
segments 24 being connected between the rod members 16A and 16C,
another subset 24B of the tie rod segments 24 being connected
between the rod members 16B and 16D as best shown in FIG. 4.
Additionally, a third pair (16E and 16F) of the main rod members
are connected proximate opposite ends of the first transverse rod
subset 18A opposite the first pair 16A and 16B, and a fourth pair
(16G and 16H) of the main rod members connected proximate opposite
ends of the second transverse subset 18B. Thus each of the truss
units 26A and 26B is laterally symmetrical on opposite sides of a
(typically planar) surface defined by the respective transverse rod
segment subsets 18A and 18B for maximum resistance to deflection
from loads applied (at least locally) coplanar with that surface.
It will be understood that for additional lateral stability and/or
for resistance to loading in directions having components parallel
to the tie rod segments 24, the cage truss 12 can include
additional diagonal rod segments 20 in other orientations (not
shown), such as diagonally between pairs of the tie rod segments 24
of the respective subsets 24A and 24B.
[0041] As shown in FIG. 2, the cage truss 12 also includes a
plurality of fastener attachments 30 for mounting the cushion beam
10 to other structure and/or for mounting other structural elements
to be supported by the cushion beam 10. As shown in FIG. 1, a first
plurality of the attachments, designated threaded sleeves 32, is
welded to the cage frame 10 and forming a rigidly connected
component thereof at spaced locations defining a first mounting
surface 33. A second plurality of attachments, designated floating
sleeve 34, are imbedded proximate a second mounting surface 35 the
resilient body 14 so as to form a cushioned mounting for other
supported structure as described below in connection with FIGS. 9
and 10. It will be understood that, particularly for connections
required to transmit mainly compressive and/or shear forces, it is
contemplated that fasteners such as lag screws can be threadingly
engaged with the plastic body, without requiring imbedded
attachments, whether or not such attachments form a part of the
cage structure 11.
[0042] An important feature of the present invention is a
formulation of polymeric material that is suitable for
encapsulating the cage truss 12 and that does not form voids and
cracks due to tensile thermal strains being generated during
solidification. This problem is exacerbated by the absence of a
tubular mandrel that can receive cooling water as disclosed in the
camel structure of the above-referenced '711 patent. It has been
discovered that a particularly suitable composition for forming the
plastic body 14 as an uninterrupted covering of the cage truss 12
is a main first quantity of low density polyethylene of which at
least 60 percent and preferably 65 percent is linear low-density
polyethylene (LLDPE), the balance being regular low-density
polyethylene (LDPE), and a process additive second quantity
including an effective amount of UV inhibitor, the composition not
having any significant volume of filler material such as calcium
carbonate. Preferably, the first quantity is at least 90 percent of
the total volume of the plastic body 14, approximately 5 percent of
the total volume being a mixture of coloring, foaming agent, and UV
inhibitor. Preferably the composition is substantially free (not
more than 5 percent) of high density polyethylene.
[0043] Thus the composition of the cushion member 14 has polymeric
elements being preferably exclusively polyethylene as described
above (substantially all being of low-density and mainly linear
low-density), together with process additives as described below.
As used herein, the term "process additive" means a substance for
enhancing the properties of the polymeric elements, and does not
include filler material such as calcium carbonate. The composition
preferably contains a process additive which can be a foaming or
blowing agent in an amount of up to about 0.9% by weight to insure
than when the plastic body 14 is made by extruding the plastic
composition into a mold, the mold is completely filled. The foaming
agent can be a chemical blowing agent such as azodicarbonamide. A
suitable chemical blowing agent is available from Uniroyal of
Middlebury, Conn., under the trade name Celogen AZ 130.
[0044] Other process additives of the composition can include a
coupling agent, preferably a silane, for improved bonding between
the plastic body 14 and the cage truss 12.
[0045] The plastic composition can also include a fungicide,
typically in an amount of about 0.25% by weight, and an emulsifier,
in an amount of from about 0.1% to 0.3% by weight. The use of
emulsifier improves surface appearance of the product.
[0046] The composition can also contain a carbon black, generally a
furnace black, as a colorant, to improve the physical properties,
and as a UV stabilizer. The amount of carbon black used is
generally about 2.5% by weight.
[0047] A mold apparatus (not shown) for encapsulating the cage
truss 12 to form the plastic body 14 of the cushion beam 10
includes a mold assembly and a conventional extruder press,
including one or more flanged tubular mold segments as further
described in the above-referenced '014 patent, but with the
cross-sectional shape of the mold segments conforming to the
cross-sectional shape of the body 14, with appropriate allowances
for shrinkage as further described in the '014 patent.
[0048] As further described in the '014 patent, the cage truss 12
centered within a main cavity of the mold assembly, being supported
by a plurality of projections 20, and/or by fasteners temporarily
engaging one or more of the fastener attachments 30, or by
centering screws as disclosed in the above-referenced '711 patent.
Alternative mold construction is also described in the
above-referenced '431 patent.
[0049] With further reference to FIG. 5, a process 100 for forming
the cushion beam 10 includes providing the main and transverse rods
16 and 18 in a provide rods step 102, a weld trusses step 104 in
which the truss units 26A and 26 B are assembled and welded, the
truss units 26 being joined in spaced relation in a weld cage step
105. Then, in a load mold step 106, the cage truss 12 is placed
within the mold assembly and anchored in registration therewith.
The mold is closed in a close mold step 108 and, optionally in an
incline mold step 109, the mold assembly is propped up on a
suitable support for elevating an exhaust vent thereof.
[0050] Next, the material of the plastic body 14 is fed into the
main cavity in an inject body step 110. Then in a cooling step 112,
the mold assembly with its contents is submerged in cooling water
for solidifying the material of the plastic body 14, after which
the assembly 42 is removed from the water (step 114), the mold is
opened (step 116), and the substantially complete cushion beam 10
is withdrawn (step 118). Further details of this process are
described in the above-referenced '014 and '431 patents.
[0051] With further reference to FIG. 6, an alternative
configuration of the cushion beam, designated 10', a counterpart of
the cage truss, designated 12', has a single formed rod member,
designated 20', substituted for the diagonal rod segments of each
of the truss units 26A and 26B. As also shown in FIG. 6, some of
the other transverse rod segments of the configuration of FIGS. 1-4
are omitted, namely all but the endmost column rod segments 22 and
every other one of the tie rod segments 24. With further reference
to FIG. 7, a counterpart of the cage truss 12', designated 12", has
the members omitted from the truss 12' restored, the restored
column rod segments, designated 22', being foreshortened and
abutting formed portions of the diagonal rod member 20'.
[0052] With further reference to FIG. 8, another alternative
configuration of the cushion beam, designated 10", has a
non-rectangular cross-sectional configuration, and a counterpart of
the cage truss, designated 12'", is non-rectangular. In particular,
counterparts of the first and second truss units, respectively
designated 26A' and 26B', are inclined laterally, counterparts of
the main rod members 16A and 16D being shared by the truss units
26A' and 26B', the tie rod segments 24 of the first subset 24A
being omitted. Thus the first truss unit 26A' includes counterparts
of the main rod members 16A, 16B, 16C, and 16F, the second truss
unit 26B including counterparts of the main rod members 16A, 16C,
16D, and 16H, there being no counterparts of the main rod members
16E and 16G. Also, the alignment of locally proximate pairs of the
main rod members, namely 16A and 16C, 16B and 16F, and 16D and 16H,
are oriented in facing relation to the longitudinal axis 19 for
simultaneous engagement at opposite sides of the transverse rod
segments that project in respective acutely divergent planes, which
in the exemplary configuration shown in FIG. 8 form an equilateral
triangle. Further, counterparts of the threaded sleeves 32 are
located proximate a counterpart of the first mounting surface 32
and proximate opposite end extremities of the tie rod segments 24,
being welded thereto and to adjacent ones of the main rod segments
16 as well as transverse rod segments 18 of the first and second
truss units 26A' and 26B'. As yet further shown in FIG. 8, one or
more counterparts of the floating sleeve, designated 34', is
located proximate a second mounting surface and in spaced relation
proximate the main rod members 16A and 16C. One or more formed
counterparts of the anchor member, designated 36', has opposite
ends welded to opposite sides of the floating sleeve 34', the
anchor members 36' together with the floating sleeve 34' enclosing
the main rod members 16A and 16C in spaced relation such that the
floating sleeve 34' is resiliently supported relative to the cage
truss 12'".
[0053] With further reference to FIGS. 9 and 10, a fending panel
assembly 40 includes at least one cushion beam, three vertically
spaced and transversely mounted beams 10" being shown, and at least
one panel member 42, a plurality of panel members 42 being shown
connected between the cushion beams 10". More particularly, the
first mounting surfaces 34 of the beams 10" are oriented
vertically, being fastened against a stationary structure 43 by a
plurality of first fasteners 44 that engage respective ones of the
fastener attachments 30. The panel member 42 is fastened against
the second mounting surface 35 by a plurality of second fasteners
46 that engage the floating sleeves 34 to form a fender assembly
for cushioning moored ships. A plurality of sheathing planks 48 are
also shown fastened in generally coplanar relation to the panel
members 42 in FIG. 9, it being understood that any combination of
panel(s) and/or plank(s) (or other structural elements) can be
supported by one or more of the cushion beams 10, 10' and/or 10".
Moreover, the sheathing planks can be additional counterparts of
the cushion beams, such as the cushion beams 10 and 10'.
[0054] In some military based naval applications, it is undesirable
for a marine-exposed structure to be electro-magnetically
sensitive. In such applications the cage truss 12 can be formed
with non-magnetic materials, such as nickel reinforcing bar (formed
of a corrosion-resistant steel alloy), which is available from MMFX
Steel Corp. of America, Charlotte, N.C. Another suitable material
is carbon-reinforced plastic bar, available from Aero Space
Composite Products of San Leandro, Calif. The cage truss 12 can
also be developed by using fiberglass reinforcing rods, with
reinforced epoxy joints at points of contact between the main rods
12 and the various transverse rod segments 18 and/or diagonal rod
segments 20. Additional suitable materials include Nylon
Reinforcement, available from McMasters Co. of Los Angeles, Calif.,
plastic dowels, also available from McMasters, and wooden dowels,
which are available from typical lumber yards.
[0055] With further reference to FIG. 11, certain of the
non-metallic materials, most particularly the fiberglass
reinforcing rods, are suitably joined with epoxy resin and locally
applied layers or other quantities of fiberglass reinforcement to
form rigidly bonded joints. When this form of construction is
utilized it is often possible to dispense with the diagonal rod
segments 20 in that the resulting frame, designated 12"", imparts a
desired amount or resistance to bending. As shown in FIG. 11, one
or more of the column rod segments 22 and the tie rod segments 24
are rigidly bonded to the main rod members 16 by epoxy resin 52
having one or more layers of fiberglass fabric 54 therein.
[0056] With further reference to FIGS. 12-15, another alternative
configuration of the cushion beam, designated 60, has an
alternative configuration of the cage structure 11 that
incorporates shear panels as some or all of the transverse elements
17 of the cage truss 12, in place of (or in addition to) some or
all of the diagonal rod segments 20 (or the diagonal rods 20' of
FIG. 6) and column rod segments 22 (and/or 22' of FIG. 7) as
described herein. As shown in FIGS. 12 and 13, one such cage
structure, designated cage frame 62, has a spaced plurality of
rectangular shear panels 64 joined along opposite edges thereof to
a spaced pair of the main rod members 16. It will be understood
that although the term "cage truss" as applied to the cage
structures 11 of FIGS. 1-11 does not strictly apply in that the
shear panels 64 (and portions of the main rod members 16 between
the shear panels) have shear loading, the deflection of the cage
frame 62 that is attributable to shear loading of the main rod
members is much less than would be present in the cage truss 12 of
FIG. 1 if the diagonal rod segments 20 were omitted, because the
portions of the main rod members 16 that are subject to shear
loading (and consequent strain) make up only a small proportion of
the length of the cage frame 62.
[0057] In the exemplary configuration of FIGS. 12 and 13, there are
two sets of the shear panels 64, designated 64A and 64B in FIG. 13,
that are sandwiched between pairs of the main rod members, the
panels 64A being welded along one edge between the main rod members
16A and 16E, and along the opposite edge between the main rod
members 16B and 16F. Similarly, the other panels 64B are welded
along one edge between the main rod members 16C and 16G, and along
the opposite edge between the main rod members 16D and 16H as shown
in FIG. 13. The tie rod segments 24 (24A and 24B) are located
within gaps between the shear panels 64 as shown in FIG. 12. It is
not necessary that there be tie rod segments in each of the gaps,
depending on the size of the panels 64, the gaps having a primary
purpose of providing structural integrity of the plastic body 14
within and outside of the cage frame 62 in that the material of the
body 14 extends through passages formed by the gaps. The gaps also
result in a reduction in the total weight of the shear panels 64,
which are preferably provided in a thickness sufficient to carry
compressive loading between the main rod members (16A and 16B, for
example) at opposite edges of the panels 64. Thus the shear panels
64 are substituted for both the diagonal rod segments 20 and the
column rod segments 22 of FIG. 1. In a counterpart of the exemplary
12-inch by 12-inch beam 10 described above, the shear panels 64 can
be provided as approximately {fraction (1/8)} inch thick mild steel
plates measuring {fraction (93/8)} inch in a direction
perpendicular to the main rods 16 (for extending just beyond the
midpoints of the rods to which they are welded), and from 6 to 8
inches in a direction parallel to the main rods, the spacing
between the panels 64 being from approximately 1 inch to
approximately 3 inches. The shear panels 64 can also be formed of
non-metallic materials such as fiberglass, being suitably bonded to
the main rod members 16, substituting for some or all of the
transverse rod elements (the column rod segments 22 and the tie rod
segments 24) in the cage truss 12"" of FIG. 11.
[0058] With particular reference to FIG. 14, an alternative
configuration of the cage frame, designated 62', has one or more
counterparts of shear panels, designated 64', in extended lengths
and having notches and/or openings therein for clearing the tie rod
segments 24 and/or providing passages connecting outer and inner
portions of the plastic body 14. In the exemplary configuration of
FIG. 14, the shear panel 64' extends substantially the full length
of the cage frame 64, having notches 66 formed along opposite edges
thereof for clearing the tie rods 24, and having a spaced plurality
of openings 68 that are configured for maintaining shear and
transverse compression strength while robustly connecting inner and
outer portions of the plastic body and reducing the overall weight
of the cage frame 62'.
[0059] With particular reference to FIG. 15, another alternative
configuration of the cage frame, designated 62", is arranged
similarly to the cage truss 12'" of FIG. 8. The cage frame 62"
includes counterparts of the main rod members 16A, 16B, 16C, and
16D, the rod members 16A and 16C being closely spaced, the rod
members 16B and 16D being spread apart. A sloping spaced plurality
of the shear panels 64A are connected between the main rod members
16A and 16B, and an oppositely sloping spaced plurality of the
shear panels 64B are connected between the main rod members 16C and
16D. Also, an additional plurality of shear panels, designated 64C,
are rigidly connected between the main rod members 16B and 16D, the
shear panels 64C being substituted for the tie rod segments 24 of
FIG. 8. Optionally, further shear panels 64D can be vertically
oriented and connected between certain ones of the shear panels 64C
and the main rod members 16A and 16C as shown in FIG. 15. The shear
panels 64C provide augmented resistance to compressive loading of
the cushion beam in regions between the main rod members 16B and
16D. As further shown in FIG. 15, the shear panels 64D are extended
longitudinally, spanning pluralities of the shear panels 64C, and
having counterparts of the openings 68 formed therein for
connection of opposite portions of the plastic body 14. It will be
understood that the main rod members 16A and 16C are rigidly
connected at suitable locations along the cage frame 62", and the
connection of the upper edges of the shear panels 64D to the main
rod members 16A and 16C also forms corresponding connections
between those main rod members. Also, although the plastic body 14
in FIG. 15 is rectangular in cross-section, other shapes, such as
that of FIG. 8, are also contemplated.
[0060] With further reference to FIGS. 16-19, a further and
preferred configuration of the cushion beam, designated 60',
includes a counterpart of the cage structure, designated cage frame
62'" and described below, and incorporates one or more load-bearing
panel members 70 that are formed of materials having higher scuff
resistance than those of the plastic body 14. More particularly,
the panel members 70 are preferably resilient as defined above, but
having higher rigidity as defined above than that of the plastic
body 14. A particularly suitable and preferred material for the
panel members 70 is ultra-high molecular-weight (UHMW) polymer,
whereas the plastic body 14 preferably includes high and
low-density polymer components, the low-density component forming
not less than 50 percent of the plastic body 14, thereby providing
the preferred combination of the panel members 70 having relatively
high rigidity and the plastic body having relatively lower
rigidity. Although these materials are preferred for their
combination of load-bearing capacity, cushioning, and scuff
resistance, attachment of the panel members 70 presents a problem
in that no suitable adhesive has been developed for joining the
panel members to the plastic body. Further, it is desired that
shear loads bourne by the panel members 70 be coupled directly to
the cage frame 62'". Moreover, it is important in applications
wherein fending of moving objects such as ships is contemplated
that the panel members 70 present a load-bearing surface that does
not have fasteners or the like projecting outwardly therefrom.
[0061] While threaded fasteners had been considered for joining the
panel members 70 to the frame, an additional problem is that the
molding process alters the spacing between different locations of
the frame. More particularly, if threaded studs are welded to
specific locations on the frame to match a hole spacing of the
panel members, there will be significant initial expansion of the
frame when the encapsulating plastic is introduced at approximately
450.degree. F. As the plastic cools and hardens at about
350.degree. F. the steel is still significantly extended, causing
compressive forces within the plastic body as the combination cools
to ambient. As a result, the frame remains somewhat extended, even
at ambient temperatures.
[0062] It has been discovered that a particularly suitable means
for affixing the panel members 70 to the plastic body 14 is a
plurality of headed fasteners 72 that directly engage the cage
frame 62'". More particularly, and as best shown in FIGS. 18 and
19, a preferred form of the cage frame 62'" includes one or more
attachment members 74 that are affixed at adjustably selected
locations along the frame to provide a properly spaced plurality of
threaded openings 75 for engagement by respective ones of the
fasteners 72. Each of the attachment members 74 has a transversely
spaced pair of the threaded openings 75, the distance between those
openings being relatively small (typically under eight inches)
compared with the length of typical panel members 70 (about four
feet). The fasteners 72 project through the panel members 70 and
portions of the plastic body 14, the fasteners having head portions
73 that are recessed within respective counterbore cavities 71 of
the panels 72. This configuration advantageously facilitates
exclusion of corrosive contamination from the frame, the fasteners
72 being preferably formed of corrosion-resistant steel.
[0063] As further shown in FIGS. 16-18, the cage frame 62'" has the
attachment members 74 configured as counterparts of the tie rod
segments 24, the attachment members being affixed at suitable
intervals along the main rod members 16A (16E and 16G, if present)
and 16C, by suitable means, such as welding. Advantageously, the
attachment members 24 are located opposite the main rod members 16B
and 16D, conveniently for affixing anywhere along the frame
according to placement of the panel members 70 with allowances for
extension of the frame as a result of the encapsulation
process.
[0064] The cage frame 62'" also includes counterparts of the shear
panels 64A and 64B of FIGS. 12 and 13, as well as the shear panels
64C of FIG. 15, the shear panels 64C connecting the main rod
members 16F and 16H. Additional shear members 64C also connect the
main rod members 16E and 16G. In the exemplary configuration of
FIGS. 16-19, the panel members are positioned end-to-end, forming a
load-bearing surface 76 that is approximately parallel with the
longitudinal axis 19 of the cushion beam 60', substantially
co-extensive with one face of the cushion beam 60'. The
load-bearing surface 76 has a planar central region 76C and a
relatively narrow perimeter region 76P that is formed with a
shallow chamfer for protection against chipping by passing objects.
In a typically configured example of the cushion beam 60', the
panel members can be formed in lengths of approximately four feet,
having a width such as one foot to match the width W of the cushion
beam, and a thickness of from about two to about four inches. It
will be understood that the attachment members 74 can serve as some
or all of the shear members 16C connecting the main rod members 16A
(16E and 16G, if present) and 16C, particularly when configured in
suitable widths. Also, the cage frame 62'" can incorporate one or
more of the shear panels 64' having extended lengths as described
above in connection with FIG. 14. Alternatively, the cage frame
62'" can be configured as a truss as described above in connection
with FIGS. 1-3, 7, and 8.
[0065] The cushion beam 10 (as well as the alternatively configured
beams 10', 10", 60, 60', and 60") of the present invention is
immune to marine borer attack, and thus requires no further
protection, such as creosote or plastic sheathing, being
practically maintenance free. The cushion beam 10 is abrasion
resistant, and thus has excellent effectiveness as a marine fender
plank without any added protective covering.
[0066] The composite cushion beam 10 is chemically inert, so it can
last indefinitely. It does not react with sea water, is corrosion
free, is substantially immune to the effects of light, is not
bothered by most petroleum products, and is not subject to dry rot.
Because it can be made with recycled plastic, it is an
environmentally sound investment.
[0067] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. For example, the main rods 16
can be formed having a flattened or elongate cross-section that is
preferably oriented to facilitate forming the connections with the
transverse rod elements 18. Also, the one or more panel members 70
can be concentrated at one end of the cushion beam 60 for use of
the beam as a cushioned piling. Therefore, the spirit and scope of
the appended claims should not necessarily be limited to the
description of the preferred versions contained herein.
* * * * *