U.S. patent application number 12/937991 was filed with the patent office on 2011-02-10 for adjustably rigid floating island system.
This patent application is currently assigned to Fountainhead L.L.C.. Invention is credited to Bruce G. Kania, Frank M. Stewart.
Application Number | 20110030602 12/937991 |
Document ID | / |
Family ID | 41255352 |
Filed Date | 2011-02-10 |
United States Patent
Application |
20110030602 |
Kind Code |
A1 |
Kania; Bruce G. ; et
al. |
February 10, 2011 |
ADJUSTABLY RIGID FLOATING ISLAND SYSTEM
Abstract
A floating island structure comprising a plurality of
rectangular- and/or freeform-shaped modules and an internal linkage
system; wherein the modules are comprised of nonwoven fibers;
wherein the internal linkage system comprises a plurality of joiner
plates and flexible or rigid tensioning members; wherein the
modules are joined together by joiner plates; wherein the
tensioning members are attached to the joiner plates and/or to
internal plates; and wherein the joiner plates of adjacent modules
are joined together to form the floating island structure. Natural
and/or synthetic fibers are optionally used to fill in the cavities
surrounding the tensioning members. A decking assembly is
optionally installed on top of the modules to provide homogeneous
or heterogeneous rigidity to the overall structure.
Inventors: |
Kania; Bruce G.; (Shepherd,
MT) ; Stewart; Frank M.; (Bozeman, MT) |
Correspondence
Address: |
ANTOINETTE M. TEASE
P. O. BOX 51016
BILLINGS
MT
59105
US
|
Assignee: |
Fountainhead L.L.C.
|
Family ID: |
41255352 |
Appl. No.: |
12/937991 |
Filed: |
March 20, 2009 |
PCT Filed: |
March 20, 2009 |
PCT NO: |
PCT/US09/37745 |
371 Date: |
October 14, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61049417 |
Apr 30, 2008 |
|
|
|
Current U.S.
Class: |
114/85 ;
114/264 |
Current CPC
Class: |
B63B 35/38 20130101 |
Class at
Publication: |
114/85 ;
114/264 |
International
Class: |
B63B 35/00 20060101
B63B035/00; B63B 3/48 20060101 B63B003/48 |
Claims
1. A floating island structure comprising a plurality of
rectangular-shaped modules and an internal linkage system; wherein
the rectangular-shaped modules are comprised of nonwoven fibers;
wherein the internal linkage system comprises a plurality of joiner
plates and flexible tensioning members; wherein each
rectangular-shaped module has a perimeter and comprises four joiner
plates oriented perpendicularly to one another around the perimeter
of the rectangular-shaped module; wherein each flexible tensioning
member comprises a first end and a second end, and wherein the
first end of each flexible tensioning member is attached to one of
the joiner plates and the second end of each flexible tensioning
member is attached to the joiner plate that is directly opposite
the joiner plate to which the first end of the flexible tensioning
member is attached; and wherein the joiner plates of adjacent
rectangular-shaped modules are joined together to form the floating
island structure.
2. The floating island structure of claim 1, wherein each
rectangular-shaped module comprises a top layer, a center layer,
and a bottom layer; and wherein the flexible tensioning members are
situated within the center layer of the rectangular-shaped
module.
3. The floating island structure of claim 1, wherein each
rectangular-shaped module comprises four flexible tensioning
members, two of which are attached at one end to a first joiner
plate and at the other end to a second joiner plate, and two of
which are attached at one end to a third joiner plate and at the
other end to a fourth joiner plate; and wherein the first and
second joiner plates are parallel to each other and the third and
fourth joiner plates are parallel to each other.
4. The floating island structure of claim 1, wherein at least one
flexible tensioning member is a chain and turnbuckle, and wherein
initial tensioning is provided by tightening the turnbuckle.
5. The floating island structure of claim 1, wherein at least one
flexible tensioning member is a chain, and wherein the chain is
attached to each joiner plate by means of shackles.
6. The floating island structure of claim 1, wherein at least one
flexible tensioning member is comprised of wire cable, and wherein
the wire cable is attached to each joiner plate by means of an eye
hook.
7. The floating island structure of claim 1, wherein at least one
flexible tensioning member is comprised of polymer rope, and
wherein the polymer rope is attached to each joiner plate by means
of an eye hook.
8. The floating island structure of claim 1, wherein at least one
flexible tensioning member is comprised of woven polymer strapping
that passes through a slot in each joiner plate to which it is
attached and is joined with a strapping clamp.
9. The floating island structure of claim 1, further comprising a
box frame that defines a central cavity of the rectangular-shaped
module.
10. The floating island structure of claim 9, wherein the central
cavity is filled with fiber wool; and wherein the fiber wool
comprises synthetic or natural materials or a combination of
synthetic and natural materials.
11. The floating island structure of claim 1, wherein rigid beam
tensioning members are used in lieu of the flexible tensioning
members; wherein each rigid beam tensioning member comprises a
rigid internal beam with a first end and a second end; wherein the
first end of each rigid internal beam is attached to one of the
joiner plates and the second end of each rigid internal beam is
attached to the joiner plate that is directly opposite the joiner
plate to which the first end of the rigid internal beam is
attached; wherein initial rigidity is provided during installation
of the rigid internal beam; and wherein the joiner plates of
adjacent rectangular-shaped modules are joined together to form the
floating island structure, thereby providing further rigidity to
the overall structure.
12. The floating island structure of claim 11, wherein the rigid
internal beams are attached to the joiner plates by means of beam
tensioning bolts; and wherein angle brackets are used to connect
intersections of the beams to keep the intersections square.
13. The floating island structure of claim 11, wherein each
rectangular-shaped module comprises a top layer, a center layer,
and a bottom layer; and wherein the rigid tensioning members are
situated within the center layer of the rectangular-shaped
module.
14. The floating island structure of claim 1, wherein each
rectangular-shaped module comprises four rigid tensioning members,
two of which are attached at one end to a first joiner plate and at
the other end to a second joiner plate, and two of which are
attached at one end to a third joiner plate and at the other end to
a fourth joiner plate; and wherein the first and second joiner
plates are parallel to each other and the third and fourth joiner
plates are parallel to each other.
15. The floating island structure of claim 11, further comprising a
box frame that defines a central cavity of the rectangular-shaped
module.
16. The floating island structure of claim 15, wherein the central
cavity is filled with fiber wool; and wherein the fiber wool
comprises synthetic or natural materials or a combination of
synthetic and natural materials.
17. The floating island structure of claim 1, further comprising
one or more freeform-shaped modules, wherein each freeform-shaped
module is comprised of nonwoven fibers; wherein each
freeform-shaped module further comprises at least one joiner plate,
at least one internal plate, and at least one flexible tensioning
member; wherein the freeform-shaped module comprises at least one
straight side, and the joiner plate is situated along the straight
side of the freeform-shaped module; wherein the freeform-shaped
module has an interior portion, and the internal plate is situated
in the interior portion of the freeform-shaped module and is
oriented so that it is parallel to the joiner plate; wherein the
internal plate is held in place by at least one adhesive bond
between the internal plate and the nonwoven fibers that comprise
the freeform-shaped module; wherein each flexible tensioning member
comprises a first end and a second end, and wherein the first end
of the flexible tensioning member is attached to the joiner plate
and the second end of each flexible tensioning member is attached
to the internal plate; and wherein the joiner plate of the
freeform-shaped module is joined to the joiner plate of another
freeform-shaped module or the joiner plate of a rectangular-shaped
module to form the floating island structure.
18. The floating island structure of claim 17, wherein rigid beam
tensioning members are used in lieu of the flexible tensioning
members; wherein each rigid beam tensioning member comprises a
rigid internal beam with a first end and a second end; wherein the
first end of the rigid internal beam is attached to the joiner
plate and the second end of the rigid internal beam is attached to
the internal plate; wherein initial rigidity is provided during
installation of the rigid internal beam; and wherein the joiner
plate of the freeform-shaped module is joined to the joiner plate
of a rectangular-shaped module to form the floating island
structure, thereby providing further rigidity to the overall
structure.
19. The floating island structure of claim 18, wherein the rigid
internal beams are attached to the joiner plates and internal
plates by means of beam tensioning bolts; and wherein angle
brackets are used to connect intersections of the beams to keep the
intersections square.
20. A floating island structure comprising a plurality of
freeform-shaped modules and an internal linkage system; wherein the
freeform-shaped modules are comprised of nonwoven fibers; wherein
the internal linkage system comprises a plurality of joiner plates,
a plurality of internal plates, and flexible tensioning members;
wherein each freeform-shaped module has at least one straight side
and comprises at least one joiner plate that is situated along the
straight side of the freeform-shaped module; wherein the
freeform-shaped module has an interior portion, and each
freeform-shaped module comprises at least one internal plate that
is situated in the interior portion of the freeform-shaped module
and is oriented so that it is parallel to a joiner plate of the
same module; wherein the internal plate is held in place by at
least one adhesive bond between the internal plate and the nonwoven
fibers that comprise the freeform-shaped module; wherein each
flexible tensioning member comprises a first end and a second end,
and wherein the first end of the flexible tensioning member is
attached to a joiner plate and the second end of each flexible
tensioning member is attached to an internal plate of the same
module; and wherein the joiner plate of the freeform-shaped module
is joined to the joiner plate of another freeform-shaped
module.
21. The floating island structure of claim 20, wherein each
freeform-shaped module comprises a top layer, a center layer, and a
bottom layer; and wherein the flexible tensioning members are
situated within the center layer of the freeform-shaped module.
22. The floating island structure of claim 20, wherein at least one
flexible tensioning member is a chain and turnbuckle, and wherein
initial tensioning is provided by tightening the turnbuckle.
23. The floating island structure of claim 20, wherein at least one
flexible tensioning member is a chain, and wherein the chain is
attached to the joiner plate and the internal plate by means of
shackles.
24. The floating island structure of claim 20, wherein at least one
flexible tensioning member is comprised of wire cable, and wherein
the wire cable is attached to the joiner plate and the internal
plate by means of an eye hook.
25. The floating island structure of claim 20, wherein at least one
flexible tensioning member is comprised of polymer rope, and
wherein the polymer rope is attached to the joiner plate and the
internal plate by means of an eye hook.
26. The floating island structure of claim 20, wherein at least one
flexible tensioning member is comprised of woven polymer strapping
that passes through a slot in the joiner plate and a slot in the
internal plate and is joined with a strapping clamp.
27. The floating island structure of claim 20, wherein rigid beam
tensioning members are used in lieu of the flexible tensioning
members; wherein each rigid beam tensioning member comprises a
rigid internal beam with a first end and a second end; wherein the
first end of each rigid internal beam is attached to a joiner plate
and the second end of each flexible tensioning member is attached
to an internal plate of the same module; wherein initial tensioning
is provided during installation of the rigid tensioning member; and
wherein the joiner plate of the freeform-shaped module is joined to
the joiner plate of another freeform-shaped module, thereby
providing further tensioning.
28. The floating island structure of claim 27, wherein the rigid
internal beams are attached to the joiner plates by means of beam
tensioning bolts; and wherein angle brackets are used to connect
intersections of the beams to keep the intersections square.
29. The floating island structure of claim 27, wherein each
freeform-shaped module comprises a top layer, a center layer, and a
bottom layer; and wherein the rigid tensioning members are situated
within the center layer of the rectangular-shaped module.
30. The floating island structure of claim 1, 17 or 20, wherein
each rectangular- or freeform-shaped module comprises a cavity
surrounding each flexible tensioning member; wherein fiber wool is
packed into the cavity surrounding each flexible tensioning member;
and wherein the fiber wool comprises synthetic or natural materials
or a combination of synthetic and natural materials.
31. The floating island structure of claim 11, 18 or 27, wherein
each rectangular- or freeform-shaped module comprises a cavity
surrounding each rigid tensioning member; wherein fiber wool is
packed into the cavity surrounding each rigid tensioning member;
and wherein the fiber wool comprises synthetic or natural materials
or a combination of synthetic and natural materials.
32. The floating island structure of claim 1, 11, 17, 18, 20 or 27,
further comprising a decking assembly, wherein the decking assembly
comprises decking runners and lateral decking boards; wherein the
decking runners are attached to the joiner plates; and wherein the
decking boards are attached to the decking runners.
33. The floating island structure of claim 32, wherein there is a
seam between each adjoining rectangular- or freeform-shaped module;
and wherein the decking runners are situated on top of the seams
between adjoining modules.
34. The floating island structure of claim 1, 11, 17, 18, 20 or 27,
further comprising a decking assembly, wherein the decking assembly
comprises decking runners, a grid support, and a plurality of
stepping stones; wherein the decking runners are attached to the
joiner plates; wherein the grid support is attached to the decking
runners; wherein each rectangular- or freeform-shaped module is
comprised of a top layer of nonwoven matrix; and wherein the
stepping stones are attached to the grid support and/or the top
layer of the nonwoven matrix.
35. The floating island structure of claim 34, wherein there is a
seam between each adjoining rectangular- or freeform-shaped module;
and wherein the decking runners are situated on top of the seams
between adjoining modules.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority back to U.S. Patent
Application No. 61/049,417, filed on 30 Apr. 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of
man-made floating islands, and more specifically, to a floating
island system in which individual floating island modules are
connected to one another through an internal linkage system that
provides adjustable rigidity to the overall island structure.
[0004] 2. Description of the Related Art
[0005] Man-made floating islands (also known as floating platforms)
are currently being utilized for a wide range of applications in
both freshwater and marine environments. Some examples of these
floating islands include floating wetlands for wastewater
treatment, floating gardens for hydroponic food production and
decoration, floating bridges and walkways for transportation, and
floating wildlife habitat for fish cover and waterfowl nesting.
[0006] In many of these applications, the islands are required to
support relatively heavy and/or concentrated loads. For example,
floating treatment wetlands may be required to support the weight
of pumps, wind turbines, and emergent vegetation. Floating bridges
may be required to support the temporary weight of vehicles and
pedestrians (temporary or "live" loads), as well as roadways and
railings (permanent or "dead" loads). In order to maintain buoyancy
and prevent sagging or buckling under the loads, floating islands
typically comprise internal or external stiffeners, such as boards
or beams, to distribute the load weights over the surface area of
the island.
[0007] In designing man-made floating islands, there are several
challenges that need to be overcome. First, the islands must have
sufficient buoyancy and rigidity to support the design load.
Second, the islands must be capable of being transported to the
deployment site and launched into the water as quickly and
economically as possible. Third, the islands must have sufficient
strength and durability to withstand dynamic forces produced by
wind, current, waves, and design loads.
[0008] In general, there are two major categories of floating
islands in the prior art: (1) islands that are constructed as a
single unit (or in several relatively large segments) with internal
or external load distribution components to provide the required
stiffness for the structure; and (2) islands that are constructed
as a set of relatively small, uniformly shaped modules that are
connected at the deployment site as the island assembly is
launched. Both of these island types suffer from one or more
serious shortcomings, however. The large, single or multiple
segment islands can be made with adequate stiffness and rigidity,
but they are expensive to manufacture, inefficient to transport,
and difficult to launch. In addition, these islands, which are
rigid over their entire surface, are more prone to adverse wave
effects than flexible islands. Totally rigid islands tend to rise
out of the water and then fall abruptly when exposed to waves.
These sudden movements produce large transient forces in anchor
lines and cause damage to plant roots extending through the bottom
surface of the island. Flexible islands, in contrast, are able to
bend and follow the curvature of wave crests and troughs, and
therefore do not experience the rapid and undesirable lifts and
drops of rigid islands.
[0009] Modular-component islands are efficient to manufacture,
transport, and deploy, but they tend to flex at the connection
joints, and therefore do not provide adequate load distribution for
many applications.
[0010] Floating islands that are constructed from multiple segments
tend to develop gaps along their internal seams because the
segments cannot be kept tightly connected during the dynamic
stressing that occurs as a result of wind, current and wave action.
These gaps are undesirable because they allow bedding mix or soil
to escape from the top surface of the islands. Even without the
stress associated with wind, current and wave action, tight seams
between segments are required to prevent the loss of bedding mix or
soil as a result of rainfall or snow melt. Some floating islands
also tend to wear and then eventually fail at the connection points
between segments because the connectors apply a concentrated stress
to a small surface area of the island material along the seams.
[0011] The present invention overcomes the shortcomings of the
prior art by providing a structure comprised of multiple modular
units having novel construction and connection means that result in
a large floating structure with optional, designable rigid zones
and that is easy and economical to manufacture, transport, assemble
and deploy. Portions of the island that require load distribution
and stability (such as walkways) are made rigid, while the
remaining portions of the island are constructed to have some
flexibility. This amalgamation of rigid and flexible zones provides
the combined advantages of load distribution and wave
tolerance.
[0012] In addition, the internal linkage system of the modules
results in module-to-module connections that are strong and durable
under dynamic forces of wind, current, and waves. The floating
islands of the present invention may be constructed so as to
provide an outer perimeter that is either geometrical or freeform
in shape (or a combination of geometrical on a portion of the
perimeter and freeform on the remainder of the perimeter), as
required for a specific application. The connection seams of the
present invention remain tightly joined during flexing of the
structure, thereby preventing bedding mix or soil from escaping.
Furthermore, the construction methods of the present invention
allow the use of inexpensive filler materials such as natural
and/or man-made fibers, scrap rubber, recycled plastics and plastic
trim.
[0013] The walkways of prior art floating islands are generally
constructed with an air gap between the decking and the island top.
This gap provides hiding places for undesirable animals such as
rodents, reptiles and insects that eat island vegetation and may
pose human health hazards. The walkways of the present invention
eliminate this gap, thereby minimizing populations of pest
animals.
[0014] Prior art floating islands that use flotation grids around,
through or under the modules or structures tend to be highly
buoyant around the outer perimeter and less buoyant in the center,
resulting in sagging of the plant growth media within each module
or structure. The present invention is comprised of modules whose
buoyancy is internally distributed throughout the volume of each
module (through the use of regularly spaced, preferably vertically
injected, foam nodules), thereby eliminating the sagging that
results from poorly distributed flotation.
[0015] Accordingly, it is an object of the present invention to
provide a modular system of floating islands wherein the modules
combine the economy of mass manufacture with the ability to produce
large, natural, freeform assembled structures. It is a further
object of the present invention to provide floating island modules
that combine economical transport capability with the ability to
construct very large assembled structures. Yet another object of
the present invention is to provide floating island modules that
comprise a variety of natural or man-made materials while
maintaining structural integrity, natural appearance, and the
ability to support the growth of plants and beneficial
microbes.
[0016] Another object of the present invention is to provide
floating islands modules that may be easily and quickly connected
to achieve a selectively rigid structure. It is a further object of
the present invention to provide floating island modules that can
be fitted with decking that provides additional rigidity to support
concentrated live and dead loads. Yet another object of the present
invention is to provide a stiffening strut or joist system that
allows for selective rigidity across the top of an island.
[0017] Another object of the present invention is to provide a
joiner plate connection system with compression seals along the
seams, thereby minimizing the escape of bedding mix or other fine
materials. It is a further object of the present invention to
provide joiner plate connections that are spread over a wide area,
as opposed to prior art seams or pins that are attached at discrete
intervals. Spreading the connections over a wide area eliminates
localized high-stress points, which thereby reduces joint
separation due to localized material failure. Yet another object of
the present invention is to provide a joiner plate connection
system for the modular floating islands that does not occupy space
on top of an island, thus providing for comprehensive,
discretionary plant growth over the entire top surface of the
island.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention is a floating island structure
comprising a plurality of rectangular-shaped modules and an
internal linkage system; wherein the rectangular-shaped modules are
comprised of nonwoven fibers; wherein the internal linkage system
comprises a plurality of joiner plates and flexible tensioning
members; wherein each rectangular-shaped module has a perimeter and
comprises four joiner plates oriented perpendicularly to one
another around the perimeter of the rectangular-shaped module;
wherein each flexible tensioning member comprises a first end and a
second end, and wherein the first end of each flexible tensioning
member is attached to one of the joiner plates and the second end
of each flexible tensioning member is attached to the joiner plate
that is directly opposite the joiner plate to which the first end
of the flexible tensioning member is attached; and wherein the
joiner plates of adjacent rectangular-shaped modules are joined
together to form the floating island structure.
[0019] In a preferred embodiment, each rectangular-shaped module
comprises a top layer, a center layer, and a bottom layer, and the
flexible tensioning members are situated within the center layer of
the rectangular-shaped module. Preferably, each rectangular-shaped
module comprises four flexible tensioning members, two of which are
attached at one end to a first joiner plate and at the other end to
a second joiner plate, and two of which are attached at one end to
a third joiner plate and at the other end to a fourth joiner plate,
and the first and second joiner plates are parallel to each other
and the third and fourth joiner plates are parallel to each
other.
[0020] In a preferred embodiment, at least one flexible tensioning
member is a chain and turnbuckle, and wherein initial tensioning is
provided by tightening the turnbuckle. In an alternate embodiment,
at least one flexible tensioning member is a chain, and the chain
is attached to each joiner plate by means of shackles. In yet
another alternate embodiment, at least one flexible tensioning
member is comprised of wire cable, and the wire cable is attached
to each joiner plate by means of an eye hook. In yet another
alternate embodiment, at least one flexible tensioning member is
comprised of polymer rope, and the polymer rope is attached to each
joiner plate by means of an eye hook. In yet another alternate
embodiment, at least one flexible tensioning member is comprised of
woven polymer strapping that passes through a slot in each joiner
plate to which it is attached and is joined with a strapping
clamp.
[0021] In a preferred embodiment, the present invention further
comprises a box frame that defines a central cavity of the
rectangular-shaped module. Preferably, the central cavity is filled
with fiber wool, and the fiber wool comprises synthetic or natural
materials or a combination of synthetic and natural materials.
[0022] In an alternate preferred embodiment, rigid beam tensioning
members are used in lieu of the flexible tensioning members; each
rigid beam tensioning member comprises a rigid internal beam with a
first end and a second end; the first end of each rigid internal
beam is attached to one of the joiner plates and the second end of
each rigid internal beam is attached to the joiner plate that is
directly opposite the joiner plate to which the first end of the
rigid internal beam is attached; initial rigidity is provided
during installation of the rigid internal beam; and the joiner
plates of adjacent rectangular-shaped modules are joined together
to form the floating island structure, thereby providing further
rigidity to the overall structure. Preferably, the rigid internal
beams are attached to the joiner plates by means of beam tensioning
bolts, and angle brackets are used to connect intersections of the
beams to keep the intersections square.
[0023] In a preferred embodiment, each rectangular-shaped module
comprises a top layer, a center layer, and a bottom layer, and the
rigid tensioning members are situated within the center layer of
the rectangular-shaped module. Preferably, each rectangular-shaped
module comprises four rigid tensioning members, two of which are
attached at one end to a first joiner plate and at the other end to
a second joiner plate, and two of which are attached at one end to
a third joiner plate and at the other end to a fourth joiner plate,
and the first and second joiner plates are parallel to each other
and the third and fourth joiner plates are parallel to each
other.
[0024] In a preferred embodiment, the floating island structure
further comprises a box frame that defines a central cavity of the
rectangular-shaped module. Preferably, the central cavity is filled
with fiber wool, and the fiber wool comprises synthetic or natural
materials or a combination of synthetic and natural materials.
[0025] In a preferred embodiment, the present invention further
comprises one or more freeform-shaped modules, wherein each
freeform-shaped module is comprised of nonwoven fibers; wherein
each freeform-shaped module further comprises at least one joiner
plate, at least one internal plate, and at least one flexible
tensioning member; wherein the freeform-shaped module comprises at
least one straight side, and the joiner plate is situated along the
straight side of the freeform-shaped module; wherein the
freeform-shaped module has an interior portion, and the internal
plate is situated in the interior portion of the freeform-shaped
module and is oriented so that it is parallel to the joiner plate;
wherein the internal plate is held in place by at least one
adhesive bond between the internal plate and the nonwoven fibers
that comprise the freeform-shaped module; wherein each flexible
tensioning member comprises a first end and a second end, and
wherein the first end of the flexible tensioning member is attached
to the joiner plate and the second end of each flexible tensioning
member is attached to the internal plate; and wherein the joiner
plate of the freeform-shaped module is joined to the joiner plate
of another freeform-shaped module or the joiner plate of a
rectangular-shaped module to form the floating island
structure.
[0026] In an alternate embodiment, rigid beam tensioning members
are used in lieu of the flexible tensioning members; each rigid
beam tensioning member comprises a rigid internal beam with a first
end and a second end; the first end of the rigid internal beam is
attached to the joiner plate and the second end of the rigid
internal beam is attached to the internal plate; initial rigidity
is provided during installation of the rigid internal beam; and the
joiner plate of the freeform-shaped module is joined to the joiner
plate of a rectangular-shaped module to form the floating island
structure, thereby providing further rigidity to the overall
structure. Preferably, the rigid internal beams are attached to the
joiner plates and internal plates by means of beam tensioning
bolts, and angle brackets are used to connect intersections of the
beams to keep the intersections square.
[0027] In a preferred embodiment, the present invention is a
floating island structure comprising a plurality of freeform-shaped
modules and an internal linkage system; wherein the freeform-shaped
modules are comprised of nonwoven fibers; wherein the internal
linkage system comprises a plurality of joiner plates, a plurality
of internal plates, and flexible tensioning members; wherein each
freeform-shaped module has at least one straight side and comprises
at least one joiner plate that is situated along the straight side
of the freeform-shaped module; wherein the freeform-shaped module
has an interior portion, and each freeform-shaped module comprises
at least one internal plate that is situated in the interior
portion of the freeform-shaped module and is oriented so that it is
parallel to a joiner plate of the same module; wherein the internal
plate is held in place by at least one adhesive bond between the
internal plate and the nonwoven fibers that comprise the
freeform-shaped module; wherein each flexible tensioning member
comprises a first end and a second end, and wherein the first end
of the flexible tensioning member is attached to a joiner plate and
the second end of each flexible tensioning member is attached to an
internal plate of the same module; and wherein the joiner plate of
the freeform-shaped module is joined to the joiner plate of another
freeform-shaped module.
[0028] In a preferred embodiment, each freeform-shaped module
comprises a top layer, a center layer, and a bottom layer, and the
flexible tensioning members are situated within the center layer of
the freeform-shaped module. Preferably, at least one flexible
tensioning member is a chain and turnbuckle, and initial tensioning
is provided by tightening the turnbuckle. In an alternate
embodiment, at least one flexible tensioning member is a chain, and
the chain is attached to the joiner plate and the internal plate by
means of shackles. In yet another alternate embodiment, at least
one flexible tensioning member is comprised of wire cable, and the
wire cable is attached to the joiner plate and the internal plate
by means of an eye hook. In yet another alternate embodiment, at
least one flexible tensioning member is comprised of polymer rope,
and the polymer rope is attached to the joiner plate and the
internal plate by means of an eye hook. In yet another alternate
embodiment, at least one flexible tensioning member is comprised of
woven polymer strapping that passes through a slot in the joiner
plate and a slot in the internal plate and is joined with a
strapping clamp.
[0029] In an alternate embodiment, rigid beam tensioning members
are used in lieu of the flexible tensioning members; each rigid
beam tensioning member comprises a rigid internal beam with a first
end and a second end; the first end of each rigid internal beam is
attached to a joiner plate and the second end of each flexible
tensioning member is attached to an internal plate of the same
module; initial tensioning is provided during installation of the
rigid tensioning member; and the joiner plate of the
freeform-shaped module is joined to the joiner plate of another
freeform-shaped module, thereby providing further tensioning.
Preferably, the rigid internal beams are attached to the joiner
plates by means of beam tensioning bolts, and angle brackets are
used to connect intersections of the beams to keep the
intersections square.
[0030] In a preferred embodiment, each freeform-shaped module
comprises a top layer, a center layer, and a bottom layer, and the
rigid tensioning members are situated within the center layer of
the rectangular-shaped module. Preferably, each rectangular- or
freeform-shaped module comprises a cavity surrounding each flexible
tensioning member; fiber wool is packed into the cavity surrounding
each flexible tensioning member; and the fiber wool comprises
synthetic or natural materials or a combination of synthetic and
natural materials. Preferably, each rectangular- or freeform-shaped
module comprises a cavity surrounding each rigid tensioning member;
fiber wool is packed into the cavity surrounding each rigid
tensioning member; and the fiber wool comprises synthetic or
natural materials or a combination of synthetic and natural
materials.
[0031] In a preferred embodiment, the present invention further
comprises a decking assembly, wherein the decking assembly
comprises decking runners and lateral decking boards; wherein the
decking runners are attached to the joiner plates; and wherein the
decking boards are attached to the decking runners. Preferably,
there is a seam between each adjoining rectangular- or
freeform-shaped module, and the decking runners are situated on top
of the seams between adjoining modules.
[0032] In an alternate embodiment, the present invention further
comprises a decking assembly, wherein the decking assembly
comprises decking runners, a grid support, and a plurality of
stepping stones; wherein the decking runners are attached to the
joiner plates; wherein the grid support is attached to the decking
runners; wherein each rectangular- or freeform-shaped module is
comprised of a top layer of nonwoven matrix; and wherein the
stepping stones are attached to the grid support and/or the top
layer of the nonwoven matrix. Preferably, there is a seam between
each adjoining rectangular- or freeform-shaped module, and the
decking runners are situated on top of the seams between adjoining
modules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a plan view of a floating island structure that is
comprised of a plurality of rectangular modules and a plurality of
freeform modules.
[0034] FIG. 2 is a plan view of a floating island structure that is
comprised of a plurality of standard size freeform modules.
[0035] FIG. 3 is a plan view of a floating island structure that is
comprised of non-standard size freeform modules.
[0036] FIG. 4 is an elevation view of a rectangular module.
[0037] FIG. 5 is a plan view of the center layer of a rectangular
module.
[0038] FIG. 6 is a cross-section elevation view of a rectangular
module.
[0039] FIG. 7 is a partial plan view of the center layers of two
floating island modules that have been connected.
[0040] FIG. 8 is a plan view of the center layer of a freeform
module.
[0041] FIG. 9 is a cross-section elevation view of two connected
rectangular modules with walkway components attached to the top
surface.
[0042] FIG. 10 is an elevation view of two connected rectangular
modules that have been joined with a decking runner that sits
directly on top of the modules.
[0043] FIG. 11 is a cross-section elevation view of a rectangular
module with a decking runner that sits directly on top of the
module.
[0044] FIG. 12 is a cross-section elevation view of a first
alternate embodiment of a tensioning member.
[0045] FIG. 13 is a cross-section elevation view of a second
alternate embodiment of a tensioning member.
[0046] FIG. 14 is a cross-section elevation view of a third
alternate embodiment of a tensioning member.
[0047] FIG. 15 is a perspective view of a first embodiment of a
walkway decking assembly for the decking shown in FIG. 9.
[0048] FIG. 16 is a perspective view of a second embodiment of a
walkway decking assembly for the decking shown in FIG. 9.
[0049] FIG. 17 is a perspective view of a first embodiment of a
decking assembly for the decking shown in FIG. 11.
[0050] FIG. 18 is a perspective view of a second embodiment of a
decking assembly for the decking shown in FIG. 11.
[0051] FIG. 19 is a perspective view of an alternative embodiment
of the decking assembly in which the decking assembly comprises a
single decking runner.
[0052] FIG. 20 is a cross-section elevation view showing a method
of attaching the stepping stone of FIG. 16.
[0053] FIG. 21 is a cross-section elevation view showing a method
of attaching the stepping stone of FIG. 18.
[0054] FIG. 22 is a cross-section elevation view showing a method
of attaching the stepping stone of FIG. 19.
[0055] FIG. 23 is a plan view of a floating island structure in
which a selected portion of the structure has been made rigid, and
the remainder of the structure remains relatively flexible.
[0056] FIG. 24 is a plan view of a floating island structure in
which the entire surface has been made homogeneously rigid.
[0057] FIG. 25 is a plan view of the center layer of a rectangular
module that has rigid beam tensioning members.
[0058] FIG. 26 is an exploded perspective view of a male joiner
plate and a female joiner plate with a friction-fit decking
bracket.
[0059] FIG. 27 is a cross-section elevation view of a male joiner
plate and a female joiner plate, showing the tensioning
mechanism.
[0060] FIG. 28 is a cross-section elevation view of a male joiner
plate and a female joiner plate, showing the intra-module webbing
and slots.
REFERENCE NUMBERS
[0061] 1 Floating island structure [0062] 2 Rectangular module
[0063] 3 Freeform module (standard size) [0064] 4 Island structure
comprised of standard size freeform modules [0065] 5 Joiner plate
[0066] 6 Seam [0067] 7 Island structure comprised of non-standard
size freeform modules [0068] 8 Non-standard size freeform module
[0069] 9 Restraining bolt for tension member [0070] 10 Hole for
joiner plate connection bolt [0071] 11 Top module layer [0072] 12
Center module layer [0073] 13 Bottom module layer [0074] 14
Tensioning member [0075] 15 Turnbuckle [0076] 16 End wall [0077] 17
Side wall [0078] 18 Hole or slot in matrix [0079] 19 Central cavity
[0080] 20 Box frame [0081] 21 Compression gap [0082] 22 Connection
bolt [0083] 23 Freeform outer edge [0084] 24 Internal plate [0085]
25 Decking runner [0086] 26 Decking center bracket [0087] 27
Decking end bracket [0088] 28 Decking bolt [0089] 29 Air gap [0090]
30 Decking board [0091] 31 Chain tensioning member [0092] 32
Shackle [0093] 33 Wire cable or polymer rope [0094] 34 Eye hook
[0095] 35 Polymer strapping/intra-module webbing strap [0096] 36
Strapping clamp [0097] 37 Grid support [0098] 38 Stepping stone
[0099] 39 U-bolt [0100] 40 Injection hole [0101] 41 Nodule of
injected foam [0102] 42 Partially rigid island structure [0103] 43
Homogeneously rigid island structure [0104] 44 Rigid beam
tensioning member [0105] 45 Beam tensioning bolt [0106] 46 Angle
bracket [0107] 47 Male joiner plate [0108] 48 Female joiner plate
[0109] 49 Friction-fit decking bracket [0110] 50 Inter-module
webbing strap slot [0111] 51 Intra-module webbing strap slot [0112]
52 Decking bracker receiver hole [0113] 53 Protrusion [0114] 54
Positioning hole [0115] 55 Inter-module tensioning strap [0116] 56
Strap clamp
DETAILED DESCRIPTION OF INVENTION
[0117] In the present invention, each of the floating island module
components comprises a plurality of horizontal, flexible (or, in an
alternate embodiment, rigid) tensioning members that are partially
pre-stressed during manufacture and further stressed when the
modules are connected. These internal tensioning members provide a
durable and rigid mechanism for attaching joiner plates to each
module. The joiner plates of adjoining modules may be quickly
bolted together to provide a strong and simple method for
connecting multiple modules together. In zones of the floating
island structure where additional rigidity is desirable, stiffening
struts or joists may be placed on the top surface or bottom surface
of the structure, and these stiffeners (also called decking
runners) may be connected to the joiner plates of two or more
adjoining modules. The decking runners may be placed so that all of
the modules are rigidly attached to form a homogeneously rigid
structure, or alternately, the decking runners may be placed so
that only a portion of the structure is stiffened.
[0118] In a preferred embodiment, the modules that comprise the
interior of a multiple-module floating structure are made in
identical geometric configuration. Where a freeform shape of the
assembled structure is required, the outer modules of the structure
are individually shaped so as to connect to an adjoining module on
the inner side(s), while having a freeform (curved) shaped on the
edge(s) that form a portion of the outer perimeter of the assembled
island structure. The identical internal modules are suitable for
mass manufacturing methods and are, therefore, relatively
inexpensive to construct. In addition, their dimensions may be
chosen so as to provide efficient stacking and packing for
transport in trucks and marine containers. The standard size
freeform modules are adaptable to efficient manufacture because
they have similar internal construction regardless of outer shape
(see FIG. 8). The standard size freeform modules are also
relatively efficient to ship because each module may be designed to
fit within the same space as that occupied by a geometric module.
(As used herein, the term "standard size" means that the freeform
module fits within the outline of a rectangular module, as shown in
FIG. 2. The rectangular modules could be of any dimension, however.
As used herein, the term "rectangular" includes square.)
[0119] The outer layers (top layer, bottom layer, and sides) of
each module are preferably comprised of nonwoven fibers that are
packed and/or intertwined to form a three-dimensional shape
(hereinafter referred to as "matrix") that is porous and permeable.
The individual fibers are optionally covered with a protective
coating made from latex or polyurea to improve the quality of the
matrix by increasing the tensile strength, to provide a desired
color, and/or to protect the matrix from the deleterious effects of
ultraviolet light. The matrix is injected with adhesive that
penetrates the matting and fills a portion of the void space
between the fibers, bonding the fibers and thereby providing
mechanical strength to the matrix. In a preferred embodiment, the
injected adhesive is made of closed cell foam, which provides
buoyancy in addition to adhesion.
[0120] In a preferred embodiment, pieces of matrix ("fiber wool")
are packed into the interior portion of the floating island module.
Fiber wool is used in this manner because it is flexible and easily
shaped, and it is easy to pack into the cavities around the
tensioning member components. Fiber wool can be produced (in a
mechanical shredder) from trim pieces of matrix that are produced
during normal manufacturing of the modules; using this scrap
material as filler reduces the manufacturing cost of the product
and minimizes waste production from the manufacturing operation.
Because the majority of the volume of the module is comprised of
nonwoven fiber material (either matrix or fiber wool), the module
is porous and permeable to water and gasses.
[0121] After the module is assembled, discrete shots of uncured
closed-cell foam are injected into the module, where the foam
expands and cures in place around the nonwoven fibers, thereby
forming foam nodules. These nodules provide buoyancy for the
structure, as well as bonding the layers and wool pieces together.
Because the cured foam occupies only a portion of the interior
volume of the module (typically about 5% to 50%), the module
retains its porosity and permeability after the foam has been
installed. Due to this inherent porosity and permeability, the
modules provide excellent growth habitat for macrophytes and
bacteria, both of which can be useful for removing excess nutrients
and particulates from the water body. Alternately, for applications
where maximum buoyancy is desirable and where porosity and
permeability are not important (for example, floating bridges),
foam may be injected so that after curing, the foam occupies a
majority of the available interior volume of the module (for
example, 50% to 100%).
[0122] The fibers comprising the matrix and fiber wool may be
composed of either synthetic or natural materials or a combination
of these materials. Suitable synthetic materials include polyester,
polypropylene, and polyethylene. Suitable natural fibers include
jute, coir, cotton, hemp, rockwool and fiberglass. The fiber wool
is optionally manufactured from scrap materials such as chopped
matrix, chopped coir matting, or shredded beverage bottles made of
polyethylene terephthalate (also called "PETE"). In addition, other
inexpensive filler materials, such as scrap rubber, wood chips and
straw, can be packed into the central cavity of the module.
[0123] Most natural fibers are biodegradable. For applications in
which floating islands are used to biologically remove excess
nutrients such as nitrate and phosphate, the natural fiber fillers
can provide a source of organic carbon that is required by
beneficial bacteria in order to break down the nutrients. In
addition, natural fibers are typically the least expensive
materials that can be used as filler for the islands. Scrap rubber
(from automobile tires), while not rapidly biodegradable, provides
a very inexpensive and durable filler that acts as a substrate for
beneficial biofilms for biological removal of waterborne
contaminants.
[0124] Each floating island module optionally comprises an inner
box frame that is placed around the central cavity. The box frame
provides additional rigidity to the module and also forms a barrier
around the cavity to prevent the escape of fine filler materials
such as peat, sawdust or shredded scrap plastic. The box frame may
be comprised of wood, polymer lumber, aluminum plates or sheeting,
and/or polymer sheeting.
[0125] FIG. 1 is a plan view of a floating island structure 1 that
is comprised of a plurality of rectangular modules 2 and a
plurality of standard size freeform modules 3. Although the modules
may theoretically be produced in any size, one typical module size
is 5 feet long, 5 feet wide and 7 inches thick. Although the
structure shown in FIG. 1 is comprised of a plurality of
rectangular modules 2 and a plurality of standard size freeform
modules 3, the present invention may also be comprised of a
plurality of rectangular modules only or a plurality of freeform
modules only.
[0126] FIGS. 2 and 3 illustrate two types of structures that are
comprised of freeform modules only. FIG. 2 is a plan view of an
island structure 4 that is comprised of a plurality of standard
size freeform modules 3, in which each standard size freeform
module 3 fits within the shape of a standard rectangular module 2.
The joiner plates 5 of each module and the seams 6 between adjacent
modules are shown. FIG. 3 is a plan view of an island structure 7
that is comprised of two freeform modules 8, in which the freeform
modules 8 do not fit within the shape of a particular rectangular
module size. This embodiment, utilizing custom-shaped modules, may
be advantageous for constructing islands having particularly odd
shapes (for example, very long and narrow island structures). The
attachment system for these custom islands is the same as the
systems used for the embodiments shown in FIGS. 1 and 2.
[0127] FIG. 4 is an elevation view of a rectangular module 2,
showing the joiner plate 5, tensioning member restraining bolts 9,
joiner plate connection bolt holes 10 (through which the connection
bolts 22, shown in FIG. 5, are inserted), top module layer 11,
center module layer 12, and bottom module layer 13. The top module
layer 11 and bottom module layer 13 are preferably comprised of a
blanket of nonwoven matrix material.
[0128] FIG. 5 is a plan view of the center layer 12 of a
rectangular module. Shown are the joiner plates 5, restraining
bolts 9, tensioning members 14, optional turnbuckles 15,
compressible end walls 16, side walls 17, holes or slots in matrix
18, central cavity 19 and an optional box frame 20. The tensioning
members 14 are comprised of materials that are flexible but
non-stretchable and are used to draw opposing joiner plates 5
together, causing the end walls 16 and side walls 17 to be pulled
inward, thereby providing rigidity to the module. The tensioning
members 14 and turnbuckles 15 are connected to the joiner plates 4
via holes or slots 18 that are cut through the end walls 16 and
side walls 17. The turnbuckles 15 are used to provide initial
tensioning of the tensioning members 14 if required by drawing
opposing joiner plates inward toward each other, while final
tensioning is applied when adjacent modules are connected (see
description of FIG. 7). The optional box frame 20 adds rigidity to
the module, while simultaneously preventing the escape of fine
particles of filler material (not shown) from the central cavity
19. For clarity, the central cavity 19 is shown to be empty in this
figure; in practice, it is filled with fiber wool (or, as noted
above, other inexpensive filler materials) after the tensioning
members are installed. Also shown is the compression gap 21, which
is reduced to zero as two adjoining modules are bolted together
(see FIG. 7 for additional description). In this embodiment, the
tensioning member 14 is comprised of chain. Alternate tensioning
member systems are shown in FIGS. 12-14.
[0129] FIG. 6 is a cross-section elevation view of the center layer
of the rectangular module shown in FIG. 5 taken at Section AA, with
the top layer 11 and the bottom layer 13 installed, thereby forming
a rectangular module 2. As shown in this figure, the top layer 11
and the bottom layer 13 extend across the module, forming the
central cavity 19. The joiner plates 5 are shown extending
vertically from top to bottom of the module; these may optionally
be shortened (not shown) so that they have less height than the
module.
[0130] FIG. 7 is a partial plan view of the center layer 12 of two
modules that have been connected. (The optional box frame 20 has
been omitted in this drawing for clarity.) The modules are
connected by inserting the connection bolts 22 through the
connection holes 6 (not shown) in the joiner plates 5 and
tightening the bolts 22. When the bolts 22 are tightened, the
joiner plates 5 are drawn together, thereby compressing the
material comprising the end walls 16. The force produced during
compression of the end walls 16 as the bolts 22 are tightened
results in progressively greater tension force in the tensioning
members 14 of each module. When the bolts 22 are fully tightened,
the joiner plates 5 are pressed together, the tensioning members 14
are under maximum tension, and the end walls 16 are pressed
together and compressed. In order to allow hand access for
tightening the connection bolts 22, access holes (not shown) may be
cut vertically downward through the top layer to the connection
bolt 22. The access holes may optionally be filled with bedding
soil and planted after the structure is assembled.
[0131] Note that in FIG. 7, the joiner plates on adjacent modules
are shown as being exactly lined up with one another. The joiner
plates do not need to be precisely lined up, however, as long as a
portion of the joiner plates on adjacent modules overlaps such that
the joiner plates can be joined together.
[0132] FIG. 8 is a plan view of the center layer of a standard size
freeform module 3. The module shown in FIG. 8 is similar to the
module in the upper right corner of the structure shown in FIG. 1.
This module comprises a freeform outer edge 23, as well as two
straight sides that are identical to the straight sides of the
module shown in FIG. 5. Joiner plates 5 are secured to the module
via turnbuckles 15 and tensioning members 14. For the standard size
freeform module 3, the tensioning members 14 are secured to
internal plates 24 as shown. The internal plates 24 are surrounded
by fiber wool that is packed into place around them. After the top
lay and bottom layer (not shown) are attached to the center layer,
uncured closed-cell foam is injected (preferably vertically)
through the module, where the uncured foam penetrates the fibers of
the wool and the fibers of the top and bottom layers and flows into
contact with the internal plates 24. When the foam expands and
cures, it provides an adhesive bond between the internal plates 24,
the fiber wool, and the top and bottom layers. The foam forms a
rigid solid when cured. The combination of adhesive bonding and
added rigidity from the cured foam act to lock the internal plates
24 in place, thereby preventing their movement when the tensioning
members 14 are tightened.
[0133] FIG. 8 is intended to illustrate generally how the joiner
plates and internal plates work in connection with a freeform
module, but the present invention is not limited to any particular
shape for a freeform module or any particular configuration for the
internal plates. There may be one or more joiner plates on each
connecting side of a module, depending on the size of the module
and the intended application of the assembled structure. Each
freeform module comprises a minimum of one joiner plate. Each
rectangular module comprises a minimum of four joiner plates. Large
modules may require more than one joiner plate per connecting side;
for example, if the structure shown in FIG. 3 has a seam length of
20 feet, it may require four joiner plates per module along the
joining seam, with each joiner plate having a length of about three
to five feet. For other applications, the lengths of the joiner
plates may range from about 0.5 feet to about 20 feet.
[0134] As previously described, island structures that are
comprised of a group of connected modules may be selectively
stiffened (i.e., the top surface may be made so as to carry heavy
loads without sagging). The selective stiffening may be installed
over a portion of the top surface or over the entire top surface by
attaching stiffening struts (or decking runners) at proper
intervals across some or all of the top or bottom surface. One
common embodiment of a selectively stiffened island is a structure
that comprises a rigid walkway. In this embodiment, the decking
runners provide stiffening and load distribution, while the lateral
decking boards provide secure footing.
[0135] FIG. 9 is a cross-section elevation view of two connected
rectangular modules 2 with walkway components attached to the top
surface of the modules. In this embodiment, the walkway is
comprised of decking runners 25 that are attached to the joiner
plates 5 by means of a decking center bracket 26 and decking end
brackets 27, which are connected to the decking runners 25 by
decking bolts 28. The decking center bracket 26 and end brackets 27
are installed by pushing them down over the top of the joiner
plates 5. A portion of the matrix material is cut away from each
top layer 11 to provide space for the brackets 26, 27; no other
modifications to the rectangular modules 2 are required to install
a walkway. The decking runners 25 may be comprised of wood,
polymer, wood/polymer composite, or other standard decking
material. The center and end brackets 26, 27 may be comprised of
molded or machined thermoplastic or thermoset polymer, aluminum, or
stainless steel. The decking bolts 28 may be comprised of nylon,
steel, stainless steel, aluminum or brass. The compressive and
tensile strength of the decking runners 25 and brackets 26, 27
provide additional stiffness and load distribution to the floating
island structure, which additional stiffness and load distribution
helps to support live loads. Note that this method of construction
results in an air gap 29 between the walkway and the top layer 11
of the floating island module.
[0136] FIG. 10 is an elevation view of two connected rectangular
modules 2 that have been joined with a decking runner 25 that sits
directly on top of the modules, thereby eliminating the air gap 29
of the design shown in FIG. 9. Elimination of the air gap 29 is
beneficial in some applications because gaps can provide hiding
areas for undesirable animals such as snakes, mice and roaches.
[0137] FIG. 11 is a cross-section elevation view of the structure
shown in FIG. 10, taken at Section AA. As shown, decking runners 25
are connected to joiner plates 5 via connection bolts 22. A portion
of the matrix material of the top layer 11 is removed by cutting to
provide for clearance of the decking runner 25 and connection bolt
22, so that the decking runner 25 sits directly on top of the end
wall 16, causing the bottom surface of the decking boards 30 to sit
directly on the top surface of the top layer 11, thereby preventing
any air gaps between the top layer 11, decking runner 25 and
decking boards 30.
[0138] FIGS. 12, 13 and 14 are cross-section elevation views of
three designs for tensioning members that are alternatives to the
chain and turnbuckle system shown in FIGS. 5-11. FIG. 12 shows a
tensioning member comprised of a chain 31 connected to joiner
plates 5 by means of shackles 32. FIG. 13 shows a tensioning member
comprised of wire cable or polymer rope 33 connected to joiner
plates 5 by means of eye hooks 34. FIG. 14 shows a tensioning
member comprised of woven polymer strapping 35 that passes through
slots (not shown) in joiner plates 5 and is joined with a strapping
clamp 36. The tensioning mechanisms for the examples shown in FIGS.
12, 13 and 14 do not have a pre-tensioning adjuster (for example, a
turnbuckle); to install these tensioning members, the modules are
temporarily compressed either manually or with an external
compression tool (not shown) while the tensioning members 31, 33,
or 36 are attached to the joiner plates 5. The tensioning members
shown in FIGS. 3-9 and 12-14 are examples of systems that are
suitable for pre-tensioning the modules (final tensioning is
discussed in connection with FIG. 7 and is the same regardless of
the type of tensioning member used); however, there may be other
durable and flexible materials that are suitable for use as
tensioning members.
[0139] FIGS. 15 and 16 are perspective views of two alternative
walkway decking assemblies for the decking shown in FIG. 9. FIG. 15
shows a conventional board walkway in which lateral decking boards
30 are attached to the decking runners 25. The decking boards 30
may be composed of wood, polymer, or polymer/wood composite. FIG.
16 illustrates walkway decking in which a grid support 37 is used
as a base to connect stepping stones 38 to decking runners 25. As
shown, the stepping stones 38 have a significant thickness (for
example, one to 12 inches) so that they extend a significant
distance above the support grid 37. A method of attaching the
stepping stones to the structure is shown in FIG. 19. When this
"step-stone decking" is installed on a module assembly, the spaces
between the stepping stones 38 are preferably filled with peat,
sod, bedding plants and/or gravel to produce a visual appearance of
natural stones set into natural soil or grass.
[0140] The stepping stones 38 may be composed of polymer or polymer
foam, composite polymer/wood lumber, polymer lumber, wood, stone,
or cement that has sufficient strength to support foot traffic. The
grid support 37 may be constructed of aluminum rods, polymer-coated
steel wire, or molded polymer. The construction methodology
illustrated in FIGS. 15 and 16 results in an air gap underneath the
decking or step stones because of the decking runners. This void
space may optionally be filled with sprayed-in polyurethane foam,
which adds additional reserve buoyancy to the structure and
eliminates hiding spaces for undesirable animals.
[0141] FIGS. 17 and 18 are perspective views of two alternative
decking assemblies for the decking shown in FIG. 11. FIG. 17 shows
a board walkway in which lateral decking boards 30 are connected
between decking runners 25, so that the lateral decking boards 30
and decking runners 25 are set flush on the top surface of modules
with no air gap between these components. FIG. 18 shows a series of
stepping stones 38 that are attached to a grid support 37. In FIG.
18, the spaces between stepping stones 38 are filled with peat,
sod, bedding plants and/or gravel, to produce a visual appearance
of natural stones set into natural soil or grass. The construction
methodology illustrated in FIGS. 17 and 18 eliminates void space
between the decking/step stones and the underlying island surface,
but open pore spaces in the island matrix material itself may
provide covered hiding spaces for insects underneath the decking or
step stones. These pore-space hiding areas may be eliminated by
injecting a layer of polyurethane foam into the matrix beneath the
decking/stepping stones, thereby creating foamed zones, so that the
foam penetrates two to ten inches into the matrix and fills all of
the matrix pore spaces within the foamed zones. In addition to
eliminating the open pore spaces, the foam serves to bond the
decking/stepping stones to the island matrix while providing
additional reserve buoyancy to the structure.
[0142] FIG. 19 is a perspective view of an alternative decking
assembly, which comprises a single decking runner 25. This
embodiment is installed on a group of assembled modules by setting
decking runner 25 on top of the seam between adjoining modules. The
grid support 37, which is the same as the grid support shown in
FIG. 18, helps to stabilize the stepping stones 38 by transferring
a portion of the live load to the top of the modules on which the
grid support 37 is resting. As in the previous embodiments, the
spaces between the stepping stones 38 may be filled with peat, sod,
bedding plants and/or gravel, to produce a visual appearance of
natural stones set into natural soil or grass.
[0143] FIG. 20 is a cross-section elevation view showing a method
for attaching the stepping stone 38 of FIG. 16 to the grid support
37. As shown, U-bolts 39 pass around bars from the grid support 37
and through holes (not shown) drilled in the stepping stone 38,
thereby attaching these two components.
[0144] FIG. 21 is a cross-section elevation view showing a method
for attaching the stepping stone 38 of FIG. 18 to the top layer 11
of a module. The stepping stone 38 is secured to the top layer 11
of a module by injecting uncured closed-cell foam into the top
layer 11 through an injection hole 40, thereby forming a nodule of
injected foam 41 that bonds to the lower surface of the stepping
stone 38 while also penetrating into the matrix fibers of the top
layer 11, where it cures in place. In addition to bonding the
stepping stone 38 to the top layer 11, the foam nodule 41 also
provides strength, rigidity and buoyancy beneath the stepping
stone.
[0145] FIG. 22 is a cross-section elevation view showing a method
for attaching the stepping stone 38 of FIG. 19 to the top layer 11
of a module. A slot 18 is cut into the matrix of the top layer 11
in order to receive a decking runner 25. Uncured closed-cell foam
is injected into the matrix fibers of the top layer 11 via
injection holes 40, thereby forming a nodule of cured foam that
bonds to the lower surface of the stepping stone 38 while also
penetrating into the matrix fibers of the top layer 11, where it
cures in place. In addition to bonding the stepping stone 38 to the
top layer 11, the foam nodule 41 also provides strength, rigidity
and buoyancy beneath the stepping stone.
[0146] FIGS. 23 and 24 illustrate the difference between a
partially rigid island structure and a homogeneously rigid island
structure. FIG. 23 is a plan view of a partially rigid island 42
that has two decking runners 25 installed across the top surface of
the structure. The decking runners 25 will be used to support a
walkway (not shown) that will be attached to the decking runners.
In this embodiment, the decking runners 25 provide stiffness and
load distribution (i.e., a rigid zone) for the walkway only; other
portions of the island surface do not contain stiffeners (or
decking runners) and are, therefore, relatively flexible. FIG. 24
is a plan view of a homogeneously rigid island 43 that has decking
runners 25 installed over the top of each module seam across the
entire top surface of the structure. In this embodiment, the entire
structure has been stiffened due to the uniformly distributed
decking runners 25.
[0147] FIG. 25 illustrates the use of rigid beams (or rigid beam
tensioning members) in lieu of the flexible tensioning members in a
rectangular module, for the purpose of increasing the rigidity of
the module. FIG. 25 is a plan view of the center layer 12 of a
rectangular module that comprises rigid internal beams (or rigid
beam tensioning members) 44. In this embodiment, the rigid internal
beams 44 are connected to the joiner plates 5 via the beam
tensioning bolts 45, which screw into threaded holes on the ends of
the rigid internal beams 44. The angle brackets 46 are used to
connect intersections of the beams 44 in order to the keep the
intersections square. When the beam tensioning bolts 45 are
tightened, opposing end walls 16 and side walls 17 are drawn toward
the center of the module, thereby causing the module to gain
rigidity. When multiple modules having rigid internal beams are
connected at their joiner plates to form a floating island
assembly, the rigid internal beams of the adjoining modules are
effectively joined, thereby providing rigidity to the assembled
island structure. This embodiment may be advantageous for
applications in which maximum rigidity of the assembled floating
island is more important than flexibility of a portion of the
structure; for example, when the floating island is used as a
bridge for automobiles in calm waters.
[0148] Floating island structures assembled from the module
embodiment of FIG. 25 may optionally be provided with additional
stiffness by installing decking as described in connection with
FIGS. 15 through 22. The cross-sectional shape of the rigid
internal beams 44 may be rectangular, I-beam shaped, or round. An
example of a suitable material having a rectangular cross-section
is polymer-wood composite decking lumber. An example of a suitable
material having an I-beam cross-section is EXTREM.TM. fiberglass
I-beams manufactured by Strongwell, Inc. of Chatfield, Minn. An
example of a suitable material having a round cross-section is
recycled polymer fence posts.
[0149] FIG. 26 is a perspective view of an alternate embodiment of
the joiner plates used to connect two modules. Shown are the male
joiner plate 47, the female joiner plate 48, and the friction-fit
decking bracket 49. Each joiner plate comprises two inter-module
webbing strap slots 50, two intra-module webbing strap slots 51,
and one decking bracket receiver hole 52. In addition, the male
joiner plate 47 comprises two protrusions 53, which fit into
positioning holes 54 within the female joiner plate 48 when the two
joiner plates are connected, thereby causing the two plates to be
drawn into proper alignment when they are connected. In this
embodiment, the decking runner 27 (not shown) would attach to the
joiner plates 47, 48 by inserting the decking runner 27 into the
decking bracket 49 and attaching it to the decking bracket 49 with
screws or bolts. In an alternate embodiment (not shown), the
friction-fit decking bracket 49 is eliminated, and decking runners
are installed directly into grooves that are formed into the top
surfaces of the joiner plates.
[0150] FIG. 27 is a cross-section elevation view of the male joiner
plate 47 and the female joiner plate 48 taken at section line A of
FIG. 26, with the two joiner plates connected. The inter-module
tensioning strap 55 is used to manually draw the joiner plates 47
and 48 together, after which the strap clamp 56 is clamped around
the tensioning strap 55 while the tensioning strap 55 is manually
held under tension. The residual tension in the inter-module
tensioning strap 55 that exists after the clamp 56 is tightened
causes the two joiner plates 47 and 48 to be held together under
tension, which provides a strong and rigid means for connecting two
modules.
[0151] As shown, the protrusion 53 of the male joiner plate 47 fits
into the positioning hole 54 of the female joiner plate 48 when the
two plates are drawn together. In FIG. 27, the two joiner plates
are shown slightly separated for clarity; however, in practice, the
two joiner plates are in contact when they are connected. The strap
clamp 56 may optionally be replaced by tying a knot in the tension
strap 55. The joiner plates 47 and 48 are preferably manufactured
by injection molding and are comprised of thermoplastic polymer
such as polyethylene, polypropylene, or poly-urea.
[0152] FIG. 28 is a cross-section elevation view of the male joiner
plate 47 and the female joiner plate 48 taken at section line B of
FIG. 26, with the two joiner plates connected by the means shown in
FIG. 27. FIG. 28 shows that intra-module webbing strap slots 51 are
used to recess the intra-module webbing straps 35 into their
respective joiner plates 47 and 48, thereby allowing the joiner
plates to contact each other without pinching the webbing straps
35. The surfaces of the intra-module webbing slots 51 are rounded
at locations that come into contact with the intra-module webbing
straps 35 in order to minimize abrasion to the intra-module webbing
straps 35. The intra-module webbing straps 35 are used to provide
internal tension for their respective modules, as shown in FIG.
14.
[0153] As an alternative embodiment to the joiner plate
configuration shown in FIG. 27, adjacent joiner plates may be
constructed so as to have one or more protrusion and one or more
connecting hole per plate, rather than the plates shown, which have
either protrusions only or connecting holes only.
[0154] Although the preferred embodiment of the present invention
has been shown and described, it will be apparent to those skilled
in the art that many changes and modifications may be made without
departing from the invention in its broader aspects. The appended
claims are therefore intended to cover all such changes and
modifications as fall within the true spirit and scope of the
invention.
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