Apparatus and method for dock support or composite piling

Abstract

A piling and method of making same for elevating or supporting a structure such as a dock in marine environments. An inner core structural support material is surrounded by an outer impact absorbing water impervious plastic shell with an impact absorbent fill between shell and inner core. The shell is sealed to the core.

1 . A piling for elevation or support of a structure comprising: 
 a) an inner core comprising structural support material elongated along a longitudinal axis and having a bottom end and a top end;    b) an outer impact resistant, non-abrasive plastic shell surrounding but spaced from a portion of the inner core;    c) an impact absorbing intermediate material generally filling space between inner core and outer shell; and    d) a sealing member to deter entry of fluid or particles into the space between inner core and oute shell.    
   
   
       2 . The piling of  claim 1  wherein the structure is related to marine functions.  
   
   
       3 . The piling of  claim 2  wherein the marine function is a dock.  
   
   
       4 . The piling of  claim 2  wherein the marine function is a sign or light.  
   
   
       5 . The piling of  claim 2  wherein the marine function is a sea wall.  
   
   
       6 . The piling of  claim 1  wherein the inner core is between 8 feet and 40 feet in length.  
   
   
       7 . The piling of  claim 1  wherein the structural support material comprises a tube.  
   
   
       8 . The piling of  claim 7  wherein the tube comprises metal.  
   
   
       9 . The piling of  claim 8  wherein the metal is steel.  
   
   
       10 . The piling of  claim 8  wherein the metal is aluminum.  
   
   
       11 . The piling of  claim 7  comprising of fiberglass.  
   
   
       12 . The piling of  claim 1  wherein the structural support comprises wood.  
   
   
       13 . The piling of  claim 12  wherein the wood is solid in cross section.  
   
   
       14 . The piling of  claim 12  wherein the wood is chemically treated.  
   
   
       15 . The piling of  claim 1  wherein the shell is from several feet long to several tens of feet long.  
   
   
       16 . The piling of  claim 1  wherein the shell is tubular.  
   
   
       17 . The piling of  claim 1  wherein the shell comprises plastic that includes some impact absorbent capability.  
   
   
       18 . The piling of  claim 17  wherein the plastic comprises high density polyethylene.  
   
   
       19 . The piling of  claim 17  wherein the plastic comprises vinyl.  
   
   
       20 . The piling of  claim 1  wherein the sheet is on the order of an inch or less thick.  
   
   
       21 . The piling of  claim 1  wherein the exterior of the shell is textured.  
   
   
       22 . The piling of  claim 1  wherein the exterior of the shell is colored.  
   
   
       23 . The piling of  claim 1  wherein the exterior of the shell includes indicia.  
   
   
       24 . The piling of  claim 1  wherein the shell is not as long along its longitudinal axis as the inner core.  
   
   
       25 . The piling of  claim 1  wherein the core extends above the top of the shell and below the bottom of the shell when assembled.  
   
   
       26 . The piling of  claim 1  wherein the intermediate material comprises a material having impact absorbing properties.  
   
   
       27 . The piling of  claim 26  wherein the intermediate material comprises pellets.  
   
   
       28 . The piling of  claim 27  wherein the pellets comprise rubber or recycled rubber.  
   
   
       29 . The piling of  claim 28  wherein the rubber is recycled at least in part.  
   
   
       30 . The piling of  claim 1  further comprising a retainer at the bottom of the shell.  
   
   
       31 . The piling of  claim 30  wherein the retainer comprises a ring attached around the exterior of core.  
   
   
       32 . The piling of  claim 31  wherein the ring is metal and welded to the core.  
   
   
       33 . The piling of  claim 31  wherein the ring has an outside diameter equal or greater to the inside diameter of the shell.  
   
   
       34 . The piling of  claim 30  wherein the retainer comprises an elastomeric member.  
   
   
       35 . The piling of  claim 34  wherein the elastomeric member is a ring positioned at or near the bottom of the shell.  
   
   
       36 . The piling of  claim 35  further comprising an additioral elastomeric ring at or near the top of the shell.  
   
   
       37 . The piling of  claim 36  further comprising one or more additional elastomeric rings positionable intermediate between the top and the bottom of the shell.  
   
   
       38 . The piling of  claim 30  comprising top, bottom and intermediate elastomeric rings placed between the inner core and the shell.  
   
   
       39 . The piling of  claim 34  wherein the sealing member comprises the elastomeric ring.  
   
   
       40 . The piling of  claim 34  further comprising a sealing member at the top and bottom of the shell.  
   
   
       41 . The piling of  claim 40  wherein the sealing ring seal and position the shell concentrically to the piling.  
   
   
       42 . The piling of  claim 1  wherein the intermediate material comprises a foam.  
   
   
       43 . The piling of  claim 42  wherein the foam is an expanding foam.  
   
   
       44 . The piling of  claim 43  wherein the expanding foam is an expanding urethane foam.  
   
   
       45 . The piling of  claim 1  wherein the sealing member comprises an elastomeric member.  
   
   
       46 . The piling of  claim 1  wherein the sealing member comprises foam.  
   
   
       47 . The piling of  claim 1  wherein the intermediate material and sealing member comprises foam which adheres between the core and shell.  
   
   
       48 . The piling of  claim 47  wherein the foam seals and provides shock absorbing capacity.  
   
   
       49 . A method of making a piling comprising: 
 a) selecting a length of core of structural material;    b) placing impact resistant, non-abrasive a plastic outer shell surrounding and spaced from a selected part of the core;    c) filling at least a portion of space between core and shell with impact absorbent material; and    d) sealing the space.    
   
   
       50 . The method of  claim 49  wherein the material comprises pellets or discrete pieces of various sizes and shapes retained in the space.  
   
   
       51 . The method of  claim 50  wherein the pellets or pieces are retained by one or more spacers positioned between the core and the shell.  
   
   
       52 . The method of  claim 49  wherein the fill is inserted between the space between the core and shell near the bottom of the shell, compressed, and a spacer installed over an in abutnent with the compressed material.  
   
   
       53 . The method of  claim 52  further comprising filling a second part of the space between core and shell with fill, compressing and installing a spacer above it.  
   
   
       54 . The method of  claim 49  wherein the shock absorbent intermediate material is an expandable foam.  
   
   
       55 . The method of  claim 54  wherein the expandable foam is injected in the space between core and shell, leaving space for expansion of the foam.  
   
   
       56 . The method of  claim 49  wherein the core is tubular.  
   
   
       57 . The method of  claim 55  wherein the core is alumininum or steel.  
   
   
       58 . The method of  claim 49  wherein the fill is pelletized.  
   
   
       59 . The method of  claim 58  wherein the fill is rubber recycled pieces.  
   
   
       60 . The method of  claim 49  wherein the core is a solid material.  
   
   
       61 . The method of  claim 60  wherein the solid material is wood.  
   
   
       62 . The method of  claim 60  wherein the fill is expandable foam.  
   
   
       63 . The method of  claim 62  wherein the expandable foam is expandable urethane foam.  
   
   
       64 . The method of  claim 59  wherein the recycle pellets are various sizes and shapes.  
   
   
       65 . The method of  claim 49  further comprising capping the top of the inner core and shell.  
   
   
       66 . The method of  claim 65  firther comprising sealing the cap to the shell.  
   
   
       67 . The method of  claim 49  wherein the shell is one inch or less thickness.  
   
   
       68 . The method of  claim 49  wherein the shell is made of high density polyethylene.  
   
   
       69 . A method of supporting a dock comprising: 
 a) surrounding a substantial portion of a piling with an impact resistant non-abrasive plastic shell and impact absorbing fill therebetween;    b) sealing the ends of the shell relative to the piling.    
   
   
       70 . The method of  claim 69  wherein the shell extends around the piling from above water level to below water floor level.  
   
   
       71 . The method of  claim 69  wherein shell is made of environmentally friendly material.  
   
   
       72 . The method of  claim 69  wherein the shell is made of marine grade material that is resistant to degradation by water, sun, or marine organisms.  
   
   
       73 . The method of  claim 69  flirther comprising selecting a plurality of pilings of  claim 69  of selected lengths and installing lower ends below water floor level and attaching structure to upper ends.  
   
   
       74 . The method of  claim 69  wherein the piling has a selected color and texture.