Anchoring floating structures to underwater ground

Abstract

In a general aspect, an anchor includes a tubular body formed at least partially from a cementitious material and having an open end and a closed end. The anchor also includes an eye pad coupled to the tubular body and configured to be coupled to a mooring line. The tubular body includes a base wall, a peripheral wall, and a shear key. The base wall defines a closed end of the tubular body and has first and second surfaces on opposite sides of the base wall. A peripheral wall extends from a first surface of the base wall to an open end of the tubular body, and a shear key extends from a second surface of the base wall. The shear key is configured to penetrate into the subsea surface and to resist lateral displacement of the anchor along the subsea surface upon penetration.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 400,656, filed on August 24, 2022, entitled “Anchoring a Floating Structure to Submerged Ground”. The disclosure of the priority application is incorporated herein by reference in its entirety. Background Art

[0003] The following description relates to anchoring floating structures to an underwater floor.

[0004] Anchors can be used to fix or limit the position of an object floating on the water. To this end, the anchor can be deployed on the underwater ground and connected to the floating body via a cable, rope or chain. The anchor can rely on its mass to remain stationary on the underwater ground, thereby generating tension in the connector that constrains the movement of the floating body. In some cases, multiple anchors can be used to apply multiple restraining forces to the floating body. The presence of multiple anchors can be used to reduce the risk of failure of one or more connectors. The presence of multiple anchors can also limit the drift of the floating body around the desired position. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a schematic diagram of an exemplary floating photovoltaic system anchored to underwater ground by mooring lines, shown in perspective;

[0006] Figure 2A is a schematic diagram of an example anchor for securing a floating structure to underwater ground, shown in perspective above;

[0007] Figure 2B It is shown in a semi-transparent manner in the stereogram below. Figure 2A A schematic diagram of a portion of an example anchor;

[0008] Figure 2C It is shown in the three-dimensional diagram below. Figure 2A Schematic diagram of an example anchor of , but wherein the example anchor includes a shear key having a peripheral wall and four linear walls;

[0009] Figure 3 is a schematic diagram showing an alternative configuration of a shear key;

[0010] Figure 4 is a schematic diagram of an example anchor, shown in perspective, manufactured at least in part using a 3D concrete printing process;

[0011] Figure 5 is a schematic diagram of an example anchor having a body printed with ribs and a textured surface shown in elevation;

[0012] Figure 6 is a schematic diagram of an example tension leg platform shown in elevation, the tension leg platform supporting a wind turbine and secured to the underwater ground using nine anchors;

[0013] Fig. 7A is a schematic diagram of an example anchor having a tubular body and a pad eye, shown in perspective above;

[0014] Figure 7B It is shown in the three-dimensional diagram below. Fig. 7A Schematic diagram of an example anchor;

[0015] Figure 7C It is shown in cross-section Fig. 7A Schematic diagram of an example anchor;

[0016] Fig.7D It is shown in the above three-dimensional diagram Fig.7D A schematic diagram of an example anchor of , but wherein the example anchor includes a cap covering an open end of the example anchor;

[0017] Figure 8 Shown in side view Fig. 7A but wherein the example anchor includes a dome cover; and

[0018] Fig. 9 is a schematic diagram of an example anchor having multiple reinforcing walls shown in perspective view above. DETAILED DESCRIPTION

[0019] In general terms, an anchor for securing a floating structure to an underwater ground surface is described. The floating structure may be, for example, a renewable energy structure, such as a floating solar energy system, a wave energy system, and a wind energy system in a fresh or salt water body (e.g., inland or offshore). In some implementations, the anchor is configured to secure a floating solar energy system, which may have a mooring load that is one or two orders of magnitude lower than that of a floating wave energy system and a wind energy system (e.g., 15 tons holding capacity versus 1500 tons holding capacity).

[0020] Mooring and anchoring are critical challenges in systems and applications, such as in the development of reliable and low-cost floating photovoltaic (FPV) and other types of systems. FPV systems can attach photovoltaic (PV) panels to floating buoys, which are held in place by mooring lines connected to anchors. Figure 1 A schematic diagram of an example FPV system anchored to the underwater ground via mooring lines is shown in perspective.Deploying photovoltaic panels on bodies of water can create opportunities for solar energy where ground-mounted systems or rooftop systems are limited or not feasible.

[0021] FPV systems can be anchored using concrete blocks (e.g., deadweight / gravity bodies), screw anchors, and driven piles. However, these anchors may have constraints on their deployment. For example, screw anchors typically require divers to install them underwater, and they only work in small clumps of soil. Steel piles typically require expensive heavy equipment to install. Concrete gravity anchors work in a wide range of soil conditions and are quickly installed, but their rough shape makes them heavy and material intensive.

[0022] As an example, FPV systems can use 10 to 30 conventional block anchors per megawatt, each weighing 2 to 5 tons and costing $350 to $500 (US dollars) per ton. Therefore, a typical 10MWp power plant may use 700 tons of concrete, costing about $300,000 (US dollars). This large amount of concrete may be difficult to handle, and in order to install the block anchors, it may be necessary to manufacture customized barges at each location. In addition, each block is significantly overdesigned due to its limited horizontal load capacity (approximately one-third in the vertical direction). This overdesign is also needed to mitigate the risk of incorrect mooring, because anchor failure may cause catastrophic system failure, injury and possible death.

[0023] The anchors described herein can provide advantages over conventional anchors. For example, the anchors described herein can reduce costs, improve efficiency, simplify manufacturing and construction, and improve mechanical stability and functionality. Other advantages are also possible.

[0024] In some implementations, the anchor described herein includes a "stubby" (e.g., wide aspect ratio) body that relies on the mass of the anchor structure during installation to secure the floating structure to the underwater ground. In some variations, the anchor also includes a suction chamber that provides suction during installation. The suction force can assist the mass of the anchor when the anchor is secured to the underwater ground. In these variations, the anchor can correspond to a hybrid anchor. In some implementations, the anchor lacks a fluid port (e.g., for generating suction force in the suction chamber), which gives the anchor's body a simpler construction. However, the anchor can still benefit from generating suction force during short periods of high dynamic loads (such as during severe weather). The anchor can be formed of cementitious materials (e.g., concrete, reinforcing elements, aggregates, etc.). In some variations, the anchor includes features that reduce the amount of cementitious materials and reinforcements required for its construction. This reduction can reduce the cost of the anchor and reduce the amount of greenhouse gases emitted during the manufacture of cementitious materials.

[0025] Additional features or benefits of the anchor may include one or more of the following: [1] low-cost (and low carbon strength) ballast material (e.g., locally sourced aggregate, recycled concrete, or other waste material) in the body of the anchor; [2] corrugated or wavy walls to increase the rigidity and strength of the walls defining the body of the anchor; [3] co-located reinforcement material for the eyelets, the floor of the body (e.g., the base wall), and the shear keys to reduce the amount of reinforcement; [4] incorporation of fillets and cavities in the floor of the anchor to reduce stress concentrations and reduce the amount of concrete and reinforcement material; [5] a closed shear key shape that creates a suction force; [6] a shear key shape configured to support a ballast gravity load on the body floor (e.g., the base wall); and [7] a shear key shape having a profile that increases the torsional resistance of the anchor. Other features and benefits are possible.

[0026] exist Figure 2A In the above, a schematic diagram of an example anchor for securing a floating structure (such as an FPV system) to the underwater ground is presented in a perspective view from above. The example anchor may include one or more of the above features and benefits. Figure 2A As shown, the example anchor includes a shear key, a base wall, one or more pad eye connectors, a main body wall (e.g., a peripheral wall) and a cover. In many variations, the components of the anchor are manufactured using additive manufacturing processes such as 3D concrete printing processes. However, other manufacturing methods are feasible, including a combination of multiple methods. Examples of other possible manufacturing methods include 3D casting (which can 3D print concrete materials to be cast into the formwork (stayform) wall), concrete spraying, precasting, casting and slide molding. The example anchor can use gravity - and in some configurations also use suction - to resist vertical forces and overturning forces. The example anchor can also use friction and bearing forces to resist the horizontal force of one or more pad eyes applied to the example anchor by the mooring line. In some implementations, the example anchor is connected to a mooring line. In some implementations, the example anchor is connected to multiple mooring lines (such as in a shared anchor structure) to reduce the number of anchors required.

[0027] During installation, one or more shear keys of the example anchor are partially or completely buried beneath the underwater ground to increase the load bearing capacity of the example anchor. The shear keys may take a variety of shapes including open and closed profiles. Figure 2A Examples of shear keys are shown, where the shear keys have a closed profile. The shear keys can increase the vertical load capacity and the rollover load capacity of the anchor example. The shear keys can also increase the horizontal load capacity of the anchor. These increases can be caused by a pressure differential in the example anchor (e.g., between the interior and exterior of the example anchor) that is created when the anchor is raised or rotated about a horizontal axis.

[0028] Figure 3Schematic diagrams showing alternative configurations 300a-300f of shear keys 300 are presented. (Shapes are reduced for illustration purposes.) In the schematic diagrams, six example anchors are shown, each anchor being oriented "upside down" so that its shear key 300 faces upward. The shear keys 300 of the example anchors may include one or more walls extending outwardly from a surface 304 of a base wall 306. For example, the shear key 300 may include a peripheral wall 302 extending outwardly from a surface 304 of the base wall 306. The peripheral wall 302 may have a variety of shapes, such as a circular shape for the peripheral walls 302a-302d or a star shape for the peripheral wall 302e. In some variations, the shear key 300 includes a second wall nested within the peripheral wall 302, such as a concentric circular wall 308 of the shear key 300d. In some variations, the base wall 306 defines a closed end of the tubular body of the example anchor (e.g., see shear key 300f). In these variations, the peripheral wall 302 can be configured to convert a closed end into an open end (e.g., see shear keys 300a-300e). For example, the peripheral wall 302 can extend outwardly from the surface 302 sufficiently to define an opening into a chamber of the tubular body. In some cases, the chamber can be configured as a suction chamber of the example anchor. For example, the peripheral wall 302c of the shear key 300c can define a chamber deep enough to serve as a suction chamber 310. The suction chamber 310 can be fluidly coupled to the exterior of the example anchor via a conduit. 7A to 7D An example of such a configuration is described in relation.

[0029] Multiple walls may be used to increase the load bearing resistance of the shear key. The example anchor may also include a reinforcing wall located in the inner chamber to provide additional rigidity and strength to the base wall of the example anchor, thereby allowing the use of a thinner, more efficient floor structure, which reduces the material used during construction. For example, the material used to construct the floor structure may be reduced by approximately 50% compared to a solid floor. In some variations, the shear key may include a profile with teeth to increase the torsional resistance of the example anchor. The teeth may also strengthen the shear key to allow less material and reinforcements to be used during construction. In some variations, the shear key may include a peripheral wall extending from the base wall and defining an open end of the example anchor. The peripheral wall may be referred to as a "skirt" and may help limit scouring of the underwater ground from beneath the example anchor. In some cases, such as Figure 2A As shown, the peripheral wall defines a portion of the outer peripheral surface of the example anchor.

[0030] In some implementations, the shear key can provide additional mass to resist mooring loads. The body of the example anchor can have a base wall, such as Figure 2B As shown in the perspective view below, in addition to the shear keys, eyelets or lifting connectors can be connected to the base wall. For clarity, Figure 2BThe internal shear keys are omitted to allow better visibility of the reinforcement materials (e.g., ribs). The body can be hollow or solid. In some variations, the body includes a peripheral wall that defines a tubular structure. The body can also include a hollow chamber to facilitate the addition of low-cost, locally sourced ballast materials such as sand, rock, or recycled concrete materials. The base wall can include a reinforcement cage that transfers the mooring loads from the pad eye to the body and shear keys. In some configurations, the base wall reinforcements can extend into the shear keys and their walls to provide reinforcement to these portions of the example anchor. Other reinforcement materials that can be used include any fibers, cables, tendons, or nails. The reinforcement material can be part of a cementitious material. Figure 2C Shows Figure 2A An implementation of an example anchor of the embodiment of the present invention, wherein the example anchor includes a shear key forming an anchor skirt. The shear key includes four straight walls that intersect the anchor floor and define a suction chamber (e.g., nine suction sub-chambers) of the example anchor.

[0031] The profile of the body can take a variety of shapes, such as cylindrical, triangular, rectangular, or some other type of shape (e.g., a truncated cone). For example, the body can be cylindrical in shape with a wavy or sinusoidal circumferential wall that increases the rigidity of the body compared to a smooth wall. The wavy or sinusoidal wall can also increase the strength of the circumferential wall, thereby reducing the amount of material required to manufacture the wall. As another example, the body can be triangular in shape and configured to allow a mooring line to be connected at the midpoint of the base of the triangle. This shape and configuration can provide better rollover resistance by positioning the connection point of the pad eye closer to the center of gravity of the body. In some cases, ribs can be printed into the body to form reinforcing walls that increase its rigidity and strength. Figure 5 A schematic diagram of an example anchor having a body printed with ribs and a textured surface is presented in elevation view.

[0032] In some implementations, the example anchor may include a cover that forms an enclosure for the body and constrains loose ballast material (e.g., sand) from escaping the body. In some implementations, the cover may be used with the body to create a buoyancy chamber to aid in mounting the example anchor, particularly in the case of very large, high-capacity anchors. The buoyancy chamber, when unfilled, may allow the example anchor to float when deployed on the water. However, in some configurations, the body is almost completely filled with material to maximize the mass of the example anchor.

[0033] In many variations, the cover may include a textured surface that mimics shapes found in nature, such as corals or chambers that provide a protective habitat for marine life. The textured surface may be defined, for example, by a wavy wall on the cover. In doing so, the cover may promote the growth of marine life to support the marine ecosystem and grow additional organic matter on the anchor. However, other cover shapes are also possible, such as a cover with a smooth surface or a cover that partially encloses the body. For example, the cover may take the form of a net filled with a large ballast material (such as a large rock). Alternatively, the thickness of the cover may be increased to place additional mass on the top of the anchor. As another example, the cover may take the shape of a barrel that may be filled with additional ballast to further increase the mass of the example anchor. The additional mass may increase the downward force on the shear key, which in turn may provide assistance during the installation of the example anchor in an underwater bed with hard soil. In some variations, the cover may include a lifting ring to assist during the installation and removal of the cover. In addition, the cover may be designed to sit on the top of the body or on a lip just below the surface of the body to facilitate positioning and placing the cover on the anchor. The cover can also be fastened to the body using fasteners or other reinforcing materials. The cover can also be configured to receive an adhesive (e.g., grout, epoxy resin, etc.) for fastening.

[0034] In some implementations, the example anchors may have features that may include: [1] a body that combines the use of ballast material with shear keys. The shear keys may have a closed profile that generates a suction force, thereby increasing the vertical and rollover load resistance of the example anchor; [2] the body may also have a wide aspect ratio shape (e.g., a height to length ratio of approximately 1:1) that maximizes the amount of ballast material in the body relative to the amount of cementitious structural material. The large footprint of the body may also provide greater rollover resistance; [3] one or more pad eye connectors that are integrated into the floor of the body, such as a portion of the base wall or the peripheral wall near the base wall. Other locations of the body are possible. Such integration may allow for the incorporation of reinforcement material in the floor or body to help resist mooring loads on the pad eyes and to resist the load of ballast material on the base wall; [4] reinforcements in the floor of the body that may extend into the shear keys, base wall, and peripheral wall; [5] the shape and location of the shear key wall may be designed to maximize the rigidity of the example anchor and reduce the amount of concrete material required to manufacture the base wall; [6] anchor transportation and installation methods that allow for easy expansion to larger anchor sizes. For example, for very large and heavy anchors, the body - which may be hollow - may be floated to the installation site without ballast and lowered to the surface underwater using a smaller crane (e.g., before ballast is added to the example anchor). Any combination of these features is possible with the example anchor.

[0035] The example anchor may also include features that facilitate its manufacture. For example, the perimeter wall, base wall, and shear key may be constructed using 3D printing, 3D casting, or 3D spraying processes that facilitate inclusion of reinforcing materials. In particular, the 3D casting process may allow for the use of recycled concrete materials in the concrete mix, or the use of large, low-cost, and low-carbon footprint aggregates (e.g., up to 3 / 4" or larger in diameter) that may otherwise be difficult to print or spray through a small hose or nozzle. As another example, the use of a plugging material and a formwork to create the radiused surfaces of the shear keys and body may reduce the amount of cementitious material used to form the base wall. Additionally, manufacturing the anchor shell at an offsite printing facility allows for the transportation of a lighter weight anchor assembly that can be filled with locally sourced ballast material at the installation site. The anchor shell may be part of the body of the example anchor.

[0036] Various methods may be used to manufacture the example anchors. For example, additive manufacturing may allow the example anchors to be manufactured in multiple layers that can be cured, optionally repositioned, flipped, or receive a castable material. Additive manufacturing may also allow the example anchors to be manufactured without having to first create a support form. Furthermore, 3D printed material may be added to the body of the example anchor after the body of the example anchor has hardened for a period of time.

[0037] In some implementations, manufacturing an anchor—such as FIG. 2A to FIG. 2C An example anchor-method described includes 3D printing an outline of a shear key (or its walls) and a base wall. The outline can be referred to as a formwork. The method includes inserting a plugging material (e.g., sand or foam), a reinforcing material (e.g., non-corrosive reinforcing bars), and a gasket eye connector (e.g., concrete or metal hoops) into or around the formwork. The plugging material can create voids in the concrete structure to reduce material usage where concrete material is not needed. The method also includes casting the concrete material into or around the formwork and allowing the subassembly (or manufactured body) to cure. In many implementations, the method includes printing a wall of the anchor's body (e.g., a peripheral wall, a reinforcing wall, etc.) on the base wall. Figure 4 A schematic diagram of an example anchor fabricated at least in part using a 3D concrete printing process is presented in perspective view.

[0038] The anchors described herein may also provide advantages related to their design and manufacture. These advantages may relate to a digital design manufacturing process, which may include parametric design software combined with an additive manufacturing method. The digital design process allows for the rapid and cost-effective manufacture and installation of anchor configurations without creating new mold shells. These configurations include various anchor sizes and shapes of bodies, shear keys, and surface textures, and may also include configurations for installation in solar equipment or FPV systems. In addition, the modeling software may quickly change the design of the anchor for different input assumptions, and the resulting design may be quickly printed. The digital design and additive manufacturing processes may provide the opportunity to optimize the design of each anchor to the desired holding capacity, thereby improving the overall material efficiency of the anchor at the factory level. This increase may reduce over-design of the anchors, since a limited number of different molds are typically used.

[0039] The 3D printing process associated with the designed anchor can be very fast and cost-effective in many cases due to the elimination of the formwork and the reduction in labor in manufacturing. In some cases, an anchor for an FPV system may take about 20 minutes to print with the printer operated by 1 to 2 people.

[0040] Lightweight anchor shells can be manufactured using automated methods at a variety of locations, such as off-site in an existing concrete manufacturing facility. The manufactured shells can then be cost-effectively transported to the installation site before being filled with ballast. The off-site construction process may result in higher quality anchors due to the sheltered and more consistent manufacturing environment. Anchors can also be manufactured on-site (e.g., in situ) if a larger number of anchors, larger sizes, or shorter shipping distances are required.

[0041] Furthermore, as floating wind technology advances, anchor configurations can be applied and deployed on a large scale for mooring floating offshore wind turbines. In some settings, the main advantage of suction anchors is their mass to resist vertical loads. For example, the mass of a suction anchor can resist the average vertical loads generated by a floating wind turbine substructure such as a tension leg platform (TLP). In some cases, the suction anchor can therefore withstand greater vertical forces. Deepwater (about 1000 meters) deployments may require a TLP design with shorter, more environmentally friendly mooring lines, such as Figure 6As shown in . In addition, the TLP design may be the most stable platform design for large waves. The anchors described herein may be particularly advantageous because, in many cases, they can provide a connection to the underwater ground using both suction and gravity loads. In addition, the size of the anchor can be scaled and can float to the installation location. For example, during floating, the anchor can be oriented vertically in the same direction as the installation direction and then submerged more cheaply using a smaller container. The anchor may have benefits for other floating wind turbine substructures (such as semi-submersible platforms or barge platforms). These platforms may use various mooring configurations, such as tensioned, semi-tensioned or slack mooring configurations. The anchor may have benefits for other mooring configurations for mooring lines shared between wind turbines or for sharing anchors between multiple mooring lines.

[0042] In some variations, such as in the case of a TLP design, the eyelets of the anchor may be connected directly to the base wall to directly resist the ballast loads and prevent the concrete in the anchor from being in tension. Alternatively, the eyelets may be connected to the perimeter wall of the body, the cap, or the periphery of the anchor near the base wall.

[0043] Reference now Fig. 7A , presents a schematic diagram of an example anchor 700 having a tubular body 702 and an eyelet 704 in an upper perspective view. The eyelet 704 is coupled to the tubular body 702 and is configured to couple to a mooring line. Figure 7B and Figure 7C They are shown respectively Fig. 7A Below is a perspective view and a cross-sectional view of an example anchor. Figure 7C The cross-sectional view is taken relative to a mid-plane 706 passing through the example anchor 700.

[0044] The tubular body 702 is at least partially formed of a cementitious material and has an open end 708 and a closed end 710. The cementitious material may include cement and aggregate (e.g., sand or gravel). In some cases, the cementitious material may also include reinforcing elements such as fibers (e.g., steel fibers, polymer fibers, basalt fibers, glass fibers, etc.), reinforcing bars (e.g., steel reinforcing bars, basalt reinforcing bars, etc.), meshes (e.g., steel mesh, fiber mesh, etc.), cables, tendons, nails, etc. The tubular body 702 includes a base wall 712 defining a closed end 710 of the tubular body 702, and has a first surface 712a and a second surface 712b on opposite sides of the base wall 712. In some variations, the base wall 712 includes an outer surface that defines a portion of the outer surface of the tubular body 702. In some variations, the base wall 712 defines an internal support structure of the tubular body 702 to support the ballast material and provide rigidity to the example anchor 700. In some variations, the eyelet 704 is coupled to a central portion of the first surface 712a of the base wall 712. In some variations, such as 7A to 7CAs shown, the eyelet 704 is coupled to an outer side surface of the base wall 712. The outer side surface can define a portion of the outer surface of the tubular body 702 proximate the closed end 710.

[0045] The tubular body 702 also includes a peripheral wall 714 extending from a first surface 712a of the base wall 712 to an open end 708 of the tubular body 702. The peripheral wall 714 defines an opening into a chamber 716 of the tubular body 702 at the open end 708. In some variations, the chamber 716 is configured to define a volume that, when unfilled, allows the example anchor 700 to float when set on a body of water. In some variations, the eyelet 704 can be coupled to an edge surface of the peripheral wall proximate the open end 708. In some variations, the eyelet 704 is coupled to an outer surface of the peripheral wall 714 near the closed end 710 of the tubular body 702 (e.g., adjacent the base wall 712).

[0046] In some cases, the peripheral wall 714 can be configured at the open end 708 of the tubular body 702 to receive a cover that covers the open end 708 (e.g., to close the chamber 716). For example, the edge of the peripheral wall 714 at the open end 708 can define a lip or rim in which the cover can be set to cover the open end 708. Fig.7D The above stereogram shows Fig. 7A Schematic diagram of an example anchor 700 of FIG. 700 , but wherein the example anchor 700 includes a cover 717 covering the open end 708 of the tubular body 702. The cover 717 may include a surface 717a that is configured to face the exterior of the example anchor 700 when covering the open end 708. One or more features may extend from or into the surface 717a, such as a recess, a wall, a bump, etc. In some variations, such as Fig.7D As shown, the cover 717 includes a corrugated wall 717b extending from the surface 717a. The corrugated wall 717b can define a coral-like pattern on the surface 717a. However, other patterns are also possible. In some variations, the cover 717 has one or more pad eyes 704 connected thereto. Although Fig.7D The cover 717 is depicted as having a planar shape, but the cover 717 may also have other shapes, such as a dome shape. The dome shape may allow the example anchor 700 to hold more ballast material. The dome shape may also present an increased surface area, thereby providing more space for marine animals to attach themselves to the cover 717. Figure 8 A schematic diagram of an example anchor 800 including a dome cover 802 is presented in side view. Example anchor 800 and 7A to 7D The example anchor 700 of is similarly constructed, but lacks the conduit 728 and valve 730 of the example anchor 700 .

[0047] The tubular body 702 additionally includes a shear key 718 extending from the second surface 712b of the base wall 712. The shear key 718 is configured to penetrate into the underwater ground and resist lateral displacement of the example anchor 700 along the underwater ground when penetrated therein. In certain configurations, the shear key 718 can also resist rotational displacement of the example anchor 700 about the axis 720 of the tubular body 702 when penetrated into the underwater ground. The shear key 718 can include one or more walls extending from the second surface 712b of the base wall 712.

[0048] For example, the shear key 718 may include a straight wall 722 extending from the second surface 712b of the base wall 712. As another example, the shear key 718 may include a plurality of radial walls (e.g., straight walls 722, curved walls, etc.) extending from the second surface 712b of the base wall 712, wherein each radial wall is aligned along a different radial direction extending outward from the center of the base wall 712. In some cases, the shear key 718 may include a first set of chord walls and a second set of chord walls extending from the second surface 712b of the base wall 712. In these cases, each chord wall has a chord end terminating on the second peripheral wall 712, and the first set of chord walls is perpendicular to the second set of chord walls. Examples of these cases are shown in FIG. Figure 2B to Figure 2C is shown in the bottom perspective view. Figure 3 Other walls that may be used for shear key 718 are shown.

[0049] In some variations, the shear key 718 includes a second peripheral wall 724 configured to transform the closed end 710 of the tubular body into a second open end, such as with respect to Figure 3 In another embodiment, such as 7A to 7D As shown, the second peripheral wall 724 defines an opening into a second chamber 726 of the tubular body 702. The second chamber 726 is configured as a suction chamber of the example anchor 700, and the example anchor 700 includes a conduit 728 configured to fluidically couple the suction chamber to the exterior of the example anchor 700. To this end, in some cases, the conduit 728 may include a valve 730 to control the flow of a fluid (e.g., water, air, etc.) between the suction chamber and the exterior of the example anchor 700. Other fluid control devices are feasible. In some cases, the conduit 728 is defined by a conduit wall of the tubular body 702 that is at least partially formed of a cementitious material. In other cases, the conduit 728 is defined by a metal or plastic body (e.g., a steel pipe, a PVC pipe, etc.) arranged through the tubular body 702.

[0050] In some variations, the second peripheral wall 724 includes a plurality of teeth 732, wherein each tooth 732 protrudes from the second peripheral wall 724 in a direction perpendicular to the axis 720 of the tubular body 702. The plurality of teeth 732 may be defined, for example, by a wavy portion of the second peripheral wall 724, such as 7A to 7D However, other configurations are possible for the plurality of teeth 732. After the example anchor 700 is installed, the plurality of teeth 732 can help the shear key 718 resist rotational displacement of the example anchor 700 about the axis 720 of the tubular body 702. The straight wall 722 can also help the shear key 718 resist rotational displacement of the example anchor 700.

[0051] In some implementations, the example anchor 700 is configured to resist flipping when penetrated into the underwater ground. For example, the tubular body 702 can be configured to have a length and a maximum diameter, wherein the length is not greater than the maximum diameter. In this configuration, the tubular body 702 can define a "stubby" body of the example anchor 700. As another example, the tubular body 702 can have a frustoconical shape. Thus, the diameter of the peripheral wall 714 at the open end 708 of the tubular body 702 can be smaller than the diameter of the peripheral wall 714 at or near the base wall 712.

[0052] In some implementations, the example anchor 700 includes a reinforcing wall to increase the rigidity of its body. For example, the tubular body 702 can extend along an axis 720 and include a reinforcing wall oriented parallel to the axis 720 in the chamber 716. The reinforcing wall can have a first wall end and a second wall end and extend therebetween. The first wall end and the second wall end can be terminated by a peripheral wall 714. Fig. 9 A schematic diagram of an example anchor 900 having a plurality of reinforcing walls 902 is presented in the upper perspective view. Each reinforcing wall 902 passes through an axis 904 of a tubular body 906 to define a common wall intersection 908. The tubular body 906 includes a base wall (not shown), a peripheral wall 910, and a shear key 912. An eyelet 914 is coupled to the common wall intersection 908 near an open end 916 of the tubular body 906. The shear key 912 includes a second peripheral wall 918 that converts the originally closed end of the tubular body 906 into a second open end 920. Four eyelets 910 are also coupled to an outer side surface of the base wall. The outer side surface can define a portion of the outer surface of the tubular body 906.

[0053] The anchors described herein can be manufactured by depositing layers of flowable cementitious material. In some implementations, the method of manufacturing the anchor includes depositing layers of flowable cementitious material on top of each other to form at least a portion of a tubular body. The flowable cementitious material can harden into a solidified cementitious material. In addition, the tubular body can have a plurality of Figures 2A to 9The features described. For example, the tubular body may have an open end and a closed end, and include a base wall, the base wall defining the closed end of the tubular body and having a first surface and a second surface on opposite sides of the base wall. The tubular body may also include a peripheral wall extending from the first surface of the base wall to the open end of the tubular body. The peripheral wall may define an opening into a chamber of the tubular body at the open end. The tubular body may further include a shear key extending from the second surface of the base wall. The shear key is configured to penetrate the underwater ground and resist the lateral displacement of the anchor along the underwater ground when the anchor penetrates the underwater ground. The method also includes fixing the eye to the tubular body, the eye configured to be connected to a mooring line, and in many implementations, also includes hardening the layer of flowable cementitious material into a layer of cured cementitious material. In some variations, fixing the eye to the tubular body includes connecting the eye to a reinforcing element of the tubular body before hardening the layer of flowable cementitious material.

[0054] The operation of depositing layers of flowable cementitious material can be part of a manufacturing process that includes 3D casting (which can 3D print the formwork walls into which the concrete material is cast), concrete spraying, precasting, casting, slip forming, etc. In some implementations, depositing layers of flowable cementitious material includes spraying layers of flowable cementitious material on top of each other. In some implementations, depositing layers of flowable cementitious material includes printing layers of flowable cementitious material on top of each other.

[0055] In some embodiments, the shear key includes a second peripheral wall that is configured to convert the closed end of the tubular body into a second open end. The second peripheral wall may define an opening into a second chamber of the tubular body, and the second chamber may be configured as a suction chamber of the anchor. In addition, the anchor may include a conduit configured to fluidly connect the suction chamber to the outside of the anchor. In this case, the conduit may be defined by a conduit wall of the tubular body. Therefore, and in some variations, depositing a layer of flowable cementitious material may include depositing a layer of flowable cementitious material to at least partially form a conduit wall.

[0056] In some aspects of what is described, anchors may be illustrated by the following examples. In some cases, anchors may be used to secure floating structures to underwater ground.

[0057] Example 1. An anchor comprising:

[0058] A tubular body formed at least in part of a cementitious material and having an open end and a closed end, the tubular body comprising:

[0059] a base wall defining the closed end of the tubular body and having a first surface and a second surface on opposite sides of the base wall,

[0060] a peripheral wall extending from the first surface of the base wall to the open end of the tubular body, the peripheral wall defining an opening into a chamber of the tubular body at the open end, and

[0061] a shear key extending from the second surface of the base wall, the shear key being configured to penetrate underwater ground and resist lateral displacement of the anchor along the underwater ground while penetrating the underwater ground; and

[0062] An eyelet is coupled to the tubular body and is configured to be coupled to a mooring line.

[0063] Example 2. The anchor of Example 1, wherein the tubular body extends along an axis and comprises:

[0064] A reinforcing wall in the chamber, the reinforcing wall being oriented parallel to the axis, the reinforcing wall having and extending between first and second wall ends, the first and second wall ends being terminated by the peripheral wall.

[0065] Example 3. The anchor of Example 2,

[0066] wherein the reinforcing wall comprises a plurality of reinforcing walls, each of the reinforcing walls passing through the axis to define a common wall intersection; and

[0067] Wherein the eyelet is coupled to the common wall intersection proximate the open end of the tubular body.

[0068] Example 4. The anchor of example 1 or any one of examples 2-3, wherein the eye is coupled to an edge surface of the peripheral wall proximate the open end.

[0069] Example 5. The anchor of example 1 or any one of examples 2-3, wherein the eye is coupled to an outside surface of the base wall.

[0070] Example 6. The anchor of example 1 or any of examples 2-3, wherein the eye is coupled to a central portion of the first surface of the base wall.

[0071] Example 7. The anchor of example 1 or any one of examples 2 to 6, wherein the anchor includes a ballast material disposed in the chamber.

[0072] Example 8. The anchor of example 1 or any one of examples 2 to 7, wherein the chamber is configured to define a volume that, when unfilled, allows the anchor to float when deployed on a body of water.

[0073] Example 9. The anchor of example 1 or any one of examples 2 to 8, wherein the peripheral wall at the open end of the tubular body is configured to receive a cap covering the open end.

[0074] Example 10. The anchor of Example 9, comprising the cover.

[0075] Example 11. The anchor of Example 10, wherein the cover comprises:

[0076] a surface configured to face an exterior of the anchor when covering the open end; and

[0077] A corrugated wall extends from the surface.

[0078] Example 12. The anchor of example 1 or any one of examples 2 to 11, wherein the shear key is further configured to resist rotational displacement of the anchor about the axis of the tubular body when penetrating the underwater ground.

[0079] Example 13. The anchor of Example 12, wherein the shear key comprises a straight wall extending from the second surface of the base wall.

[0080] Example 14. The anchor of Example 12 or 13, wherein the shear key comprises a plurality of radial walls extending from the second surface of the base wall, each radial wall aligned along a different radial direction extending outward from a center of the base wall.

[0081] Example 15. The anchor of Example 1 or any one of Examples 2-14, wherein the shear key comprises a second peripheral wall configured to transform the closed end of the tubular body into a second open end.

[0082] Example 16. The anchor of Example 15, wherein the shear key comprises a first set of chord walls and a second set of chord walls extending from the second surface of the base wall, each chord wall having a chord end terminating on the second peripheral wall, the first set of chord walls being perpendicular to the second set of chord walls.

[0083] Example 17. The anchor of Example 15 or 16,

[0084] wherein the second peripheral wall defines an opening into a second chamber of the tubular body, the second chamber being configured as a suction chamber of the anchor; and

[0085] Wherein the anchor includes a conduit configured to fluidly couple the suction chamber to an exterior of the anchor.

[0086] Example 18. The anchor of Example 17, wherein the conduit is defined by a conduit wall of the tubular body, the conduit wall being formed at least in part from a cementitious material.

[0087] Example 19. The anchor of Example 15 or any one of Examples 16 to 18, wherein the second peripheral wall comprises a plurality of teeth, each tooth protruding from the second peripheral wall in a direction perpendicular to the axis of the tubular body.

[0088] Example 20. The anchor of Example 19, wherein each tooth is defined by an undulating portion of the second peripheral wall.

[0089] Example 21. The anchor of Example 1 or any one of Examples 2 to 20,

[0090] wherein the tubular body has a frustoconical shape; and

[0091] wherein a diameter of the peripheral wall at the open end of the tubular body is smaller than a diameter of the peripheral wall at the base wall.

[0092] Example 22. The anchor of Example 1 or any one of Examples 2-21, wherein the length of the tubular body is no greater than the maximum diameter of the tubular body.

[0093] In some aspects of what is described, the method may be illustrated by the following examples. In some cases, the method may be used to manufacture anchors, such as anchors used to secure floating structures to underwater ground.

[0094] Example 23. A method of making an anchor, comprising:

[0095] depositing layers of a flowable cementitious material on top of each other to form at least a portion of a tubular body, the flowable cementitious material being capable of hardening into a cured cementitious material, the tubular body having an open end and a closed end and comprising:

[0096] a base wall defining the closed end of the tubular body and having a first surface and a second surface on opposite sides of the base wall,

[0097] a peripheral wall extending from the first surface of the base wall to the open end of the tubular body, the peripheral wall defining an opening into a chamber of the tubular body at the open end, and

[0098] a shear key extending from the second surface of the base wall, the shear key being configured to penetrate underwater ground and resist lateral displacement of the anchor along the underwater ground while penetrating the underwater ground; and

[0099] An eyelet is secured to the tubular body, the eyelet being configured to be coupled to a mooring line.

[0100] Example 24. The method of Example 23, comprising:

[0101] The layer of flowable cementitious material is hardened into a layer of cured cementitious material.

[0102] Example 25. The method of Example 24, wherein securing the eye to the tubular body comprises coupling the eye to a reinforcing element of the tubular body prior to hardening the layer of flowable cementitious material.

[0103] Example 26. The method of any of Examples 23 or 24-25, wherein depositing the layers of the flowable cementitious material comprises spraying the layers of the flowable cementitious material on top of each other.

[0104] Example 27. The method of any of Examples 23 or Examples 24 to 26, wherein depositing the layers of the flowable cementitious material comprises printing the layers of the flowable cementitious material on top of each other.

[0105] Example 28. The method of any one of Example 23 or Examples 24 to 27, comprising:

[0106] Reinforcing elements are arranged in the flowable cementitious material prior to depositing the layer.

[0107] Example 29. The method of any one of Examples 23 or Examples 24 to 28, wherein the tubular body extends along an axis and comprises:

[0108] A reinforcing wall in the chamber, the reinforcing wall being oriented parallel to the axis, the reinforcing wall having and extending between first and second wall ends, the first and second wall ends being terminated by the peripheral wall.

[0109] Example 30. The method of Example 23 or any of Examples 24 to 29, wherein the chamber is configured to define a volume that, when unfilled, allows the anchor to float when deployed on a body of water.

[0110] Example 31. The method of any one of Examples 23 or Examples 24 to 30, wherein the peripheral wall at the open end of the tubular body is configured to receive a cap covering the open end.

[0111] Example 32. The method of any one of Examples 23 or Examples 24 to 31, wherein the shear key is further configured to resist rotational displacement of the anchor about the axis of the tubular body when penetrating the underwater ground.

[0112] Example 33. The method of Example 32, wherein the shear key comprises a straight wall extending from the second surface of the base wall.

[0113] Example 34. The method of Example 23 or any one of Examples 24-33, wherein the shear key includes a second peripheral wall configured to transform the closed end of the tubular body into a second open end.

[0114] Example 35. The method of Example 34,

[0115] wherein the second peripheral wall defines an opening into a second chamber of the tubular body, the second chamber being configured as a suction chamber of the anchor; and

[0116] Wherein the anchor includes a conduit configured to fluidly couple the suction chamber to an exterior of the anchor.

[0117] Example 36. The method of Example 35,

[0118] wherein the conduit is defined by a conduit wall of the tubular body; and

[0119] Wherein depositing the layer of flowable cementitious material comprises depositing the layer of flowable cementitious material to at least partially form the pipe wall.

[0120] Example 37. The method of any one of Examples 34 or Examples 35-36, wherein the second peripheral wall comprises a plurality of teeth, each tooth protruding from the second peripheral wall in a direction perpendicular to the axis of the tubular body.

[0121] Although this specification contains many details, these should not be construed as limitations on the scope of what may be claimed, but rather as illustrations of features specific to a particular example. Certain features described in this specification or shown in the context of separate implementations may also be combined. Conversely, various features described or shown in the context of a single implementation may also be implemented in multiple embodiments, either individually or in any suitable subcombination.

[0122] Similarly, although operations are depicted in a particular order in the accompanying drawings, this should not be understood as requiring such operations to be performed in the particular order shown or in sequence, or performing all illustrated operations to achieve the desired result. In some cases, multitasking and parallel processing may be advantageous. In addition, the separation of various system components in the above-mentioned implementations should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single product or packaged into multiple products.

[0123] A number of embodiments have been described. However, it should be understood that various modifications may be made. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. An anchor comprising: A tubular body formed at least in part of a cementitious material and having an open end and a closed end, the tubular body comprising: a base wall defining the closed end of the tubular body and having a first surface and a second surface on opposite sides of the base wall, a peripheral wall extending from the first surface of the base wall to the open end of the tubular body, the peripheral wall defining an opening into a chamber of the tubular body at the open end, and a shear key extending from the second surface of the base wall, the shear key being configured to penetrate underwater ground and resist lateral displacement of the anchor along the underwater ground while penetrating the underwater ground; and An eyelet is coupled to the tubular body and is configured to be coupled to a mooring line.

2. The anchor of claim 1, wherein the tubular body extends along an axis and comprises: A reinforcing wall in the chamber, the reinforcing wall being oriented parallel to the axis, the reinforcing wall having and extending between first and second wall ends, the first and second wall ends being terminated by the peripheral wall.

3. An anchor according to claim 2, wherein the reinforcing wall comprises a plurality of reinforcing walls, each of the reinforcing walls passing through the axis to define a common wall intersection; and Wherein the eyelet is coupled to the common wall intersection proximate the open end of the tubular body.

4. The anchor of claim 1, wherein the eye is coupled to an edge surface of the peripheral wall proximate the open end.

5. The anchor of claim 1, wherein the eye is coupled to an outside surface of the base wall.

6. The anchor of claim 1, wherein the eye is coupled to a central portion of the first surface of the base wall.

7. The anchor of claim 1, wherein the anchor includes a ballast material disposed in the chamber.

8. An anchor according to any one of claims 1 to 7, wherein the chamber is configured to define a volume which, when unfilled, allows the anchor to float when deployed on a body of water.

9. The anchor of any one of claims 1 to 7, wherein the peripheral wall at the open end of the tubular body is configured to receive a cap covering the open end.

10. An anchor according to claim 9, comprising said cover.

11. The anchor of claim 10, wherein the cap comprises: a surface configured to face an exterior of the anchor when covering the open end; and A corrugated wall extends from the surface.

12. An anchor according to any one of claims 1 to 7, wherein the shear key is further configured to resist rotational displacement of the anchor about the axis of the tubular body when penetrating the underwater ground.

13. The anchor of claim 12, wherein the shear key comprises a straight wall extending from the second surface of the base wall.

14. The anchor of claim 12, wherein the shear key comprises a plurality of radial walls extending from the second surface of the base wall, each radial wall aligned along a different radial direction extending outward from a center of the base wall.

15. The anchor of any one of claims 1 to 7, wherein the shear key comprises a second peripheral wall configured to transform the closed end of the tubular body into a second open end.

16. The anchor of claim 15, wherein the shear key comprises a first set of chord walls and a second set of chord walls extending from the second surface of the base wall, each chord wall having a chord end terminating at the second peripheral wall, the first set of chord walls being perpendicular to the second set of chord walls.

17. An anchor according to claim 15, wherein the second peripheral wall defines an opening into a second chamber of the tubular body, the second chamber being configured as a suction chamber of the anchor; and Wherein the anchor includes a conduit configured to fluidly couple the suction chamber to an exterior of the anchor.

18. The anchor of claim 17, wherein the conduit is defined by a conduit wall of the tubular body, the conduit wall being formed at least in part from a cementitious material.

19. The anchor of claim 15, wherein the second peripheral wall includes a plurality of teeth, each tooth protruding from the second peripheral wall in a direction perpendicular to the axis of the tubular body.

20. The anchor of claim 19, wherein each tooth is defined by an undulating portion of the second peripheral wall.

21. An anchor according to any one of claims 1 to 7, wherein the tubular body has a frustoconical shape; and wherein a diameter of the peripheral wall at the open end of the tubular body is smaller than a diameter of the peripheral wall at the base wall.

22. The anchor of any one of claims 1 to 7, wherein the length of the tubular body is no greater than the maximum diameter of the tubular body.

23. A method of making an anchor, comprising: depositing layers of a flowable cementitious material on top of each other to form at least a portion of a tubular body, the flowable cementitious material being capable of hardening into a cured cementitious material, the tubular body having an open end and a closed end and comprising: a base wall defining the closed end of the tubular body and having a first surface and a second surface on opposite sides of the base wall, a peripheral wall extending from the first surface of the base wall to the open end of the tubular body, the peripheral wall defining an opening into a chamber of the tubular body at the open end, and a shear key extending from the second surface of the base wall, the shear key being configured to penetrate underwater ground and resist lateral displacement of the anchor along the underwater ground while penetrating the underwater ground; and An eyelet is secured to the tubular body, the eyelet being configured to be coupled to a mooring line.

24. The method according to claim 23, comprising: The layer of flowable cementitious material is hardened into a layer of cured cementitious material.

25. The method of claim 24, wherein securing the eye to the tubular body comprises coupling the eye to a reinforcing element of the tubular body prior to hardening the layer of flowable cementitious material.

26. The method of any one of claims 23 to 25, wherein depositing the layers of flowable cementitious material comprises spraying the layers of flowable cementitious material on top of each other.

27. The method of any one of claims 23 to 25, wherein depositing layers of the flowable cementitious material comprises printing layers of the flowable cementitious material on top of each other.

28. A method according to any one of claims 23 to 25, comprising: Reinforcing elements are arranged in the flowable cementitious material prior to depositing the layer.

29. The method of any one of claims 23 to 25, wherein the tubular body extends along an axis and comprises: A reinforcing wall in the chamber, the reinforcing wall being oriented parallel to the axis, the reinforcing wall having and extending between first and second wall ends, the first and second wall ends being terminated by the peripheral wall.

30. A method according to any one of claims 23 to 25, wherein the chamber is configured to define a volume which, when unfilled, allows the anchor to float when deployed on a body of water.

31. A method according to any one of claims 23 to 25, wherein the peripheral wall at the open end of the tubular body is configured to receive a cap covering the open end.

32. The method according to any one of claims 23 to 25, wherein: The shear key is also configured to resist rotational displacement of the anchor about the axis of the tubular body when penetrating the underwater ground.

33. The method of claim 32, wherein the shear key comprises a straight wall extending from the second surface of the base wall.

34. The method of any one of claims 23 to 25, wherein the shear key comprises a second peripheral wall configured to transform the closed end of the tubular body into a second open end.

35. The method according to claim 34, wherein the second peripheral wall defines an opening into a second chamber of the tubular body, the second chamber being configured as a suction chamber of the anchor; and Wherein the anchor includes a conduit configured to fluidly couple the suction chamber to an exterior of the anchor.

36. The method according to claim 35, wherein the conduit is defined by a conduit wall of the tubular body; and Wherein depositing the layer of flowable cementitious material comprises depositing the layer of flowable cementitious material to at least partially form the pipe wall.

37. The method of claim 34, wherein the second peripheral wall includes a plurality of teeth, each tooth protruding from the second peripheral wall in a direction perpendicular to the axis of the tubular body.

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