Modular drop-stitch utility platforms and methods of assembly and use thereof

Abstract

A drop-stitch module 100 comprises an inflatable drop-stitch envelope 102 having a top surface 110, a bottom surface 112, and an end portion 116 that extends between the top surface and the bottom sur

Description

Technical Field

[0001] The present disclosure generally relates to inflatable marine platforms. More specifically, the present disclosure relates to systems and methods for reconfigurable and scalable modular utility platforms that utilize structural locking connections between individual modules. Background

[0002] Heavy-lift capable landing craft, such as modular pontoons, are a vital asset in many amphibious situations. For example, the existing Mexeflote floating pontoon system has proven its usefulness over half a century of military and humanitarian operational theatres, from the Arctic, to the rigors of the South Atlantic, to the humanitarian challenges in the Gaza Strip. Mexeflote is a Royal Logistics Corps asset and is operated primarily by the Army and the Royal Marines for heavy-lift applications. Mexeflote is assembled from three steel sections (i.e., bow, middle, and stern), and connected using steel bolts. As such, Mexeflote cannot be easily stored, transported, assembled, or re-configured. Furthermore, Royal Marine amphibious operations also involve lighter lift use cases, for which Mexeflote fails to provide an adequate solution. Summary

[0003] Applicant has recognized the need for a fully modular solution to service vehicles and supplies across maritime and river gap crossings. Applicant additionally recognized that the solution should be scalable, which enables it to support varying pay loads, such as passengers, light and heavy vehicles, and containers. Applicant further recognized that the solution should be reconfigurable to accommodate varying use cases, such as enabling gap crossing, floating docks, and pontoons. Accordingly, present embodiments are generally related to reconfigurable and scalable modular marine platforms that use structural locking connections between modules to provide a heavy-lift capability.

[0004] One such embodiment includes a modular drop-stitch utility platform that overcomes the problems associated with existing solutions. In particular, embodiments of the modular drop-stitch utility platform may be lightweight, handleable, flexible, and packable. For example, the dropstitch modules may be deflated, rolled up, and compactly containerized to minimize storage volume, potentially freeing up space during amphibious shipping operations. Embodiments of drop-stitch modules may be connected using reliable connection features to form the modular drop-stitch utility platform, which enables the platform to be easily and quickly reconfigured without the use of specialized tools or equipment. In some embodiments, the modular drop-stitch utility platform may be scaled by connecting additional drop-stitch modules to support or transport heavier payloads, such as heavy wheeled or tracked vehicles or International Organization for Standardization (ISO) shipping containers. Embodiments of the modular drop-stitch utility platform may enable flexible interoperability by reducing burden and dependency on specialized delivery vessels. Embodiments of the modular drop-stitch utility platform may provide enhanced modularity, for example, by incorporating connection elements that enable incorporation of towing, loading / unloading, and / or propulsion modules. Embodiments of the modular drop-stitch utility platform may enable enhanced robustness to accommodate various operating conditions. For example, in some embodiments, the modular drop-stitch utility platform may incorporate additional connection features (e.g., about a perimeter of the platform) to enhance the strength and rigidity of the platform for applications involving dynamic marine environments (e.g., choppy or rough sea states, high winds, strong currents). Accordingly, embodiments of the modular dropstitch utility platform provide a fully modular system that can be easily transported and reconfigured to suit the demands of a plethora of marine applications.

[0005] Embodiments of the modular drop-stitch utility platform include suitable connection features that enable two or more drop-stitch modules to be connected together (e.g., rafted, rafted and stacked) to form one larger pontoon or raft. Unlike other connection techniques, the novel connection features and assembly method enable the modular drop-stitch utility platform to have enhanced bending stiffness at the joint or junction between adjacent, co-planar drop-stitch modules. That is, the Applicant has recognized that, while an inflated drop-stitch craft itself may have considerable bending stiffness, when multiple inflated drop-stitch crafts are connected to each other using standard methods (e.g., roped or single hinged links), the resulting structure easily bends at the joints between the drop-stitch crafts. For example, in some embodiments, the connection features and assembly method of the modular drop-stitch utility platform enable the formation of double butt hinges that provide a structural locking connection between adjacent, coplanar drop-stitch modules, enabling the transfer of internal pressure between the connection features and the drop-stitch modules. In some embodiments, the novel connection features and assembly method of the modular drop-stitch utility platform enable a five to ten-fold decrease in deflection at the joint between adjacent, coplanar drop-stitch modules of the modular drop-stitch utility platform relative to drop-stitch crafts connected each other using standard (e.g., single hinge) methods.

[0006] Embodiments discussed herein generally include modular drop-stitch utility platforms and methods of assembly and use thereof. An embodiment of one such system includes a dropstitch module having an inflatable drop-stitch envelope. The inflatable drop-stitch envelope has a top surface, a bottom surface, and an end portion that extends between the top surface and the bottom surface along an edge of the drop-stitch module. The drop-stitch module includes an upper connection feature attached to the top surface above the end portion of the inflatable drop-stitch envelope and along the edge of the drop-stitch module, and a lower connection feature attached to the bottom surface below the end portion of the inflatable drop-stitch envelope and along the edge of the drop-stitch module. The end portion of the inflatable drop-stitch envelope is configured to extend beyond the upper connection feature and the lower connection feature when the inflatable drop-stitch envelope is fully inflated while the edge of the drop-stitch module is not constrained by a connection to another drop-stitch module.

[0007] In some embodiments, the upper connection feature of the drop-stitch module is configured to removably attach to an upper connection feature of a second drop-stitch module, and the lower connection feature of the drop-stitch module is configured to removably attach to a lower connection feature of the second drop-stitch module, before the inflatable drop-stitch envelope is fully inflated, such that when the inflatable drop-stitch envelope is subsequently fully inflated, a pressure locking double butt hinge is formed between the drop-stitch module and the second dropstitch module along the edge. In some embodiments, the upper connection feature of the dropstitch module and the upper connection feature of the second drop-stitch module include a first set of interdigitated connection loop flanges configured to receive a first connection tube to removably attach the upper connection feature of the drop-stitch module to the upper connection feature of the second drop-stitch module, and the lower connection feature of the drop-stitch module and the lower connection feature of the second drop-stitch module include a second set of interdigitated connection loop flanges configured to receive a second connection tube to removably attach the lower connection feature of the drop-stitch module to the lower connection feature of the second drop-stitch module. In some embodiments, the first set of interdigitated connection loop flanges and the second set of interdigitated connection loop flanges include chlorosulfonated polyethylene synthetic rubber (CSM) (e.g., Hypalon), and the first connection tube and the second connection tube include stainless steel, aluminum, a polymer, or a fiber reinforced plastic (FRP). In some embodiments, first end caps are configured to removably connect to ends of the first connection tube to secure the first connection tube within the first set of interdigitated connection loop flanges, and second end caps are configured to removably connect to ends of the second connection tube to secure the second connection tube within the second set of interdigitated connection loop flanges. In some embodiments, the upper connection feature of the drop-stitch module and the upper connection feature of the second drop-stitch module include a first set of zippers configured to removably attach to one another, and the lower connection feature of the drop-stitch module and the lower connection feature of the second drop-stitch module include a second set of zippers configured to removably attach to one another.

[0008] In some embodiments, the inflatable drop-stitch envelope includes a nylon or a polyester material and a CSM sealing layer. In some embodiments, the drop-stitch module includes a plurality of upper connection features attached to the top surface of the inflatable drop-stitch envelope and along a perimeter of the drop-stitch module, and a plurality of lower connection feature attached to the bottom surface of the inflatable drop-stitch envelope and along the perimeter of the drop-stitch module. In some embodiments, the drop-stitch module includes an additional connection feature attached to the top surface of the inflatable drop-stitch envelope and along a center line of the top surface of the inflatable drop-stitch envelope, or attached to the bottom surface of the inflatable drop-stitch envelope and along a center line of the bottom surface of the inflatable drop-stitch envelope, or both.

[0009] An embodiment of another such system includes a modular drop-stitch utility platform. The modular drop-stitch utility platform includes a first drop-stitch module and a second dropstitch module rafted together by a first pressure locking double butt hinge. An upper connection feature of the first drop-stitch module is removably connected to an upper connection feature of the second drop-stitch module, and a lower connection feature of the first drop-stitch module is removably connected to a lower connection feature of the second drop-stitch module. An end portion of the first drop-stitch module contacts an end portion of the second drop-stitch module along a first contact length below the removably connected upper connection features and above the removably connected lower connection features of the first and second drop-stitch modules, and the first contact length is at least 50% of a fully inflated height of the first drop-stitch module or the second drop-stitch module, thereby forming the first pressure locking double butt hinge.

[0010] In some embodiments of the aforementioned modular drop-stitch utility platform, the first drop-stitch module includes a first drop-stitch envelope positioned between the upper connection feature and the lower connection feature of the first drop-stitch module, and the second drop-stitch module includes a second drop-stitch envelope positioned between the upper connection feature and the lower connection feature of the second drop-stitch module, in which the first drop-stitch envelope defines the end portion and the fully inflated height of the first dropstitch module, and the second drop-stitch envelope defines the end portion and the fully inflated height of the second drop-stitch module. In some embodiments of the aforementioned modular drop-stitch utility platform, the upper connection feature of the first drop-stitch module and the upper connection feature of the second drop-stitch module include a first set of interdigitated connection loop flanges removably connected by a first connection tube threaded therethrough, and the lower connection feature of the first drop-stitch module and the lower connection feature of the second drop-stitch module include a second set of interdigitated connection loop flanges removably connected by a second connection tube threaded therethrough.

[0011] In some embodiments, the modular drop-stitch utility platform has a deflection at the first pressure locking double butt hinge that is five to ten times less than a deflection at a joint between two drop-stitch modules rafted together by a single hinge connection. In some embodiments, the deflection of the modular drop-stitch utility platform at the first pressure locking double butt hinge is less than or equal to 115% of the fully inflated height of the first drop-stitch module or the second drop-stitch module. In some embodiments, the deflection of the modular drop-stitch utility platform at the first pressure locking double butt hinge is less than or equal to 50% of the fully inflated height of the first drop-stitch module or the second drop-stitch module. In some embodiments, the first contact length is at least 60% of the fully inflated height of the first dropstitch module or the second drop-stitch module. In some embodiments, the end portion of the first drop-stitch module contacts the end portion of the second drop-stitch module along a first vertical plane that bisects the removably connected upper connection features and the removably connected lower connection features of the first and second drop-stitch modules.

[0012] In some embodiments, the modular drop-stitch utility platform includes a third dropstitch module and a fourth drop-stitch module rafted together by a second pressure locking double butt hinge, in which an upper connection feature of the third drop-stitch module is removably connected to an upper connection feature of the fourth drop-stitch module, and a lower connection feature of the third drop-stitch module is removably connected to a lower connection feature of the fourth drop-stitch module. An end portion of the third drop-stitch module contacts an end portion of the fourth drop-stitch module along a second contact length below the removably connected upper connection features and above the removably connected lower connection features of the third and fourth drop-stitch modules, and the second contact length is at least 50% of a fully inflated height of the third drop-stitch module or the fourth drop-stitch module, thereby forming the second pressure locking double butt hinge.

[0013] In some embodiments, the end portion of the third drop-stitch module contacts the end portion of the fourth drop-stitch module along a second vertical plane that bisects the removably connected upper connection features and the removably connected lower connection features of the third and fourth drop-stitch modules. In some embodiments, the first and second drop-stitch modules form a first layer and the third and fourth drop-stitch modules form a second layer of the modular drop-stitch utility platform, the second layer positioned below the first layer, thereby to yield a rafted and stacked modular drop-stitch utility platform. In some embodiments, the first drop-stitch module is positioned directly above the third drop-stitch module and the second dropstitch module is positioned directly above the fourth drop-stitch module, and (i) at least a portion of the lower connection feature of the first drop-stitch module is removably connected to a least a portion of the upper connection feature of the fourth drop-stitch module, or (ii) at least a portion of the lower connection feature of the second drop-stitch module is removably connected to a least a portion of the upper connection feature of the third drop-stitch module, or a combination of (i) and (ii).

[0014] In some embodiments, the first pressure locking double butt hinge is positioned directly above the third drop-stitch module and the second pressure locking double butt hinge is positioned directly below the second drop-stitch module, thereby to yield the rafted and stacked modular drop-stitch utility platform having a brickwork stacked bond pattern. In some embodiments, (i) at least a portion of the lower connection feature of the first drop-stitch module, at least a portion of the lower connection feature of the second drop-stitch module, or a combination thereof, is removably connected to a least a portion of an additional upper connection feature positioned along a center line of the third drop-stitch module, or (ii) at least a portion of the upper connection feature of the third drop-stitch module, at least a portion of the upper connection feature of the fourth drop stitch module, or a combination thereof, is removably connected to a least a portion of an additional lower connection feature positioned along a center line of second third drop-stitch module, or a combination of (i) and (ii).

[0015] An embodiment of one such method includes assembling a modular drop-stitch utility platform. The assembling includes positioning two or more drop-stitch modules such that connection features of the two or more drop-stitch modules are aligned for attachment, the two or more drop-stitch modules being partially or completely deflated. The assembling includes connecting the two or more drop-stitch modules together by attaching the aligned connection features of the two or more drop-stitch modules. The assembling includes simultaneously fully inflating the two or more drop-stitch modules to form a respective pressure locking double butt hinge at each coplanar junction between the two or more drop-stitch modules, thereby to yield the modular drop-stitch utility platform.

[0016] In some embodiments, positioning the two or more drop-stitch modules includes interdigitating connection loop flanges of adjacent, coplanar drop-stitch modules. In some embodiments, connecting the two or more drop-stitch modules together includes attaching upper connection features of adjacent, coplanar drop-stitch modules and attaching lower connection features of the adjacent, coplanar drop-stitch modules. In some embodiments, assembling the modular drop-stitch utility platform further includes connecting additional connection features along an outer perimeter of the modular drop-stitch utility platform for enhanced stability or functionality.

[0017] In some embodiments, the method includes disassembling the modular drop-stitch utility platform. The disassembling includes at least partially deflating the two or more drop-stitch modules of the modular drop-stitch utility platform, and then disconnecting the connection features of the two or more drop-stitch modules to detach the two or more drop-stitch modules from one another. In some embodiments, the disassembling further includes completely deflating the dropstitch modules for compact storage and / or transport. In some embodiments, the disassembling further includes disconnecting additional connection features of the modular drop-stitch utility platform along an outer perimeter of the modular drop-stitch utility platform before or after at least partially deflating the two or more drop-stitch modules.

[0018] An embodiment of one such system is a modular drop-stitch utility platform that includes a first drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a first end portion. The modular drop-stitch utility platform includes a second drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a second end portion. The modular drop-stitch utility platform also includes a first connection tube configured to be inserted through a first set of interdigitated connection loop flanges before the first and second drop-stitch modules are fully inflated, the first set of interdigitated connection loop flanges including at least a portion of the lower connection loop flanges positioned along the first end portion of the first drop-stitch module and at least a portion of the lower connection loop flanges positioned along the second end portion of the second dropstitch module. The modular drop-stitch utility platform further includes a second connection tube configured to be inserted through a second set of interdigitated connection loop flanges before the first and second drop-stitch modules are fully inflated, the second set of interdigitated connection loop flanges including at least a portion of the upper connection loop flanges positioned along the first end portion of the first drop-stitch module and at least a portion of the upper connection loop flanges positioned along the second end portion of the second drop-stitch module.

[0019] In some embodiments, the lower connection loop flanges and upper connection loop flanges positioned along the first end portion of the first drop-stitch module are bonded to a first inflatable drop-stitch envelope of the first drop-stitch module using an adhesive, in which the lower connection loop flanges and upper connection loop flanges positioned along the second end portion of the second drop-stitch module are bonded to a second inflatable drop-stitch envelope of the second drop-stitch module using the adhesive. In some embodiments, the first and second dropstitch modules are configured to be simultaneously fully inflated after the first connection tube is inserted through the first set of interdigitated connection loop flanges and after the second connection tube is inserted through the second set of interdigitated connection loop flanges, thereby yielding a structural locking connection between the first and second drop-stitch modules.

[0020] In some embodiments, the modular drop-stitch utility platform includes a third dropstitch module having lower connection loop flanges and upper connection loop flanges positioned along a third end portion, and the first drop-stitch module includes additional lower connection loop flanges and additional upper connection loop flanges positioned along a fourth end portion. In some embodiments, the modular drop-stitch utility platform includes a third connection tube configured to be inserted through a third set of interdigitated connection loop flanges before the first and third drop-stitch modules are fully inflated, the third set of interdigitated connection loop flanges including at least a portion of the additional lower connection loop flanges positioned along the fourth end portion of the first drop-stitch module and at least a portion of the lower connection loop flanges positioned along the third end portion of the third drop-stitch module. In some embodiments, the modular drop-stitch utility platform includes a fourth connection tube configured to be inserted through a fourth set of interdigitated connection loop flanges before the first and third drop-stitch modules are fully inflated, the fourth set of interdigitated connection loop flanges including at least a portion of the additional upper connection loop flanges positioned along the fourth end portion of the first drop-stitch module and at least a portion of the upper connection loop flanges positioned along the third end portion of the third drop-stitch module.

[0021] In some embodiments, the modular drop-stitch utility platform includes a third dropstitch module having lower connection loop flanges and upper connection loop flanges positioned along a third end portion, as well as a fourth drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a fourth end portion. In some embodiments, the modular drop-stitch utility platform includes a third connection tube configured to be inserted through a third set of interdigitated connection loop flanges before the first, second, third, and fourth drop-stitch modules are fully inflated, the third set of interdigitated connection loop flanges including at least a portion of the lower connection loop flanges positioned along the third end portion of the third drop-stitch module and at least a portion of the lower connection loop flanges positioned along the fourth end portion of the fourth drop-stitch module, and the first set of interdigitated connection loop flanges further includes at least a portion of the upper connection loop flanges positioned along the third end portion of the third drop-stitch module and at least a portion of the upper connection loop flanges positioned along the fourth end portion of the fourth drop-stitch module.

[0022] In some embodiments, the modular drop-stitch utility platform includes a third dropstitch module having lower connection loop flanges positioned along a center of the third dropstitch module, wherein the second set of interdigitated connection loop flanges further includes at least a portion of the lower connection loop flanges positioned along the center of the third dropstitch module, and wherein the second connection tube is configured to be inserted through the second set of interdigitated connection loop flanges before the first, second, and third drop-stitch modules are fully inflated. In some embodiments, the modular drop-stitch utility platform includes a fourth drop-stitch module having upper connection loop flanges positioned along a center of the fourth drop-stitch module, and the first set of interdigitated connection loop flanges further includes at least a portion of the upper connection loop flanges positioned along the center of the fourth drop-stitch module, and the first connection tube is configured to be inserted through the first set of interdigitated connection loop flanges before the first, second, and fourth drop-stitch modules are fully inflated.

[0023] In some embodiments, the modular drop-stitch utility platform includes a first set of end caps configured to removably attach to end portions of the first connection tube after the first connection tube is inserted through the first set of interdigitated connection loop features, in which the first set of end caps have an outer diameter that is greater than an inner diameter of the first set of interdigitated connection loop flanges. In some embodiments, either (i) the first end portion extends along a first length of the first drop-stitch module and the second end portion extends along a second length of the second drop-stitch module, or (ii) the first end portion extends along a first width of the first drop-stitch module and the second end portion extends along a second width of the second drop-stitch module.

[0024] An embodiment of one such method is a method of connecting drop-stitch modules. The method includes interdigitating lower connection loop flanges positioned along a first end portion of a first drop-stitch module and lower connection loop flanges positioned along a second end portion of a second drop-stitch module. The method includes inserting a first connection tube through the interdigitated lower connection loop flanges. The method includes interdigitating upper connection loop flanges positioned along first end portion of the first drop-stitch module and upper connection loop flanges positioned along the second end portion of the second dropstitch module. The method also includes inserting a second connection tube through the interdigitated upper connection loop flanges. The method further includes concurrently inflating the first and second drop-stitch modules to a rated pressure, thereby to yield a structural locking connection between the first and second drop-stitch modules.

[0025] In some embodiments, prior to interdigitating the lower connection loop flanges, the method includes positioning the first and second drop-stitch modules such that the first end portion of the first drop-stitch module is adjacent to the second end portion of the second drop-stitch module while the first and second drop-stitch modules are fully or partially deflated. In some embodiments, after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module and the second end portion of the second drop-stitch module apply pressure to one another, and wherein the applied pressure results in locking tension (i) between the interdigitated lower connection loop flanges and the first connection tube and (ii) between the interdigitated upper connection loop flanges and the second connection tube. In some embodiments, after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module contacts the second end portion of the second drop-stitch module along a substantially vertical plane that bisects the interdigitated lower connection loop flanges, the first connection tube, the interdigitated upper connection loop flanges, and the second connection tube. In some embodiments, after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module contacts the second end portion of the second drop-stitch module along a contact length, such that a ratio of the contact length to a height of the first and second drop-stitch modules ranges from about 0.5:1 to about 1:1.

[0026] In some embodiments, the rated pressure is greater than or equal to about 12 psi, and when biased with a load of about 135 kilograms after inflating the first and second drop-stitch modules to the rated pressure, the structural locking connection demonstrates a deflection that is (i) less than or equal to 225 mm, (ii) less than or equal to 15% of a length of the first and second drop-stitch modules after inflation, or (iii) less than or equal to 115% of a height of the first and second drop-stitch modules after inflation. In some embodiments, the rated pressure is greater than or equal to about 16 psi, and when biased with a load of about 135 kilograms after inflating the first and second drop-stitch modules to the rated pressure, the structural locking connection demonstrates a deflection that is (i) less than or equal to 100 mm, (ii) less than or equal to 5% of a length of the first and second drop-stitch modules after inflation, or (iii) less than or equal to 50% of a height of the first and second drop-stitch modules after inflation.

[0027] Aspects and advantages of these exemplary embodiments and other embodiments, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations. Brief Description of the Drawings

[0028] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure.

[0029] FIGS. 1A and IB are diagrammatic representations of an example of a drop-stitch module capable of being combined to form a modular drop-stitch utility platform, according to an embodiment.

[0030] FIG. 2 is a diagrammatic representation of an example of a modular drop-stitch utility platform formed from two drop-stitch modules that are connected to one another in accordance with the assembly technique discussed herein, according to an embodiment.

[0031] FIG. 3A is a cross-sectional diagrammatic representation of connection features of an example of a drop-stitch module, according to an embodiment.

[0032] FIG. 3B is a diagrammatic representation of an example connection tube for connecting two drop-stitch modules to form a modular drop-stitch utility platform, according to an embodiment.

[0033] FIGS. 4A, 4B, and 4C are cross-sectional diagrammatic representations visually depicting an example of an assembly process whereby two drop-stitch modules are rafted together using a pressure locking double butt hinge, thereby to yield an example of a modular drop-stitch utility platform, according to an embodiment.

[0034] FIG. 5 is a graphical representation of a deflection study of example modular drop-stitch utility platforms having two drop-stitch modules joined together in different manners, according to an embodiment.

[0035] FIG. 6 is a diagrammatic representation of an example of a rafted and stacked modular drop-stitch utility platform, according to an embodiment.

[0036] FIG. 7 is a diagrammatic representation of an example of a partially constructed modular drop-stitch utility platform to illustrate how layers of a stacked modular drop-stitch utility platform may be connected together in certain implementations, according to an embodiment.

[0037] FIGS. 8A, 8B, 8C, and 8D are cross-sectional diagrammatic representations visually depicting an example of an assembly process whereby four drop-stitch modules are rafted and stacked together using pressure locking double butt hinges, thereby to yield an example of a rafted and stacked modular drop-stitch utility platform, according to an embodiment.

[0038] FIG. 9A is a diagrammatic representation of an example of a method of constructing a modular drop-stitch utility platform, according to an embodiment.

[0039] FIG. 9B is a diagrammatic representation of an example of a method of deconstructing a modular drop-stitch utility platform, according to an embodiment. Detailed Description

[0040] The present disclosure describes various embodiments related to scalable drop-stitch utility platforms that utilize structural locking connections between modules to provide a heavy-lift capability. The description may use the phrases “in certain embodiments,” “in various embodiments,” “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. The term “plurality” as used herein refers to two or more items or components. The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, these terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%. The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having,” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0041] FIGS. 1A and IB are diagrammatic representations of an embodiment of a drop-stitch module 100 capable of being combined to form a modular drop-stitch utility platform. The dropstitch module 100 includes an inflated drop-stitch envelope 102, which may be made of nylon, polyester, or another suitable drop-stitch material. For the illustrated embodiment, the inflated drop-stitch module 100 generally has a rectangular profile with a length 104 of about 2 meters (m), a width 106 of about 1.5 m, and a height 108 of about 0.2 m. In some embodiments, the inflated drop-stitch module 100 generally has a rectangular profile with a length 104 of about 6 m, a width 106 of about 4 m, and a height 108 of about 0.2 m. The illustrated drop-stitch module 100 is merely provided as an example, and in other embodiments, the drop-stitch module 100 may have a different shape (e.g., square shaped, triangular, hexagonal) and / or have different dimensions or aspect ratios.

[0042] For the embodiment illustrated in FIGS. 1A and IB, the inflated drop-stitch envelope 102 includes a top surface 110 and a bottom surface 112 with drop-stitching 114 extending between the top surface 110 and the bottom surface 112. While the drop-stitching 114 may be formed from a suitable thread, such as a nylon thread, the top surface 110 and bottom surface 112 are typically coated in a sealing layer, such as a chlorosulfonated polyethylene synthetic rubber (CSM), which facilitates the airtight and watertight properties of the drop-stitch envelope 102. Those skilled in the art will appreciate that, once the drop-stitch envelope 102 is inflated to a desired pressure (e.g., greater than 10 pounds per square inch (psi), or about 12 psi, or about 16 psi) the drop-stitching 114 is stretched taut, which desirably imparts rigidity to the top surface 110 and bottom surface 112 of the drop-stitch envelope 102. The inflated drop-stitch envelope 102 also includes end portions 116. When the drop-stitch module 100 is inflated without being constrained by attachment to another drop-stitch module, the end portions 116 of the inflated drop-stitch envelope 102 are rounded, defining a bulge or belly that extends from the edges or sides of the drop-stitch module 100. Additionally, the illustrated drop-stitch module 100 includes ports 118A and 118B that enable inflation and deflation of the drop-stitch envelope 102. In some embodiments, the ports 118A and 118B enable inflation and deflation of different portions or chambers of the drop-stitch envelope 102. In some embodiments, one or both of the ports 118A and 118B may include integrated valving or sealing features to prevent the inflated drop-stitch envelope 102 from being unintentionally or prematurely deflated. In some embodiments, the ports 118A and 118B (or additional ports) may be positioned elsewhere on the drop-stitch envelope 102 (e.g., on the top surface 110) to enable easier access to inflate and deflate the drop-stitch module 100

[0043] For the embodiment illustrated in FIGS. 1A and IB, the drop-stitch module 100 includes connection features 120 (e.g., 120A, 120B) that are designed to enable multiple drop-stitch modules to be connected to one another to form a modular drop-stitch utility platform. More specifically, the drop-stitch module 100 includes upper connection features 120A and lower connection features 120B that are implemented as connection loop flanges for the illustrated embodiment. In some examples, the connection features 120 can be a connector. In examples, any suitable connector may be used that results in the connected inflatable envelopes exhibiting a bending stiffness that enables a limited deflection (e.g., less than 300 mm, less than about 250 mm, less than 200 mm, about 100 mm) during use, as discussed in greater detail with respect to FIG. 5.

[0044] For embodiments that utilize connection loop flanges as connection features 120, the connection loop flanges 120A, 120B may be made of a suitably strong fabric or elastomer, such as a chlorosulfonated polyethylene synthetic rubber (CSM) (e.g., hypalon). As discussed below, for embodiments that utilize connection loop flanges as connection features 120, connection tubes (also referred to herein as tubular hinge pin) may be threaded through the interdigitated upper and lower connection loop flanges 120A and 120B of adjacent drop-stitch modules to form a double butt hinge (also referred to herein as a pressure locking butt hinge) structural locking connection that imparts substantial rigidity at the joint or connection between the connected drop-stitch modules of the resulting modular drop-stitch utility platform.

[0045] It should be appreciated that the upper connection loop flanges 120A and lower connection loop flanges 120B illustrated in FIGS. 1A and IB are merely provided as an example, and in other embodiments, other suitable connection features 120 may be utilized to form the structural locking connection, such as high-strength zippers (e.g., metal, separating zippers with a zipper number from 8 to 10). In some embodiments, the connection features 120 may include high-strength snaps or hook and loop fasteners. It may be appreciated that, for certain embodiments having connection features 120 other than the illustrated connection loop flanges, these connection features 120 may also be implemented as a set of upper connection features (e.g., an upper high-strength zipper) and a set of lower connection features (e.g., a lower high-strength zipper) at each end portion 116 of the drop-stitch modules 100.

[0046] The connection features 120 enable multiple drop-stitch modules 100 to be connected together in a number of different manners to form a drop-stitch platform. For example, using the connection features 120, two or more drop-stitch modules 100 may be connected together at any of end portions 116 (e.g., along one or both of the end portions that define the length 104 of the modules, along one or both of the end portions that define the width 106 of the modules). Additionally, in some embodiments, multiple drop-stitch modules 100 may additionally or alternatively be stacked and the layers of drop-stitch modules connected together by suitable connection features 120, as discussed in greater detail below. In some embodiments, the dropstitch modules 100 may include additional connection features 120, such as connection features (e.g., connection loop flanges) positioned on the surface of the top surface 110 and / or the bottom surface 112 of the drop-stitch envelope 102 (e.g., along a midline or center line of the drop-stitch envelope 102) to enable additional stacking configurations (e.g., brickwork stacked bond pattern), as discussed in greater detail below.

[0047] For the embodiment illustrated in FIGS. 1A and IB, the relative dimensions and positions of the drop-stitch envelope 102 and the connection loop flanges 120A and 120B, as well as the assembly method discussed below, facilitate the formation of structural locking connection between adjacent drop-stitch modules 100. For the illustrated embodiment, the connection loop flanges 120A and 120B are attached to (e.g., adhered to, bonded to, stitched to, sewn to) the dropstitch envelope 102 along a bonded length 122. It is recognized that stitching or sewing the connection features to the drop-stitch envelope 102 may result in air leaks. As such, for embodiments that rely on connection features that are stitched or sewn to the drop-stitch envelope, it may be desirable to coat the bonded length 122 of the connection feature with a sealant after attachment to block or prevent such air leaks. In other embodiments, an adhesive may be used to primarily bond the connection features to the drop-stitch envelope, which advantageously avoids the potential air leaks associated with stitched or sewn connection features. For embodiments that involve adhesives or sealants, the adhesive or sealant may be a suitable airtight, ultraviolet (UV) light resistant, water-proof material, such as a polychloroprene rubber-based adhesive (e.g., BOSTIK® NE486). In some embodiments, certain connection features, such as the connection loop flanges 120A, 120B, may be integrated into the drop-stitch envelope 102. For example, the connection loop flanges 120A, 120B may be implemented as extensions of the same material used to manufacture the drop-stitch envelope 102, such that at least the drop-stitch envelope and the connection features form a monolithic structure, which may avoid the aforementioned issues in attaching separate connection features to the drop-stitch envelope and / or result in connection features with a higher resistance to being disconnected or removed from the drop-stitch envelope in high-strain applications.

[0048] In some embodiments, the bonded length 122 of the connection loop flanges 120A and 120B may be about 5% of the length 104 of the inflated drop-stitch envelope 102. For example, for an embodiment of the drop-stitch module 100 having a length 104 of about 2 meters, the connection loop flanges 120A and 120B may be about 100 millimeters (mm). For the illustrated embodiment, the connection loop flanges 120A and 120B may have a total length 124 (including the bonded length 122) of about 12% of the length 104 of the inflated drop-stitch envelope 102. For example, for an embodiment of the drop-stitch module 100 having a length 104 of about 2 meters, the total length 124 of the connection loop flanges 120A and 120B may be about 230 mm. Additionally, for the illustrated embodiment, a distance 126 from the beginning of the bonded portion of the connection loop flanges 120A and 120B to the unconstrained, bulged end portions 116 of the inflated drop-stitch envelope 102 may be about 13% of the length 104 of the inflated drop-stitch envelope 102. For example, for an embodiment of the drop-stitch module 100 having a length 104 of about 2 meters, the distance 126 may be about 260 mm. For the illustrated embodiment, a distance 128 between the outer end of the connection loop flanges 120A and 120B and the unconstrained, bulged end portions 116 may be from about 1% to about 2% (e.g., 1.5%) of the length 104 of the inflated drop-stitch envelope 102. For example, for an embodiment of the drop-stitch module 100 having a length 104 of about 2 meters, the distance 128 may be about 30 mm.

[0049] FIG. 2 is a diagrammatic representation of an embodiment of a modular drop-stitch utility platform 200 formed from two drop-stitch modules 202A, 202B that are connected to one another in accordance with the assembly techniques discussed herein. The illustrated modular drop-stitch utility platform 200 may also be described herein as including two drop-stitch modules 202A, 202B that are rafted together (e.g., connected along one edge in a coplanar manner). Those skilled in the art will appreciate that rafting together multiple drop-stitch modules increases buoyancy and stability by increasing breadth and volume / displacement, which enables increased payloads and / or expanded operating conditions and marine conditions (e.g., sea states). The dropstitch module 202A includes an upper connection feature 204A and a lower connection feature 204B that are implemented as connection loop flanges along the perimeter of the drop-stitch module 202A in the illustrated embodiment. Similarly, the drop-stitch module 202B includes an upper connection feature 206A and a lower connection feature 206B that are implemented as connection loop flanges along the perimeter of the drop-stitch module 202B in the illustrated embodiment.

[0050] For the embodiment illustrated in FIG. 2, the drop-stitch modules 202A and 202B are connected to one another at the joint 208 to form the modular drop-stitch utility platform 200. More specifically, for the illustrated embodiment, the upper connection loop flanges 204A of the drop-stitch module 202A and the upper connection loop flanges 206A of the drop-stitch module 202B are interdigitated along the joint 208, and a first connection tube 210A extends through interdigitated upper connection loop flanges 204A and 206A along the joint 208 to form a first portion of the pressure locking butt hinge. Additionally, for the illustrated embodiment, the lower connection loop flanges 204B of the drop-stitch module 202A and the lower connection loop flanges 206B of the drop-stitch module 202B are also interdigitated along the joint 208, and a second connection tube 210B extends through interdigitated lower connection loop flanges 204B and 206B along the joint 208 to form a second portion of the pressure locking butt hinge. As discussed herein, the pressure locking butt hinge significantly enhances the rigidity and reduces the flexibility of the modular drop-stitch utility platform 200 at the joint 208 compared other connection mechanisms, which desirably enables the modular drop-stitch utility platform 200 to function substantially more like a single, monolithic platform than like two connected drop-stitch modules.

[0051] For the embodiment illustrated in FIG. 2, the upper and lower connection loop flanges 204A, 204B are offset from one another or staggered along the perimeter of the drop-stitch module 202A, while the upper and lower connection loop flanges 206A, 206B are similarly offset from one another or staggered along the perimeter of the drop-stitch module 202B. Additionally, the illustrated drop-stitch modules 202A, 202B are designed to be reversible, such that either planar face may serve as a bottom surface (in contact with the water) or as the top surface (opposite the water). As such, those skilled in the art will appreciate that, in some embodiments, the drop-stitch modules 202A, 202B may be identically manufactured and the interdigitation of the upper connection loop flanges 204A and 206A along the joint 208, as well as the interdigitation of the lower connection loop flanges 204B and 206B along the joint 208, may be achieved by inverting one of the drop-stitch modules 202A, 202B, as illustrated in FIG. 2, such that the connection loop flanges suitably align for interdigitation. In some embodiments, to provide additional stability for certain applications, at least a portion of the upper connection loop flanges 204A, 206A along the outer perimeter of the modular drop-stitch utility platform 200 may be connected to one another using additional connection tubes and / or at least a portion of the lower connection loop flanges 204B, 206B along the outer perimeter of the modular drop-stitch utility platform 200 may be connected to one another using additional connection tubes. In some embodiments, at least a portion of the upper connection loop flanges 204A, 206A, at least a portion of the lower connection loop flanges 204B, 206B, or both, may be used as mooring points or to attach other features or modules to the modular drop-stitch utility platform 200, such as modules with ramps to enable roll-on / roll-off (RORO) capability, modules for attachment to vessels for towing, modules with a motor and propeller for propulsion, or any other suitable module and combinations of modules for a given application.

[0052] FIG. 3A is a cross-sectional diagrammatic representation of connection features of an embodiment of a drop-stitch module 300. The drop-stitch module 300 includes a drop-stitch envelope 302 that is illustrated as fully inflated. The connection features of the illustrated dropstitch module 300 include upper connection loop flanges 304A and lower connection loop flanges 304B that are attached to opposite planar surfaces of the drop-stitch module 300. FIG. 3A also illustrates cross-sectional views of the connection tubes 306A and 306B, which are designed to be inserted within the connection loop flanges 304A and 304B, respectively, as illustrated and discussed with respect to FIG. 2. As such, the connection tubes 306A and 306B have an outer diameter 308 that is slightly less than an inner diameter 310 of the connection loop flanges 304A, 304B. In addition to the connection loop flanges 304A, 304B and the connection tubes 306A, 306B, the ability of the illustrated embodiment of the drop-stitch module 300 to form a pressure locking butt hinge with another drop-stitch module is also enabled by the design and operation of the end portion 312. For the embodiment illustrated in FIG. 3A, the drop-stitch envelope 302 of the drop-stitch module 300 is fully inflated and unconstrained by another drop-stitch module, and as such, the end portion 312 of the drop-stitch module 300 bulges out a distance 314 farther than a vertical plane 316 that bisects the connection loop flanges 304A, 304B. As discussed below, the shape of the end portion 312, as well as the distance 314 that the end portion 312 bulges upon inflation is different when the drop-stitch module 300 is constrained by attachment to another module, which facilitates the formation of the pressure locking butt hinge.

[0053] FIG. 3B is a diagrammatic representation of an embodiment of a connection tube 320 for connecting two drop-stitch modules to form a modular drop-stitch utility platform. For the illustrated embodiment, the connection tube 320 includes a tube body 322 that, as noted in FIG. 3A, has a sufficiently small outer diameter 308 to be inserted within the connection loop flanges 304A, 304B of the drop-stitch modules. In some embodiments, the connection tube 320 includes end caps 324A, 324B having a diameter 326 that is greater than an inner diameter 310 of the connection loop flanges 304A, 304B. For such embodiments, the tube body 322 of the connection tube 320 may be inserted through the connection loop flanges 304A, 304B of one or more dropstitch modules before the end caps 324A, 324B are removably connected to the end portions 328A, 328B of the tube body 322. For example, in some embodiments, the end portions 328A, 328B of the tube body 322 may include threads or another suitable attachment or locking mechanism designed to enter a mating correspondence with threads or another suitable attachment or locking mechanism within the end caps 324A, 324B to removably secure the end caps to the tube body 322 after insertion into the connection loop flanges 304A, 304B of one or more drop-stitch modules. Once the end caps 324A, 324B are secured to the tube body 322, the larger diameter 326 of the end caps 324A, 324B blocks or prevents the connection tube 320 from slipping out of the connection loop flanges 304A, 304B until after the end caps are removed. In addition to preventing slipping, in some embodiments, the end caps 324A, 324B may also serve additional purposes, such as preventing the connection tube from filling with water, protecting the end of the connection tube from being damaged (e.g., cracking, internally corroding, or being crushed) or causing damage (e.g., puncturing other equipment).

[0054] In different embodiments, the connection tube 320 may be made of different materials that provide suitable properties to facilitate a given application. For example, for an application in which highest strength connections are important, the connection tube 320 may be formed from steel. When high strength is important and corrosion issues are likely due to the presence of brine, the connection tube 320 may be formed from stainless steel. For applications in which a fairly high strength is desired, corrosion may be an issue, and in which it is desirable to decrease the stored or operational weight of the modular drop-stitch utility platform, the connection tube 320 may be formed from aluminum. For applications in which decreasing the stored weight of the modular drop-stitch utility platform is more important, the connection tube 320 may be formed from a polymer (e.g., polyvinyl chloride (PVC)) or a fiber reinforced plastic (FRP) (e.g., fiberglass). In some embodiments, the connection tube 320 may be manufactured from a suitable material and / or include interior air pockets such that the connection tube 320 is buoyant, when may help to prevent the loss of connection tubes as the modular drop-stitch utility platform is being deployed or deconstructed in a marine environment. In some embodiments, the tube body 322 may be made of a first material (e.g., aluminum, stainless steel), and the end caps 324A, 324B may be made of a second material (e.g., PVC, FRP).

[0055] FIGS. 4A-4C are cross-sectional diagrammatic representations visually depicting an embodiment of an assembly process whereby two drop-stitch modules 400A and 400B are connected or rafted together by a pressure locking butt hinge 402, thereby to yield an embodiment of a modular drop-stitch utility platform 404. As illustrated in FIG. 4A, first the drop-stitch modules 400A and 400B are positioned such that the upper connection loop flanges 406A of the drop-stitch module 400A are aligned to interdigitate with the upper connection loop flanges 408A of the drop-stitch module 400B and the lower connection loop flanges 406B of the drop-stitch module 400A are aligned to interdigitate with the lower connection loop flanges 408B of the dropstitch module 400B. Importantly, as illustrated in FIG. 4A, the drop-stitch envelopes 410A, 410B of the drop-stitch modules 400A, 400B are either fully deflated or only partially inflated at this stage in the assembly process. Once aligned, the connection tube 412A is threaded through the interdigitated upper connection loop flanges 406A, 408A and the connection tube 412B is threaded through the interdigitated lower connection loop flanges 406B, 408B, as illustrated in FIG. 4B, while the drop-stitch envelopes 410A, 410B of the drop-stitch modules 400A, 400B remain in either the fully deflated or partially inflated state.

[0056] For the embodiment illustrated in FIG. 4C, after the connection tubes 412A and 412B have been respectively inserted into the interdigitated upper connection loop flanges 406A, 408A and the interdigitated lower connection loop flanges 406B, 408B, the assembly process continues with fully inflating the drop-stitch envelopes 410A, 410B of the drop-stitch modules 400A, 400B. For example, in some embodiments, the drop-stitch envelopes 410A, 410B may be simultaneously or concurrently inflated. Because the drop-stitch modules 400A, 400B are constrained by their attachment to one another, the drop-stitch envelopes 410A, 410B are unable to form the bulging end portion (e.g., bulging end portion 312 of FIG. 3A) when fully inflated. Instead, for the embodiment illustrated in FIG. 4C, the fully inflated drop-stitch envelopes 410A, 410B only extend to about a center of the connection loop flanges 406A, 408A and 406B, 408B. Moreover, the fully inflated drop-stitch envelopes 410A, 410B apply pressure to one another, as indicated by the arrows 414. Even prior to the modular drop-stitch utility platform 404 being loaded with weight at the joint, the pressure 414 results in additional tension (e.g., a locking tension) on the connection tubes 412A, 412B, as indicated by the arrows 416, as the connection loop flanges 406A, 408A and 406B, 408B attempt to move away from one another. As such, the pressure locking butt hinge 402 facilitates an effective connection between closely abutting drop-stitch modules, which enables the structural behaviour of the two connected drop-stitch modules to approach that of a single panel of the same combined dimensions.

[0057] As shown for the embodiment illustrated in FIG. 4C, the fully inflated drop-stitch envelopes 410A, 410B of the drop-stitch modules 400A, 400B have a height 418. Additionally, the end portion 420A of the drop-stitch module 400A and the end portion 420B of the drop-stitch module 400B contact each other along the length 422 (referred to herein as the contact length). The Applicant has recognized that the ratio of the contact length 422 to the height 418 should fall within a particular range in order to facilitate an effective pressure locking butt hinge 402. For example, in some embodiments, the ratio of the contact length 422 to the height 418 ranges from about 0.5:1 to about 1:1. In some embodiments, the ratio of the contact length 422 to the height 418 may be about 0.5:1, about 0.6:1, about 0.7:1, about 0.8:1, or about 0.9:1 to provide an effective pressure locking butt hinge 402. Indeed, Applicant has recognized that the closer the ratio of the contact length 422 to the height 418 is to 1:1, the greater the locking pressure of the resulting pressure locking butt hinge 402. Additionally, Applicant has recognized that it is generally desirable for the contact between the end portions 420A and 420B to substantially occur along a vertical plane 424 that bisects the connection loop flanges 406A, 406B, 408A, 408B and the connection tubes 412A and 412B in order to facilitate an effective pressure locking butt hinge 402.

[0058] FIG. 5 is a graphical representation of a deflection study of a modular drop-stitch utility platform having two drop-stitch modules joined together in different manners. More specifically, the drop-stitch modules used in the deflection study had a length of 2 m, a width of 1.5 m, and a height of 0.2 m. The drop-stitch modules were connected together along the width dimension to yield a modular drop-stitch utility platform having a total span of 3.6 m. Subsequently, a load of 135 kilograms (kg) was placed at the joint of the drop-stitch modules, and the deflection caused by the load was measured. For the comparative example 500, the drop-stitch modules were connected using a single hinge connection, resulting in a substantial deflection greater than 1.2 m. In contrast, for illustrative examples 502 and 504, the drop-stitch modules were connected using the pressure locking butt hinge, resulting in substantial less deflection than the comparative example 500. More specifically, for illustrative example 502, the drop-stitch modules connected by the pressure locking butt hinge were inflated to a pressure of 12 psi, while for illustrative example 504, the drop-stitch modules connected by the pressure locking butt hinge were inflated to a fill pressure of 16 psi. Illustrative example 502 demonstrated a deflection that is (i) less than or equal to about 225 millimeters (mm), (ii) less or equal to about 15% of the length of the dropstitch modules, or (iii) less than or equal to about 115% of the height of the drop-stitch modules, when inflated to a minimum fill pressure of at least 12 psi. Illustrative example 504 demonstrated a deflection that is (i) less than or equal to about 100 mm, (ii) less than or equal to about 5% of the length of the drop-stitch modules, or (iii) less than or equal to about 50% of the height of the dropstitch modules, when inflated to a minimum fill pressure of at least 16 psi. Therefore, the illustrative examples 502, 504 having the pressure locking butt hinge desirably demonstrated deflections that were between about 5 times and 10 times less than the deflection of the comparative example 500 having the single hinge connection.

[0059] In various embodiments, drop-stitch modules of different sizes may be connected in different manners to form a modular drop-stitch utility platform to facilitate different marine applications. For example, Table 1 indicates several example embodiments that utilize drop-stitch modules of different sizes, including 2 m length x 1.5 m width x 0.2 m height in some examples and 6 m length x 4 m width x 0.2 m height in other examples. In other embodiments, drop-stitch modules having other dimensions may be used. The module configurations indicated in Table 1 may either be single module, rafted (e.g., coplanar, single layer) modules, or rafted and stacked modules (e.g., multiple layers of rafted modules). For the number of modules column of Table 1, a single value (e.g., 4) indicates the number of modules that are rafted together for a single layer arrangement, while for entries with two values (e.g., 4x2), the first number indicates the number of drop-stitch modules that are rafted together per layer, and the second number indicates the number of layers, for a rafted and stacked arrangement. Finally, the payload column of Table 1 indicates examples of payloads that can be supported by the indicated modular drop-stitch utility platform in terms of kilograms or metric tonnes. A non-limiting list of example applications for the modular drop-stitch utility platform includes: passenger transport, goods transport, light vehicle transport, heavy vehicle transport, temporary roadways or bridges, pontoons, Humanitarian Assistance and Disaster Relief (HADR), and temporary ports of harbors (e.g., Mulberry harbours). The modular drop-stitch utility platform provides a solution which is cheaper to mass produce, is more lightweight, and is more compact and packable than the current steel Mexeflote-based solutions. The modular drop-stitch utility platform also enables increased rigidity and load carrying capacity when compared to current drop-stitch-based solutions.

[0060] Table 1 : Dimensions, configuration, and payload for example embodiments of the modular drop-stitch utility platform. Single Module Dimensions # of Modules Module Configuration Payload (in calm water conditions) 2 m x 1.5 m x 0.2 m 1 Single 250 kilograms (kg) 2 m x 1.5 m x 0.2 m 4 Rafted 1,000 kg light mobility vehicle 2 m x 1.5 m x 0.2 m 4x2 Rafted and Stacked 3,000 kg vehicle 6 m x 4 m x 0.2 m 1 Single 4,500 kg light mobility vehicle 6 m x 4 m x 0.2 m 2 Rafted 6,000 kg 10 feet ISO container 6 m x 4 m x 0.2 m 4x2 Rafted and Stacked 15 tonne army all-terrain vehicle 6 m x 4 m x 0.2 m 4x4 Rafted and Stacked 40 tonne 20 feet ISO container 6 m x 4 m x 0.2 m 4x5 Rafted and Stacked 60 tonne army tank

[0061] FIG. 6 is a diagrammatic representation of an embodiment of a rafted and stacked modular drop-stitch utility platform 600. More specifically, the illustrated modular drop-stitch utility platform 600 includes six drop-stitch modules, including three full width drop-stitch modules 602, 604, and 606 and three half-width drop-stitch modules 608, 610, and 612. Those skilled in the art will appreciate that stacking increases bending strength through increased depth to accommodate applications in which the payload induces excessive deflection in a single layer rafted platform, enabling a further increase in pay load compared to rafting alone. For the illustrated embodiment, the top layer of the modular drop-stitch utility platform 600 includes drop-stitch module 602 rafted to drop-stitch module 608 at joint 614, the middle layer includes drop-stitch module 604 rafted to drop-stitch module 610 at joint 616, and the bottom layer includes drop-stitch module 606 rafted to drop-stitch module 612 at joint 618. For the illustrated embodiment, in addition to connecting or rafting together the drop-stitch modules of each layer, the layers of the stacked modular drop-stitch utility platform 600 are also connected to one another at the joints 614, 616, and 618. For the illustrated embodiment, the full-width drop-stitch modules 602, 604, and 606 include connection loop flanges 620 disposed along the middle or center line of one or both planar surfaces to facilitate connection between the layers of the stacked arrangement. As a result, the rafted and stacked modular drop-stitch utility platform 600 may be further described as having a brickwork stacked bond pattern, in which the joints of each layer are offset from one another, which further increases the strength and / or stiffness of the platform at each of the joints.

[0062] FIG. 7 is a diagrammatic representation of an embodiment of a partially constructed modular drop-stitch utility platform 700 to illustrate how the layers of a stacked modular dropstitch utility platform may be connected together in certain implementations. In particular, the partially constructed modular drop-stitch utility platform 700 includes a first drop-stitch module 702A from an upper layer of the platform that is diagonally connected to a second drop-stitch module 702B from a lower layer of the platform at a partially constructed joint 704. More specifically, along the partially constructed joint 704, the lower connection loop flanges 706 of the first drop-stitch module 702A are interdigitated with the upper connection loop flanges 708 of the second drop-stitch module 702B, and the connection tube 710 has been inserted into the interdigitated connection loop flanges 706, 708.

[0063] FIGS. 8A-8D are cross-sectional diagrammatic representations visually depicting an embodiment of an assembly process whereby four drop-stitch modules 800A, 800B, 800C, and 800D are rafted and stacked together using pressure locking butt hinges 802, thereby to yield an embodiment of a modular drop-stitch utility platform 804. As illustrated in FIG. 8A, the dropstitch modules 800A, 800B, 800C, and 800D are first positioned such that the upper connection loop flanges 806A of the drop-stitch module 800A are aligned to interdigitate with the upper connection loop flanges 808A of the drop-stitch module 800B and the lower connection loop flanges 810B of the drop-stitch module 800C are aligned to interdigitate with the lower connection loop flanges 812B of the drop-stitch module 800D. Additionally, in some embodiments, at least a portion of the lower connection loop flanges 806B of the drop-stitch module 800A may be aligned to interdigitate with the upper connection loop flanges 812A of the drop-stitch module 800D, as indicated by the diagonal arrow 814. In some embodiments, at least a portion of the lower connection loop flanges 808B of the drop-stitch module 800B may be aligned to interdigitate with the upper connection loop flanges 810A of the drop-stitch module 800C, as indicated by the diagonal arrow 816. In some embodiments, the connection loop flanges between the layers of the drop-stitch module may be aligned in an alternating pattern, for example, by first interdigitating a lower connection loop flange 806B of the drop-stitch module 800A with an upper connection loop flange 812A of the drop-stitch module 800D, as indicated by the diagonal arrow 814, and then interdigitating a lower connection loop flange 808B of the drop-stitch module 800B with an upper connection loop flange 810A of the drop-stitch module 800C, as indicated by the diagonal arrow 816. It may be appreciated that, when a connection loop flange is not selected for coupling, it may be folded or compressed out of the way, thereby to avoid interfering with the attachment of selected connection loop flanges. Importantly, as illustrated in FIG. 8A, the drop-stitch envelopes 818A-D of the drop-stitch modules 800A-D are either fully deflated or only partially inflated at this stage in the assembly process. As illustrated in FIG. 8B, once aligned, a first connection tube 820A is threaded through the interdigitated upper connection loop flanges 806A, 808A, a second connection tube 820B is threaded through the interdigitated connection loop flanges 806B, 812A, 808B, and / or 810A, and a third connection tube 820C is threaded through the interdigitated lower connection loop flanges 810B, 812B, while the drop-stitch envelopes 818A-D of the drop-stitch modules 800A-D remain in either the fully deflated or partially inflated state. In at least some cases, the connection features may be specifically connected starting from the bottom of the modular drop-stitch utility platform 804 (closest to the water). For example, in some embodiments, once aligned, the third connection tube 820C is first threaded through the interdigitated lower connection loop flanges 810B, 812B, then the second connection tube 820B is threaded through the interdigitated connection loop flanges 806B, 812A, and then the first connection tube 820A is threaded through the interdigitated upper connection loop flanges 806A, 808A, while the dropstitch envelopes 818A-D of the drop-stitch modules 800A-D remain in either the fully deflated or partially inflated state.

[0064] For the embodiment illustrated in FIG. 8C, after the connection tubes 820A-C have been respectively inserted into the interdigitated connection loop flanges, the assembly process continues with fully inflating the drop-stitch envelopes 818A-D of the drop-stitch modules 800A-D. For example, in some embodiments, the drop-stitch envelopes 818A-D may be simultaneously or concurrently inflated. Because the drop-stitch modules 800A and 800B and the drop-stitch modules 800C and 800D are constrained by their attachment to one another, the drop-stitch envelopes 818A-D are unable to form the bulging end portion (e.g., bulging end portion 312 of FIG. 3A) when fully inflated. Instead, for the embodiment illustrated in FIG. 8C, the fully inflated drop-stitch envelopes 818A-D only extend to about a center of the connection loop flanges 806A, 808A and 810B, 812B. Moreover, the fully inflated drop-stitch envelopes 818A-D apply pressure to one another, as indicated by the arrows 822. Even prior to the modular drop-stitch utility platform 804 being loaded with weight at the joint, the pressure 822 results in additional tension (e.g., a locking tension) on the connection tubes 820A-D, as indicated by the arrows 824, as the connection loop flanges attempt to move away from one another. As illustrated in FIG. 8D, in some embodiment, additional stability and strength may be imparted to the modular drop-stitch utility platform 804 by threading a connection tube 820D through interdigitated lower connection loop flanges 826 of the drop-stitch module 800A and upper loop flanges 828 of the drop-stitch module 800C, and by threading a connection tube 820E through interdigitated lower connection loop flanges 830 of the drop-stitch module 800B and upper connection loop flanges 832 of the drop-stitch module 800D, either before or after inflating the drop-stitch envelopes 818A-D. As such, the dual pressure locking butt hinge 802 facilitates an effective connection between and within layers of closely abutting drop-stitch modules, which enables the structural behaviour of the four connected drop-stitch modules to approach that of a single panel of the same combined dimensions.

[0065] FIG. 9A is a diagrammatic representation of an embodiment of a method 900 of constructing a modular drop-stitch utility platform. It may be appreciated that the illustrated embodiment of the method 900 is merely an example, and in other embodiments, the method may include additional steps, repeated steps, and / or omitted steps relative to the embodiment illustrated in FIG. 9A. The illustrated embodiment of the method 900 begins with the step 902 of positioning at least two deflated or partially inflated drop-stitch modules such that connection features (e.g., connection loop flanges, high-strength zippers) of the drop-stitch modules are suitably aligned for attachment. For example, for embodiments in which the connection features include connection loop flanges, the actions of step 902 may include aligning and interdigitating connection loop flanges at the joints between the two or more deflated or partially inflated drop-stitch modules. The illustrated embodiment of the method 900 continues with the step 904 of connecting the deflated or partially inflated drop-stitch modules together using the aligned connection features of the drop-stitch modules. For example, for embodiments in which the connection features include connection loop flanges, the actions of step 904 may include inserting connection tubes through the aligned and interdigitated connection loop flanges at the joints between the drop-stitch modules. For embodiments in which the connection features include high-strength zippers, the actions of step 904 may include zipping together the upper zipper connection features and zipping together the lower zipper connection features at the joints between adjacent the drop-stitch modules.

[0066] For the embodiment illustrated in FIG. 9A, the method 900 continues with the step 906 of simultaneously or concurrently inflating the connected drop-stitch modules, thereby to yield the modular drop-stitch utility platform. For example, as shown in FIG. 4, simultaneous or concurrent inflation of the connected drop-stitch modules helps to facilitate an effective pressure locking butt hinge 402 by ensuring that the contact between the connected end portions 420A and 420B of the drop-stitch modules is substantially aligned near the vertical plane 424 and by maximizing the ratio of the contact length 422 to height 418 between the adjacent drop-stitch modules 400A and 400B to values from 0.5 to 1. For the illustrated embodiment, the method 900 concludes with the optional step 908 of connecting additional connection features along the outer perimeter of the modular drop-stitch utility platform for enhanced stability or functionality. For example, as shown in FIG. 8D, in some embodiments, additional connection tubes 820D, 820E may be threaded through interdigitated connection loop flanges 826, 828 and interdigitated connection loop flanges 830, 832, respectively, along the outer perimeter of the modular drop-stitch utility platform to enhance the stability of the platform. In some embodiments, the additional connection features along the outer perimeter of the modular drop-stitch utility platform may be used as mooring points or to attach additional features or modules to the modular drop-stitch utility platform, such as modules with ramps to enable RORO capability, modules for attachment to vessels for towing, modules with a motor and propeller for propulsion, or any other suitable module and combinations of modules for a given application.

[0067] FIG. 9B is a diagrammatic representation of an embodiment of a method 920 of deconstructing a modular drop-stitch utility platform. It may be appreciated that the illustrated embodiment of the method 920 is merely an example, and in other embodiments, the method may include additional steps, repeated steps, and / or omitted steps relative to the embodiment illustrated in FIG. 9B. The illustrated embodiment of the method 920 begins with the optional step 922 of disconnecting and removing additional connection features of the fully inflated drop-stitch modules along the outer perimeter of the modular drop-stitch utility platform, when present. The illustrated embodiment of the method 920 continues with the step 924 of at least partially deflating the drop-stitch modules of the modular drop-stitch utility platform. For example, as discussed for the embodiment illustrated in FIG. 4C, when the connected drop-stitch modules are fully inflated, this results in a pressure 414 between the end portions 420A, 420B of the drop-stitch modules 400A, 400B, and a locking tension 416 between the connection loop flanges 406A, 408A around the connection tube 412A and between the connection loop flanges 406B, 408B around the connection tube 412B, and this pressure and tension should be released before the connection tubes 412A and 412B can be removed. In some embodiments, step 922 may occur after step 924 for similar reasons.

[0068] For the embodiment illustrated in FIG. 9B, the method 920 continues with the step 926 of disconnecting the connection features of the at least partially deflated drop-stitch modules to detach the at least two drop-stitch modules from one another. For example, for the embodiment illustrated in FIG. 4B, the actions of step 926 may include removing the connection tube 412A from the interdigitated connection loop flanges 406A, 408A and removing the connection tube 412B from the interdigitated connection loop flanges 406B, 408B. For embodiments in which the connection features include high-strength zippers, the actions of step 926 may include unzipping upper and lower connection features to detach the at least partially deflated drop-stitch modules. For the illustrated embodiment, the method 920 concludes with the step 928 of completely deflating the drop-stitch modules for compact storage and / or transport.

[0069] Other objects, features, and advantages of the disclosure will become apparent from the foregoing figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the disclosure, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from the detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.

Claims

What is claimed is:

1. A drop-stitch module comprising:an inflatable drop-stitch envelope having a top surface, a bottom surface, and an end portion that extends between the top surface and the bottom surface along an edge of the dropstitch module;an upper connection feature attached to the top surface above the end portion of the inflatable drop-stitch envelope and along the edge of the drop-stitch module; anda lower connection feature attached to the bottom surface below the end portion of the inflatable drop-stitch envelope and along the edge of the drop-stitch module,the end portion of the inflatable drop-stitch envelope being configured to extend beyond the upper connection feature and the lower connection feature when the inflatable drop-stitch envelope is fully inflated while the edge of the drop-stitch module is not constrained by a connection to another drop-stitch module.

2. The drop-stitch module of claim 1, wherein the upper connection feature of the drop-stitch module is configured to removably attach to an upper connection feature of a second drop-stitch module, and the lower connection feature of the drop-stitch module is configured to removably attach to a lower connection feature of the second drop-stitch module, before the inflatable dropstitch envelope is fully inflated, such that when the inflatable drop-stitch envelope is subsequently fully inflated, a pressure locking double butt hinge is formed between the dropstitch module and the second drop-stitch module along the edge.

3. The drop-stitch module of claim 2, wherein the upper connection feature of the drop-stitch module and the upper connection feature of the second drop-stitch module comprise a first set of interdigitated connection loop flanges configured to receive a first connection tube to removably attach the upper connection feature of the drop-stitch module to the upper connection feature of the second drop-stitch module, and wherein the lower connection feature of the drop-stitch module and the lower connection feature of the second drop-stitch module comprise a second set of interdigitated connection loop flanges configured to receive a second connection tube toremovably attach the lower connection feature of the drop-stitch module to the lower connection feature of the second drop-stitch module.

4. The drop-stitch module of claim 3, wherein the first set of interdigitated connection loop flanges and the second set of interdigitated connection loop flanges comprise chlorosulfonated polyethylene synthetic rubber (CSM), and wherein the first connection tube and the second connection tube comprise stainless steel, aluminum, a polymer, or a fiber reinforced plastic (FRP).

5. The drop-stitch module of claim 3, wherein first end caps are configured to removably connect to ends of the first connection tube to secure the first connection tube within the first set of interdigitated connection loop flanges, and wherein second end caps are configured to removably connect to ends of the second connection tube to secure the second connection tube within the second set of interdigitated connection loop flanges.

6. The drop-stitch module of claim 2, wherein the upper connection feature of the drop-stitch module and the upper connection feature of the second drop-stitch module comprise a first set of zippers configured to removably attach to one another, and wherein the lower connection feature of the drop-stitch module and the lower connection feature of the second drop-stitch module comprise a second set of zippers configured to removably attach to one another.

7. The drop-stitch module of claim 1, wherein the inflatable drop-stitch envelope includes a nylon or a polyester material and a CSM sealing layer.

8. The drop-stitch module of claim 1, comprising:a plurality of upper connection features attached to the top surface of the inflatable dropstitch envelope and along a perimeter of the drop-stitch module; anda plurality of lower connection feature attached to the bottom surface of the inflatable dropstitch envelope and along the perimeter of the drop-stitch module.

9. The drop-stitch module of claim 1, comprising an additional connection feature attached tothe top surface of the inflatable drop-stitch envelope and along a center line of the top surface of the inflatable drop-stitch envelope, or attached to the bottom surface of the inflatable drop-stitch envelope and along a center line of the bottom surface of the inflatable drop-stitch envelope, or both.

10. A modular drop-stitch utility platform comprising:a first drop-stitch module and a second drop-stitch module rafted together by a first pressure locking double butt hinge,wherein an upper connection feature of the first drop-stitch module is removably connected to an upper connection feature of the second drop-stitch module, and a lower connection feature of the first drop-stitch module is removably connected to a lower connection feature of the second drop-stitch module,wherein an end portion of the first drop-stitch module contacts an end portion of the second drop-stitch module along a first contact length below the removably connected upper connection features and above the removably connected lower connection features of the first and second drop-stitch modules, andwherein the first contact length is at least 50% of a fully inflated height of the first drop-stitch module or the second drop-stitch module, thereby forming the first pressure locking double butt hinge.

11. The modular drop-stitch utility platform of claim 10, wherein the first drop-stitch module comprises a first drop-stitch envelope positioned between the upper connection feature and the lower connection feature of the first drop-stitch module, and the second drop-stitch module comprises a second drop-stitch envelope positioned between the upper connection feature and the lower connection feature of the second drop-stitch module, and wherein the first drop-stitch envelope defines the end portion and the fully inflated height of the first drop-stitch module, and the second drop-stitch envelope defines the end portion and the fully inflated height of the second drop-stitch module.

12. The modular drop-stitch utility platform of claim 10, wherein the upper connection feature of the first drop-stitch module and the upper connection feature of the second drop-stitch modulecomprise a first set of interdigitated connection loop flanges removably connected by a first connection tube threaded therethrough, and the lower connection feature of the first drop-stitch module and the lower connection feature of the second drop-stitch module comprise a second set of interdigitated connection loop flanges removably connected by a second connection tube threaded therethrough.

13. The modular drop-stitch utility platform of claim 10, wherein the modular drop-stitch utility platform has a deflection at the first pressure locking double butt hinge that is five to ten times less than a deflection at a joint between two drop-stitch modules rafted together by a single hinge connection.

14. The modular drop-stitch utility platform of claim 13, wherein the deflection of the modular drop-stitch utility platform at the first pressure locking double butt hinge is less than or equal to 115% of the fully inflated height of the first drop-stitch module or the second drop-stitch module.

15. The modular drop-stitch utility platform of claim 14, wherein the deflection of the modular drop-stitch utility platform at the first pressure locking double butt hinge is less than or equal to 50% of the fully inflated height of the first drop-stitch module or the second drop-stitch module.

16. The modular drop-stitch utility platform of claim 10, wherein the first contact length is at least 60% of the fully inflated height of the first drop-stitch module or the second drop-stitch module.

17. The modular drop-stitch utility platform of claim 10, wherein the end portion of the first drop-stitch module contacts the end portion of the second drop-stitch module along a first vertical plane that bisects the removably connected upper connection features and the removably connected lower connection features of the first and second drop-stitch modules.

18. The modular drop-stitch utility platform of claim 10, comprising:a third drop-stitch module and a fourth drop-stitch module rafted together by a second pressure locking double butt hinge,wherein an upper connection feature of the third drop-stitch module is removably connected to an upper connection feature of the fourth drop-stitch module, and a lower connection feature of the third drop-stitch module is removably connected to a lower connection feature of the fourth drop-stitch module,wherein an end portion of the third drop-stitch module contacts an end portion of the fourth drop-stitch module along a second contact length below the removably connected upper connection features and above the removably connected lower connection features of the third and fourth drop-stitch modules, andwherein the second contact length is at least 50% of a fully inflated height of the third dropstitch module or the fourth drop-stitch module, thereby forming the second pressure locking double butt hinge.

19. The modular drop-stitch utility platform of claim 18, wherein the end portion of the third drop-stitch module contacts the end portion of the fourth drop-stitch module along a second vertical plane that bisects the removably connected upper connection features and the removably connected lower connection features of the third and fourth drop-stitch modules.

20. The modular drop-stitch utility platform of claim 18, wherein the first and second drop-stitch modules form a first layer and the third and fourth drop-stitch modules form a second layer of the modular drop-stitch utility platform, the second layer positioned below the first layer, thereby to yield a rafted and stacked modular drop-stitch utility platform.

21. The modular drop-stitch utility platform of claim 20, wherein the first drop-stitch module is positioned directly above the third drop-stitch module and the second drop-stitch module is positioned directly above the fourth drop-stitch module, and wherein (i) at least a portion of the lower connection feature of the first drop-stitch module is removably connected to a least a portion of the upper connection feature of the fourth drop-stitch module, or (ii) at least a portion of the lower connection feature of the second drop-stitch module is removably connected to a least a portion of the upper connection feature of the third drop-stitch module, or a combination of (i) and (ii).

22. The modular drop-stitch utility platform of claim 20, wherein the first pressure locking double butt hinge is positioned directly above the third drop-stitch module and the second pressure locking double butt hinge is positioned directly below the second drop-stitch module, thereby to yield the rafted and stacked modular drop-stitch utility platform having a brickwork stacked bond pattern.

23. The modular drop-stitch utility platform of claim 22, wherein (i) at least a portion of the lower connection feature of the first drop-stitch module, at least a portion of the lower connection feature of the second drop-stitch module, or a combination thereof, is removably connected to a least a portion of an additional upper connection feature positioned along a center line of the third drop-stitch module, or (ii) at least a portion of the upper connection feature of the third drop-stitch module, at least a portion of the upper connection feature of the fourth dropstitch module, or a combination thereof, is removably connected to a least a portion of an additional lower connection feature positioned along a center line of second third drop-stitch module, or a combination of (i) and (ii).

24. A method comprising:assembling a modular drop-stitch utility platform, the assembling comprising: positioning two or more drop-stitch modules such that connection features of the two or more drop-stitch modules are aligned for attachment, the two or more drop-stitch modules being partially or completely deflated;connecting the two or more drop-stitch modules together by attaching the aligned connection features of the two or more drop-stitch modules; and thensimultaneously fully inflating the two or more drop-stitch modules to form a respective pressure locking double butt hinge at each coplanar junction between the two or more drop-stitch modules, thereby to yield the modular drop-stitch utility platform.

25. The method of claim 24, wherein positioning the two or more drop-stitch modules comprises interdigitating connection loop flanges of adjacent, coplanar drop-stitch modules.

26. The method of claim 24, wherein connecting the two or more drop-stitch modules togethercomprises attaching upper connection features of adjacent, coplanar drop-stitch modules and attaching lower connection features of the adjacent, coplanar drop-stitch modules.

27. The method of claim 24, wherein assembling the modular drop-stitch utility platform further comprises connecting additional connection features along an outer perimeter of the modular drop-stitch utility platform for enhanced stability or functionality.

28. The method of claim 24, wherein the method further comprises:disassembling the modular drop-stitch utility platform, the disassembling comprising:at least partially deflating the two or more drop-stitch modules of the modular drop-stitch utility platform; and thendisconnecting the connection features of the two or more drop-stitch modules to detach the two or more drop-stitch modules from one another.

29. The method of claim 28, wherein disassembling further comprises completely deflating the drop-stitch modules for compact storage and / or transport.

30. The method of claim 28, wherein disassembling further comprises disconnecting additional connection features of the modular drop-stitch utility platform along an outer perimeter of the modular drop-stitch utility platform before or after at least partially deflating the two or more drop-stitch modules.

31. A modular drop-stitch utility platform comprising:a first drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a first end portion;a second drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a second end portion;a first connection tube configured to be inserted through a first set of interdigitated connection loop flanges before the first and second drop-stitch modules are fully inflated, the first set of interdigitated connection loop flanges including at least a portion of the lower connection loop flanges positioned along the first end portion of the first dropstitch module and at least a portion of the lower connection loop flanges positioned along the second end portion of the second drop-stitch module; anda second connection tube configured to be inserted through a second set of interdigitated connection loop flanges before the first and second drop-stitch modules are fully inflated, the second set of interdigitated connection loop flanges including at least a portion of the upper connection loop flanges positioned along the first end portion of the first dropstitch module and at least a portion of the upper connection loop flanges positioned along the second end portion of the second drop-stitch module.

32. The modular drop-stitch utility platform of claim 31, wherein the lower connection loop flanges and upper connection loop flanges positioned along the first end portion of the first dropstitch module are bonded to a first inflatable drop-stitch envelope of the first drop-stitch module using an adhesive, and wherein the lower connection loop flanges and upper connection loop flanges positioned along the second end portion of the second drop-stitch module are bonded to a second inflatable drop-stitch envelope of the second drop-stitch module using the adhesive.

33. The modular drop-stitch utility platform of claim 31, wherein the first and second drop-stitch modules are configured to be simultaneously fully inflated after the first connection tube is inserted through the first set of interdigitated connection loop flanges and after the second connection tube is inserted through the second set of interdigitated connection loop flanges, thereby yielding a structural locking connection between the first and second drop-stitch modules.

34. The modular drop-stitch utility platform of claim 31, comprising:a third drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a third end portion, wherein the first drop-stitch module includes additional lower connection loop flanges and additional upper connection loop flanges positioned along a fourth end portion;a third connection tube configured to be inserted through a third set of interdigitated connection loop flanges before the first and third drop-stitch modules are fully inflated, the third set of interdigitated connection loop flanges including at least a portion of theadditional lower connection loop flanges positioned along the fourth end portion of the first drop-stitch module and at least a portion of the lower connection loop flanges positioned along the third end portion of the third drop-stitch module; anda fourth connection tube configured to be inserted through a fourth set of interdigitated connection loop flanges before the first and third drop-stitch modules are fully inflated, the fourth set of interdigitated connection loop flanges including at least a portion of the additional upper connection loop flanges positioned along the fourth end portion of the first drop-stitch module and at least a portion of the upper connection loop flanges positioned along the third end portion of the third drop-stitch module.

35. The modular drop-stitch utility platform of claim 31, comprising:a third drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a third end portion;a fourth drop-stitch module having lower connection loop flanges and upper connection loop flanges positioned along a fourth end portion; anda third connection tube configured to be inserted through a third set of interdigitated connection loop flanges before the first, second, third, and fourth drop-stitch modules are fully inflated, the third set of interdigitated connection loop flanges including at least a portion of the lower connection loop flanges positioned along the third end portion of the third drop-stitch module and at least a portion of the lower connection loop flanges positioned along the fourth end portion of the fourth drop-stitch module, and wherein the first set of interdigitated connection loop flanges further includes at least a portion of the upper connection loop flanges positioned along the third end portion of the third dropstitch module and at least a portion of the upper connection loop flanges positioned along the fourth end portion of the fourth drop-stitch module.

36. The modular drop-stitch utility platform of claim 31, comprising:a third drop-stitch module having lower connection loop flanges positioned along a center of the third drop-stitch module, wherein the second set of interdigitated connection loop flanges further includes at least a portion of the lower connection loop flanges positioned along the center of the third drop-stitch module, and wherein the second connection tubeis configured to be inserted through the second set of interdigitated connection loop flanges before the first, second, and third drop-stitch modules are fully inflated; anda fourth drop-stitch module having upper connection loop flanges positioned along a center of the fourth drop-stitch module, wherein the first set of interdigitated connection loop flanges further includes at least a portion of the upper connection loop flanges positioned along the center of the fourth drop-stitch module, and wherein the first connection tube is configured to be inserted through the first set of interdigitated connection loop flanges before the first, second, and fourth drop-stitch modules are fully inflated.

37. The modular drop-stitch utility platform of claim 31, comprising:a first set of end caps configured to removably attach to end portions of the first connection tube after the first connection tube is inserted through the first set of interdigitated connection loop features, wherein the first set of end caps have an outer diameter that is greater than an inner diameter of the first set of interdigitated connection loop flanges.

38. The modular drop-stitch utility platform of claim 31, wherein either (i) the first end portion extends along a first length of the first drop-stitch module and the second end portion extends along a second length of the second drop-stitch module, or (ii) the first end portion extends along a first width of the first drop-stitch module and the second end portion extends along a second width of the second drop-stitch module.

39. A method of connecting drop-stitch modules, the method comprising:interdigitating lower connection loop flanges positioned along a first end portion of a first drop-stitch module and lower connection loop flanges positioned along a second end portion of a second drop-stitch module;inserting a first connection tube through the interdigitated lower connection loop flanges;interdigitating upper connection loop flanges positioned along first end portion of the first drop-stitch module and upper connection loop flanges positioned along the second end portion of the second drop-stitch module;inserting a second connection tube through the interdigitated upper connection loop flanges; andconcurrently inflating the first and second drop-stitch modules to a rated pressure, thereby to yield a structural locking connection between the first and second drop-stitch modules.

40. The method of claim 39, wherein, prior to interdigitating the lower connection loop flanges, the method comprises positioning the first and second drop-stitch modules such that the first end portion of the first drop-stitch module is adjacent to the second end portion of the second dropstitch module while the first and second drop-stitch modules are fully or partially deflated.

41. The method of claim 39, wherein, after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module and the second end portion of the second drop-stitch module apply pressure to one another, and wherein the applied pressure results in locking tension (i) between the interdigitated lower connection loop flanges and the first connection tube and (ii) between the interdigitated upper connection loop flanges and the second connection tube.

42. The method of claim 39, wherein after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module contacts the second end portion of the second drop-stitch module along a substantially vertical plane that bisects the interdigitated lower connection loop flanges, the first connection tube, the interdigitated upper connection loop flanges, and the second connection tube.

43. The method of claim 39, wherein after concurrently inflating the first and second drop-stitch modules to the rated pressure, the first end portion of the first drop-stitch module contacts the second end portion of the second drop-stitch module along a contact length, such that a ratio of the contact length to a height of the first and second drop-stitch modules ranges from about 0.5:1 to about 1:1.

44. The method of claim 39, wherein the rated pressure is greater than or equal to about 12 psi, and wherein, when biased with a load of about 135 kilograms after inflating the first and second drop-stitch modules to the rated pressure, the structural locking connection demonstrates a deflection that is (i) less than or equal to 225 mm, (ii) less than or equal to 15% of a length of thefirst and second drop-stitch modules after inflation, or (iii) less than or equal to 115% of a height of the first and second drop-stitch modules after inflation.

45. The method of claim 39, wherein the rated pressure is greater than or equal to about 16 psi, and wherein, when biased with a load of about 135 kilograms after inflating the first and second drop-stitch modules to the rated pressure, the structural locking connection demonstrates a deflection that is (i) less than or equal to 100 mm, (ii) less than or equal to 5% of a length of the first and second drop-stitch modules after inflation, or (iii) less than or equal to 50% of a height of the first and second drop-stitch modules after inflation.s

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