Low friction inserts for marine pile guides

Abstract

A pile guide has a body formed of thermoplastic polymer, such as polyethylene. The body has an internal area constructed and arranged to receive and retain a pile in the internal area of the body. Inserts formed of thermoplastic polymer, such as polyethylene, are attached to the internal area of the body and extend outwardly from the internal area of the body so that contact of the pile is with the inserts. The inserts are replaceable so that as the inserts wear due to frictional engagement with the pile, worn inserts may be replaced without replacement of the other components of the pile guide. The inserts are preferred to be formed of a corrosion resistant, low friction, chemical resistant, high impact and low moisture absorbing thermoplastic material.

Description

[0001] This Application is a Continuation In Part of application Ser. No. 18 / 527,569, filed Dec. 4, 2023, the benefit of which is claimed hereby.BACKGROUND OF THE INVENTION

[0002] Piles are vertical posts or poles driven into the ground or attached to other objects. Piles may be formed of wood, concrete, steel or other materials. Commonly, piles are used to stabilize or hold other objects. In a typical application, piles are driven into the ground and a floating dock or similar floating object is held horizontally in place by the pile. The floating dock of other floating object comprises a pile guide. The pile extends through an internal area of the pile guide that allows vertical movement of the dock of other floating object relative to the pile, but retards horizonal movement.

[0003] Pile guides in common use have inadequate service lives. Most pile guides in common use are formed of metal. Metal pile guides are not sufficiently resistant to environmental factors such as weather and sunlight. Particularly in salt water applications, corrosion of metals, even galvanized metals, leads to replacement of the pile guides.

[0004] As the pile guide moves upwardly and downwardly relative to the pile, friction is present between the pile and the pile guide. Concrete piles in particular result in abrasion and wear of the pile guide. In some cases, the pile guide may comprise wheels to reduce friction, but wheels require bearings that do not have a long service life in wet applications, and particularly in salt water.

[0005] Steel piles may result in less frictional interaction with the pile guide than concrete piles or wood piles, but steel piles are subject to corrosion. Some steel piles may be coated to resist corrosion, but the coating wears off due to weather and abrasion with the pile guide, exposing steel surfaces to weather and salt water, and the resulting corrosion.

[0006] Abrasion and wear of pile guides is exacerbated by inaccurate placement of piles, especially piles that are driven or otherwise placed in the ground. The spacing of piles may not match the position of pile guides on a floating dock or floating object with precision. Piles may not be positioned exactly vertically. These factors mean that piles may place more force, and therefore more, or even complete, loading one side of the pile guide, resulting in more rapid wear of one side of the pile guide. However, the solution is frequently to replace the entire pile guide at substantial trouble and expense.

[0007] There is a need for a low friction pile guide that is resistant to environmental degradation, and also has easily replaceable components.SUMMARY OF THE INVENTION

[0008] The present invention is a pile guide having a body formed of thermoplastic polymer, such as polyethylene. The body has an internal area constructed and arranged to receive and retain a pile in the internal area of the body. A plurality of spaced apart inserts formed of thermoplastic polymer, such as polyethylene, are attached to the internal area of the body and extend outwardly from the internal area of the body so that contact of the pile is with the inserts. The inserts are replaceable so that as the inserts wear due to frictional engagement with the pile, worn inserts may be replaced without replacement of the other components of the pile guide. The inserts are preferred to be formed of a corrosion resistant, low friction, chemical resistant, high impact and low moisture absorbing thermoplastic material.BRIEF DRAWING DESCRIPTION

[0009] FIG. 1 shows an exploded view of an embodiment of the pile guide according to the invention.

[0010] FIG. 2 shows a perspective view of an embodiment of the pile guide according to the invention.

[0011] FIG. 3 shows an elevation of an embodiment of the pile guide according to the invention.

[0012] FIG. 4 shows an exploded view of another embodiment of the pile guide according to the invention.

[0013] FIG. 5 shows a perspective view of another embodiment of the pile guide according to the invention.

[0014] FIG. 6 shows an exploded view of another embodiment of the pile guide according to the invention.

[0015] FIG. 7 shows a perspective view of another embodiment of the pile guide according to the invention.

[0016] FIG. 8 shows a perspective view of another embodiment of the pile guide according to the invention.

[0017] FIG. 9 shows a perspective view of another embodiment of the pile guide according to the invention, combining the pile guide of FIG. 5 with the pile guide of FIG. 9.

[0018] FIG. 10 shows a top plan view of another embodiment of the pile guide according to the invention.

[0019] FIG. 11 shows an embodiment of low friction cylindrical sector inserts for a marine pile guide, with the cylindrical sector inserts in position in a pile guide in use with a pile.

[0020] FIG. 12 is an exploded view of the low friction cylindrical sector inserts for a marine pile guide of FIG. 11.

[0021] FIG. 13 is a perspective view of the low friction cylindrical sector inserts of positioned in a marine pile guide.

[0022] FIG. 14 is a top, plan view of an embodiment of the low friction cylindrical sector inserts.

[0023] FIG. 15 is a bottom, plan view of an embodiment of the low friction cylindrical sector inserts within a marine pile guide.

[0024] FIG. 16 is a sectioned view demonstrating low friction cylindrical sector inserts within a marine pile guide showing optional retaining clips in a recess formed in the cylindrical sector insert.

[0025] FIG. 17, FIG. 18 and FIG. 19 correspond to FIG. 11, FIG. 12, and FIG. 13, and show barriers or spacers that facilitate spacing the cylindrical sector inserts apart from each other.DESCRIPTION OF PREFERRED EMBODIMENTS

[0026] FIGS. 1, 2 and 3 show an exemplary embodiment of the pile guide of the invention. FIG. 1 shows a body 2 and inserts 4. Also shown is attachment plate 6 that allows the body to be attached to another object, such as a floating dock. The attachment plate may be of various forms depending upon the application of the pile guide. The attachment plate is preferred to be welded to the body.

[0027] The body 2 of the invention as shown in this embodiment is circular and annular. The body has an internal circumference 8 through which a pile traverses as the pile guide moves vertically in use. The body has a plurality of slots 10 formed in the top surface of the body for receiving the inserts. It is preferred that the body is formed as a continuous member having no gaps.

[0028] In this embodiment, the inserts 4 are formed as an inverted “L” shape. The shorter leg of the L meets the longer leg at 90° angle. The shorter leg is inserted into a slot 10 of the body 2 and fastened to the body. The inserts are preferred to be attached to the body by a fastener 12 that is removable, such as a threaded fastener, which allows each insert to be replaced as necessary due to wear or other defects in the insert. The inserts extend outwardly from the internal circumference of the body so that they are positioned between the pile and the body.

[0029] In this embodiment, there are eight (8) inserts 4 that are spaced apart at equal intervals. As shown in FIG. 3, an insert is present every 45°, measured from the center of the inserts. When the inserts are spaced apart, eight (8) inserts are preferred to be used to meet goals of the invention. When eight (8) inserts are used, they are 45° apart. If twelve (12) inserts are used, they are spaced 30° apart. 360° divided by the number of inserts provides the spacing.

[0030] In a preferred embodiment, the inserts 4 are formed of ultra-high molecular weight polyethylene (UHMW). UHMW is preferred because it has high sliding capabilities and is abrasion resistant. UHMW provides reduced friction and reduced wear due to abrasion as compared to other materials and other thermoplastics. UHMW is also corrosion resistant, has high impact strength and low water absorption compared to other materials and thermoplastics.

[0031] However, UHMW is difficult to form into shapes, such as by machining, compared to other thermoplastics. Therefore, the use of multiple small inserts 4 of a simple geometric shape is preferred over larger inserts of more complex geometry. The eight (8) inserts shown in the embodiments depicted in FIGS. 1-9 occupy less than ⅓ of the internal circumference 8 of the body 2, and are formed in the simple inverted L shape. The cost to form the inserts and the cost of material is reduced by this construct.

[0032] The body 2 is formed of a thermoplastic such as polyethylene. One material that may be used is high density polyethylene (HDPE). HDPE is easy to machine, easy to form and easy to weld, while providing high strength to density. HDPE has excellent impact resistance and is corrosion proof. HDPE is less expensive than UHMW. HDPE provides lower material cost for the relatively larger body than a body formed of UHMW. (UHMW would be difficult to form as the body.) The HDPE body can be welded to the attachment plate 6. The combination of UHMW and a thermoplastic such as HDPE provides a pile guide that is strong and is corrosion and weather resistant in hostile environments such as marine applications, while providing abrasion resistance and low friction when sliding against a pile. The UHMW inserts 4 can be easily and cost effectively replaced, without the necessity of removing and replacing an entire pile guide or removing the pile guide body from the pile.

[0033] The pile guide is therefore formed of two materials that are preferred to be durable and corrosion resistant, such as thermoplastics. The body 2 is formed of a first thermoplastic, and the inserts 4 are formed of a second thermoplastic that has lower frictional characteristics than the first thermoplastic; that is, the second thermoplastic has higher sliding characteristics than the first thermoplastic.

[0034] In an embodiment of the invention, attachment plate 6 is formed of the same thermoplastic as the first thermoplastic of the body 2. While the drawings show the attachment plate as a flat plate, the attachment plate is not limited to any particular structure, but may be formed as required by the particular application. FIGS. 4, 5, 8 and 9 show the body and inserts of FIGS. 1, 2 and 3, but provide examples of other attachment plate structures (106, 206, 306) that are attached, such as by welding, to the body.

[0035] FIGS. 6 and 7 demonstrate that a body 202 of the pile guide may be formed in geometric configurations other than round. The body of the pile guide in FIGS. 6 and 7, is rectangular, and more particularly, square. Some piles, such as concrete piles, have a rectangular cross section. The shape of the body is formed to accommodate the horizontal cross section of the pile. The body is continuous about its internal perimeter 208. While the rectangular cross section may be formed in four (4) pieces, there are no gaps present where each of the four sides meet adjoining sides so that the body is continuous.

[0036] The body 202 and inserts 204 as shown in FIGS. 6 and 7 are formed of materials consistent with the goals of the invention as disclosed with regard to the embodiment shown FIGS. 1, 2 and 3. The rectangular body of FIGS. 6 and 7 is preferred to have slots 210 in the top of the body that assist in holding the inserts in place. The inserts are attached in a manner that allows the inserts to be replaced due to wear or other defects. The inserts may be attached to the body with threaded fasteners 12 as shown.

[0037] The attachment plate 206 as shown in FIG. 7 is another example of a configuration for the attachment plate. The attachment plate is attached to the body 202 such as by welding, and may be formed of the same thermoplastic as the body. The body may have a receiving slot 214 for positioning the attachment plate on the body.

[0038] The attachment plate 206 as shown in FIG. 7 has an extension 216 that may be useful in attaching the pile guide to an object such as a floating dock. The attachment plate may be fastened to an object by fasteners that extend through the attachment plate, or the extension may be held in place by brackets through which the extension is inserted.

[0039] FIGS. 6 and 7 show clips 218 that may be used to further stabilize a lower end of the inserts 204. The clips are positioned at a lower end of the inserts and are attached to the body 202. In one embodiment the clips are “L” shaped, with one side of the clip attached to the body and the other side of the clip abutting the insert. A clip is present on both sides of the insert. The clips bracket the insert without attachment to the insert. The clips could be attached to the insert, such as by a fastener, although the additional fasteners make replacement of the inserts more difficult and is not preferred. If no fastener is used to attach the clips, inserts can be replaced while the clips remain in place on the body to receive the new inserts.

[0040] In another embodiment of the clips 218, the clips are Z-shaped. A first end of the Z-shaped clip is attached to the body, such as by a fastener. The opposite end of the Z-shaped clip is inserted into a slot 220 formed in the inserts. The middle section of the Z-shaped clip meets the ends at a right angle.

[0041] Clips may be used in geometric configurations of the body other than the rectangular body to provide additional stabilization of the inserts, especially where the pile guide is large and / or the inserts are exposed to substantial force. The clips should not extend across the sides of the inserts further than necessary so that the useful life of the inserts is not greatly reduced as the inserts wear. The slots 220 as shown in FIG. 6 indicate that the clip 218 extends to substantially less than the midpoint of the outwardly facing side of the insert.

[0042] FIG. 9 demonstrates that multiple pile guides according to the invention may be used with a single pile 14 to attach multiple objects to a pile. Multiple pile guide constructs used in combination need not be of the same configuration.

[0043] In yet another embodiment of the invention, the inserts may be formed in multiple parts that cover the internal circumference of the body. There are not fewer than two (2) inserts. For example, the inserts may be formed as semi-circles that collectively form a circle that covers the internal circumference of the body. The inserts could comprise more than two (2) inserts, but not less than two, since the inserts must be easily removable, and because one (1) insert is likely to be subject to more wear than the remaining inserts. The body and inserts may be formed of materials as indicated herein, and the inserts attached to the body so as to be removable. Fasteners may be used to attach the inserts to the top of the body as shown in the drawings.

[0044] In a preferred embodiment, the spaced apart cylindrical sector inserts 402,404 are semicylinders with ends ranging from 150 degrees to 179 degrees (rather than the standard 180 degrees of a half-circle semicylinder). The use of two cylindrical sector inserts that are less than 180 degrees but more than 150 degrees allows the inserts to be positioned within the pile guide and spaced apart for ease of insertion into a pile guide in use with a pile present in the pile guide

[0045] As shown in the embodiment of FIG. 11, a pair of cylindrical sector inserts 402,404 are positioned in a marine pile guide 410. A pile 436, such as a pile that extends through a dock, is present in the pile guide and extends through the cylindrical sector inserts. An attachment plate 412 is shown that can be attached to a dock, although other ways of attaching the pile guide to a dock may be used.

[0046] FIG. 12 is an exploded view of the embodiment of FIG. 11. The lower portion of cylindrical sector insert is referred to as the cylindrical sector 422,424, while the construct including the cylindrical sector and the flange 406, 408 is referred to as a cylindrical sector insert 404,404. The flanges and an upper exterior portion of the marine pile guide may have aligned receiving voids 418 for receiving attachment devices, such as screws or other fasteners, for connecting the cylindrical sector inserts to the marine pile guides.

[0047] FIG. 13 shows the cylindrical sector inserts 402,404 attached to the marine pile guide 410. The cylindrical sector inserts are spaced apart when mounted, as indicated by spaces 414,416.

[0048] In each embodiment, a cylindrical sector insert 402,404 attached to one side of the marine pile guide body 410 may extend further into the internal area of the marine pile guide body than inserts on another side of the internal area of the marine pile guide body. The installer may observe that a pile has an orientation that will bias the pile toward one side of the pile guide. To accommodate for this bias, an insert or inserts may extend further out from the body, such as by being thicker, and providing more thermoplastic material on one part of the internal area of the body to compensate for the experienced or anticipated increase in wear.

[0049] The cylindrical sector inserts 402,404 may, for example, include two to four cylindrical sector inserts. The cylindrical sector inserts are a replaceable component that is formed from a low friction material, such as a thermoplastic polymer, including ultra-high molecular weight polyethylene, or other low friction plastic materials. In one embodiment, the cylindrical sector insert can be shaped as a segment of a cylinder subtending an arc (e.g., between approximately 75° and 179°). The cylindrical sector insert can be produced by extrusion and / or machining processes to achieve a desired curvature and / or thickness. The cylindrical sector insert is positioned within the internal area of the body to provide a low-friction interface with a pile. In one implementation, the cylindrical sector inserts can be non-uniform in thickness when compared to another cylindrical insert to which it is matched to accommodate uneven wear patterns resulting from off-center and / or misaligned piles. The geometry of the cylindrical sector insert can allow for ease of installation and / or replacement, particularly in retrofit scenarios where the pile remains in place. Further, the cylindrical sector insert can be attached to the internal area of the body using removable fasteners and / or can be stabilized by barriers and / or clips to inhibit twisting and / or migration under load.

[0050] The outside diameter of the cylindrical sector inserts 402,404 is preferred to be matched to nest against the inside diameter of pile guide into which the cylindrical sector insert is fixed with as little space between the insert and the pile guide as practicable. Such fitment assists in retaining the cylindrical sector insert in place and resisting movement.

[0051] The cylindrical sector inserts need not be of uniform thickness, thereby allowing for uneven wear as a pile rubs against the cylindrical sector inserts, which occurs as a floating dock moves up and down. One cylindrical sector insert rather than two may be positioned in the pile guide if friction is significant on one portion of the pile guide.

[0052] Barriers or spacers 426 may be positioned on a top surface of the pile guide to separate and space the cylindrical sector inserts. FIG. 16 shows the construct of FIG. 11, with barriers 426 positioned to space the cylindrical sector inserts apart. The barriers may be formed as part of the pile guide, or by attaching barriers on top of the pile guide with fasteners, such as by fasteners inserted through voids 430. The barriers inhibit twisting and other movement of the cylindrical sector inserts when in use. The barriers help position the inserts as spaced apart from each other. FIG. 17 shows the construct of FIG. 12, but adds barriers between the cylindrical sector inserts. FIG. 18 shows the construct of FIG. 13, and adds barriers between the cylindrical sector inserts.

[0053] Optional clips may be used to further secure the cylindrical section inserts, as shown in FIGS. 6 and 7, and described above. FIG. 16 shows a sectioned view of the cylindrical section insert 422 attached to a marine pile guide. Clip 432 is attached to the pile guide 410, such as by a fastener. An optional recess accommodates the clip so that the clip is not exposed to movement relative to the pile guide. The insert could be attached by a fastener inserted through the insert 422 and the pile guide 410 to connect the structures, with or without the use of a clip.

[0054] In another embodiment, four spaced apart cylindrical sector inserts are used, with each cylindrical sector insert having ends ranging from 75 degrees to 88 degrees. Alternatively, a mix of one cylindrical sector insert that is 150-179 degrees with one or two cylindrical sector inserts that are 75 degrees to 88 degrees may be used. Clips may be positioned along the length of the cylindrical sector inserts to inhibit twisting and movement of the inserts.

Examples

Embodiment Construction

[0026]FIGS. 1, 2 and 3 show an exemplary embodiment of the pile guide of the invention. FIG. 1 shows a body 2 and inserts 4. Also shown is attachment plate 6 that allows the body to be attached to another object, such as a floating dock. The attachment plate may be of various forms depending upon the application of the pile guide. The attachment plate is preferred to be welded to the body.

[0027]The body 2 of the invention as shown in this embodiment is circular and annular. The body has an internal circumference 8 through which a pile traverses as the pile guide moves vertically in use. The body has a plurality of slots 10 formed in the top surface of the body for receiving the inserts. It is preferred that the body is formed as a continuous member having no gaps.

[0028]In this embodiment, the inserts 4 are formed as an inverted “L” shape. The shorter leg of the L meets the longer leg at 90° angle. The shorter leg is inserted into a slot 10 of the body 2 and fastened to the body. The...

[0001] This Application is a Continuation In Part of application Ser. No. 18 / 527,569, filed Dec. 4, 2023, the benefit of which is claimed hereby.BACKGROUND OF THE INVENTION

[0002] Piles are vertical posts or poles driven into the ground or attached to other objects. Piles may be formed of wood, concrete, steel or other materials. Commonly, piles are used to stabilize or hold other objects. In a typical application, piles are driven into the ground and a floating dock or similar floating object is held horizontally in place by the pile. The floating dock of other floating object comprises a pile guide. The pile extends through an internal area of the pile guide that allows vertical movement of the dock of other floating object relative to the pile, but retards horizonal movement.

[0003] Pile guides in common use have inadequate service lives. Most pile guides in common use are formed of metal. Metal pile guides are not sufficiently resistant to environmental factors such as weather and sunlight. Particularly in salt water applications, corrosion of metals, even galvanized metals, leads to replacement of the pile guides.

[0004] As the pile guide moves upwardly and downwardly relative to the pile, friction is present between the pile and the pile guide. Concrete piles in particular result in abrasion and wear of the pile guide. In some cases, the pile guide may comprise wheels to reduce friction, but wheels require bearings that do not have a long service life in wet applications, and particularly in salt water.

[0005] Steel piles may result in less frictional interaction with the pile guide than concrete piles or wood piles, but steel piles are subject to corrosion. Some steel piles may be coated to resist corrosion, but the coating wears off due to weather and abrasion with the pile guide, exposing steel surfaces to weather and salt water, and the resulting corrosion.

[0006] Abrasion and wear of pile guides is exacerbated by inaccurate placement of piles, especially piles that are driven or otherwise placed in the ground. The spacing of piles may not match the position of pile guides on a floating dock or floating object with precision. Piles may not be positioned exactly vertically. These factors mean that piles may place more force, and therefore more, or even complete, loading one side of the pile guide, resulting in more rapid wear of one side of the pile guide. However, the solution is frequently to replace the entire pile guide at substantial trouble and expense.

[0007] There is a need for a low friction pile guide that is resistant to environmental degradation, and also has easily replaceable components.SUMMARY OF THE INVENTION

[0008] The present invention is a pile guide having a body formed of thermoplastic polymer, such as polyethylene. The body has an internal area constructed and arranged to receive and retain a pile in the internal area of the body. A plurality of spaced apart inserts formed of thermoplastic polymer, such as polyethylene, are attached to the internal area of the body and extend outwardly from the internal area of the body so that contact of the pile is with the inserts. The inserts are replaceable so that as the inserts wear due to frictional engagement with the pile, worn inserts may be replaced without replacement of the other components of the pile guide. The inserts are preferred to be formed of a corrosion resistant, low friction, chemical resistant, high impact and low moisture absorbing thermoplastic material.BRIEF DRAWING DESCRIPTION

[0009] FIG. 1 shows an exploded view of an embodiment of the pile guide according to the invention.

[0010] FIG. 2 shows a perspective view of an embodiment of the pile guide according to the invention.

[0011] FIG. 3 shows an elevation of an embodiment of the pile guide according to the invention.

[0012] FIG. 4 shows an exploded view of another embodiment of the pile guide according to the invention.

[0013] FIG. 5 shows a perspective view of another embodiment of the pile guide according to the invention.

[0014] FIG. 6 shows an exploded view of another embodiment of the pile guide according to the invention.

[0015] FIG. 7 shows a perspective view of another embodiment of the pile guide according to the invention.

[0016] FIG. 8 shows a perspective view of another embodiment of the pile guide according to the invention.

[0017] FIG. 9 shows a perspective view of another embodiment of the pile guide according to the invention, combining the pile guide of FIG. 5 with the pile guide of FIG. 9.

[0018] FIG. 10 shows a top plan view of another embodiment of the pile guide according to the invention.

[0019] FIG. 11 shows an embodiment of low friction cylindrical sector inserts for a marine pile guide, with the cylindrical sector inserts in position in a pile guide in use with a pile.

[0020] FIG. 12 is an exploded view of the low friction cylindrical sector inserts for a marine pile guide of FIG. 11.

[0021] FIG. 13 is a perspective view of the low friction cylindrical sector inserts of positioned in a marine pile guide.

[0022] FIG. 14 is a top, plan view of an embodiment of the low friction cylindrical sector inserts.

[0023] FIG. 15 is a bottom, plan view of an embodiment of the low friction cylindrical sector inserts within a marine pile guide.

[0024] FIG. 16 is a sectioned view demonstrating low friction cylindrical sector inserts within a marine pile guide showing optional retaining clips in a recess formed in the cylindrical sector insert.

[0025] FIG. 17, FIG. 18 and FIG. 19 correspond to FIG. 11, FIG. 12, and FIG. 13, and show barriers or spacers that facilitate spacing the cylindrical sector inserts apart from each other.DESCRIPTION OF PREFERRED EMBODIMENTS

[0026] FIGS. 1, 2 and 3 show an exemplary embodiment of the pile guide of the invention. FIG. 1 shows a body 2 and inserts 4. Also shown is attachment plate 6 that allows the body to be attached to another object, such as a floating dock. The attachment plate may be of various forms depending upon the application of the pile guide. The attachment plate is preferred to be welded to the body.

[0027] The body 2 of the invention as shown in this embodiment is circular and annular. The body has an internal circumference 8 through which a pile traverses as the pile guide moves vertically in use. The body has a plurality of slots 10 formed in the top surface of the body for receiving the inserts. It is preferred that the body is formed as a continuous member having no gaps.

[0028] In this embodiment, the inserts 4 are formed as an inverted “L” shape. The shorter leg of the L meets the longer leg at 90° angle. The shorter leg is inserted into a slot 10 of the body 2 and fastened to the body. The inserts are preferred to be attached to the body by a fastener 12 that is removable, such as a threaded fastener, which allows each insert to be replaced as necessary due to wear or other defects in the insert. The inserts extend outwardly from the internal circumference of the body so that they are positioned between the pile and the body.

[0029] In this embodiment, there are eight (8) inserts 4 that are spaced apart at equal intervals. As shown in FIG. 3, an insert is present every 45°, measured from the center of the inserts. When the inserts are spaced apart, eight (8) inserts are preferred to be used to meet goals of the invention. When eight (8) inserts are used, they are 45° apart. If twelve (12) inserts are used, they are spaced 30° apart. 360° divided by the number of inserts provides the spacing.

[0030] In a preferred embodiment, the inserts 4 are formed of ultra-high molecular weight polyethylene (UHMW). UHMW is preferred because it has high sliding capabilities and is abrasion resistant. UHMW provides reduced friction and reduced wear due to abrasion as compared to other materials and other thermoplastics. UHMW is also corrosion resistant, has high impact strength and low water absorption compared to other materials and thermoplastics.

[0031] However, UHMW is difficult to form into shapes, such as by machining, compared to other thermoplastics. Therefore, the use of multiple small inserts 4 of a simple geometric shape is preferred over larger inserts of more complex geometry. The eight (8) inserts shown in the embodiments depicted in FIGS. 1-9 occupy less than ⅓ of the internal circumference 8 of the body 2, and are formed in the simple inverted L shape. The cost to form the inserts and the cost of material is reduced by this construct.

[0032] The body 2 is formed of a thermoplastic such as polyethylene. One material that may be used is high density polyethylene (HDPE). HDPE is easy to machine, easy to form and easy to weld, while providing high strength to density. HDPE has excellent impact resistance and is corrosion proof. HDPE is less expensive than UHMW. HDPE provides lower material cost for the relatively larger body than a body formed of UHMW. (UHMW would be difficult to form as the body.) The HDPE body can be welded to the attachment plate 6. The combination of UHMW and a thermoplastic such as HDPE provides a pile guide that is strong and is corrosion and weather resistant in hostile environments such as marine applications, while providing abrasion resistance and low friction when sliding against a pile. The UHMW inserts 4 can be easily and cost effectively replaced, without the necessity of removing and replacing an entire pile guide or removing the pile guide body from the pile.

[0033] The pile guide is therefore formed of two materials that are preferred to be durable and corrosion resistant, such as thermoplastics. The body 2 is formed of a first thermoplastic, and the inserts 4 are formed of a second thermoplastic that has lower frictional characteristics than the first thermoplastic; that is, the second thermoplastic has higher sliding characteristics than the first thermoplastic.

[0034] In an embodiment of the invention, attachment plate 6 is formed of the same thermoplastic as the first thermoplastic of the body 2. While the drawings show the attachment plate as a flat plate, the attachment plate is not limited to any particular structure, but may be formed as required by the particular application. FIGS. 4, 5, 8 and 9 show the body and inserts of FIGS. 1, 2 and 3, but provide examples of other attachment plate structures (106, 206, 306) that are attached, such as by welding, to the body.

[0035] FIGS. 6 and 7 demonstrate that a body 202 of the pile guide may be formed in geometric configurations other than round. The body of the pile guide in FIGS. 6 and 7, is rectangular, and more particularly, square. Some piles, such as concrete piles, have a rectangular cross section. The shape of the body is formed to accommodate the horizontal cross section of the pile. The body is continuous about its internal perimeter 208. While the rectangular cross section may be formed in four (4) pieces, there are no gaps present where each of the four sides meet adjoining sides so that the body is continuous.

[0036] The body 202 and inserts 204 as shown in FIGS. 6 and 7 are formed of materials consistent with the goals of the invention as disclosed with regard to the embodiment shown FIGS. 1, 2 and 3. The rectangular body of FIGS. 6 and 7 is preferred to have slots 210 in the top of the body that assist in holding the inserts in place. The inserts are attached in a manner that allows the inserts to be replaced due to wear or other defects. The inserts may be attached to the body with threaded fasteners 12 as shown.

[0037] The attachment plate 206 as shown in FIG. 7 is another example of a configuration for the attachment plate. The attachment plate is attached to the body 202 such as by welding, and may be formed of the same thermoplastic as the body. The body may have a receiving slot 214 for positioning the attachment plate on the body.

[0038] The attachment plate 206 as shown in FIG. 7 has an extension 216 that may be useful in attaching the pile guide to an object such as a floating dock. The attachment plate may be fastened to an object by fasteners that extend through the attachment plate, or the extension may be held in place by brackets through which the extension is inserted.

[0039] FIGS. 6 and 7 show clips 218 that may be used to further stabilize a lower end of the inserts 204. The clips are positioned at a lower end of the inserts and are attached to the body 202. In one embodiment the clips are “L” shaped, with one side of the clip attached to the body and the other side of the clip abutting the insert. A clip is present on both sides of the insert. The clips bracket the insert without attachment to the insert. The clips could be attached to the insert, such as by a fastener, although the additional fasteners make replacement of the inserts more difficult and is not preferred. If no fastener is used to attach the clips, inserts can be replaced while the clips remain in place on the body to receive the new inserts.

[0040] In another embodiment of the clips 218, the clips are Z-shaped. A first end of the Z-shaped clip is attached to the body, such as by a fastener. The opposite end of the Z-shaped clip is inserted into a slot 220 formed in the inserts. The middle section of the Z-shaped clip meets the ends at a right angle.

[0041] Clips may be used in geometric configurations of the body other than the rectangular body to provide additional stabilization of the inserts, especially where the pile guide is large and / or the inserts are exposed to substantial force. The clips should not extend across the sides of the inserts further than necessary so that the useful life of the inserts is not greatly reduced as the inserts wear. The slots 220 as shown in FIG. 6 indicate that the clip 218 extends to substantially less than the midpoint of the outwardly facing side of the insert.

[0042] FIG. 9 demonstrates that multiple pile guides according to the invention may be used with a single pile 14 to attach multiple objects to a pile. Multiple pile guide constructs used in combination need not be of the same configuration.

[0043] In yet another embodiment of the invention, the inserts may be formed in multiple parts that cover the internal circumference of the body. There are not fewer than two (2) inserts. For example, the inserts may be formed as semi-circles that collectively form a circle that covers the internal circumference of the body. The inserts could comprise more than two (2) inserts, but not less than two, since the inserts must be easily removable, and because one (1) insert is likely to be subject to more wear than the remaining inserts. The body and inserts may be formed of materials as indicated herein, and the inserts attached to the body so as to be removable. Fasteners may be used to attach the inserts to the top of the body as shown in the drawings.

[0044] In a preferred embodiment, the spaced apart cylindrical sector inserts 402,404 are semicylinders with ends ranging from 150 degrees to 179 degrees (rather than the standard 180 degrees of a half-circle semicylinder). The use of two cylindrical sector inserts that are less than 180 degrees but more than 150 degrees allows the inserts to be positioned within the pile guide and spaced apart for ease of insertion into a pile guide in use with a pile present in the pile guide

[0045] As shown in the embodiment of FIG. 11, a pair of cylindrical sector inserts 402,404 are positioned in a marine pile guide 410. A pile 436, such as a pile that extends through a dock, is present in the pile guide and extends through the cylindrical sector inserts. An attachment plate 412 is shown that can be attached to a dock, although other ways of attaching the pile guide to a dock may be used.

[0046] FIG. 12 is an exploded view of the embodiment of FIG. 11. The lower portion of cylindrical sector insert is referred to as the cylindrical sector 422,424, while the construct including the cylindrical sector and the flange 406, 408 is referred to as a cylindrical sector insert 404,404. The flanges and an upper exterior portion of the marine pile guide may have aligned receiving voids 418 for receiving attachment devices, such as screws or other fasteners, for connecting the cylindrical sector inserts to the marine pile guides.

[0047] FIG. 13 shows the cylindrical sector inserts 402,404 attached to the marine pile guide 410. The cylindrical sector inserts are spaced apart when mounted, as indicated by spaces 414,416.

[0048] In each embodiment, a cylindrical sector insert 402,404 attached to one side of the marine pile guide body 410 may extend further into the internal area of the marine pile guide body than inserts on another side of the internal area of the marine pile guide body. The installer may observe that a pile has an orientation that will bias the pile toward one side of the pile guide. To accommodate for this bias, an insert or inserts may extend further out from the body, such as by being thicker, and providing more thermoplastic material on one part of the internal area of the body to compensate for the experienced or anticipated increase in wear.

[0049] The cylindrical sector inserts 402,404 may, for example, include two to four cylindrical sector inserts. The cylindrical sector inserts are a replaceable component that is formed from a low friction material, such as a thermoplastic polymer, including ultra-high molecular weight polyethylene, or other low friction plastic materials. In one embodiment, the cylindrical sector insert can be shaped as a segment of a cylinder subtending an arc (e.g., between approximately 75° and 179°). The cylindrical sector insert can be produced by extrusion and / or machining processes to achieve a desired curvature and / or thickness. The cylindrical sector insert is positioned within the internal area of the body to provide a low-friction interface with a pile. In one implementation, the cylindrical sector inserts can be non-uniform in thickness when compared to another cylindrical insert to which it is matched to accommodate uneven wear patterns resulting from off-center and / or misaligned piles. The geometry of the cylindrical sector insert can allow for ease of installation and / or replacement, particularly in retrofit scenarios where the pile remains in place. Further, the cylindrical sector insert can be attached to the internal area of the body using removable fasteners and / or can be stabilized by barriers and / or clips to inhibit twisting and / or migration under load.

[0050] The outside diameter of the cylindrical sector inserts 402,404 is preferred to be matched to nest against the inside diameter of pile guide into which the cylindrical sector insert is fixed with as little space between the insert and the pile guide as practicable. Such fitment assists in retaining the cylindrical sector insert in place and resisting movement.

[0051] The cylindrical sector inserts need not be of uniform thickness, thereby allowing for uneven wear as a pile rubs against the cylindrical sector inserts, which occurs as a floating dock moves up and down. One cylindrical sector insert rather than two may be positioned in the pile guide if friction is significant on one portion of the pile guide.

[0052] Barriers or spacers 426 may be positioned on a top surface of the pile guide to separate and space the cylindrical sector inserts. FIG. 16 shows the construct of FIG. 11, with barriers 426 positioned to space the cylindrical sector inserts apart. The barriers may be formed as part of the pile guide, or by attaching barriers on top of the pile guide with fasteners, such as by fasteners inserted through voids 430. The barriers inhibit twisting and other movement of the cylindrical sector inserts when in use. The barriers help position the inserts as spaced apart from each other. FIG. 17 shows the construct of FIG. 12, but adds barriers between the cylindrical sector inserts. FIG. 18 shows the construct of FIG. 13, and adds barriers between the cylindrical sector inserts.

[0053] Optional clips may be used to further secure the cylindrical section inserts, as shown in FIGS. 6 and 7, and described above. FIG. 16 shows a sectioned view of the cylindrical section insert 422 attached to a marine pile guide. Clip 432 is attached to the pile guide 410, such as by a fastener. An optional recess accommodates the clip so that the clip is not exposed to movement relative to the pile guide. The insert could be attached by a fastener inserted through the insert 422 and the pile guide 410 to connect the structures, with or without the use of a clip.

[0054] In another embodiment, four spaced apart cylindrical sector inserts are used, with each cylindrical sector insert having ends ranging from 75 degrees to 88 degrees. Alternatively, a mix of one cylindrical sector insert that is 150-179 degrees with one or two cylindrical sector inserts that are 75 degrees to 88 degrees may be used. Clips may be positioned along the length of the cylindrical sector inserts to inhibit twisting and movement of the inserts.

Examples

Embodiment Construction

[0026]FIGS. 1, 2 and 3 show an exemplary embodiment of the pile guide of the invention. FIG. 1 shows a body 2 and inserts 4. Also shown is attachment plate 6 that allows the body to be attached to another object, such as a floating dock. The attachment plate may be of various forms depending upon the application of the pile guide. The attachment plate is preferred to be welded to the body.

[0027]The body 2 of the invention as shown in this embodiment is circular and annular. The body has an internal circumference 8 through which a pile traverses as the pile guide moves vertically in use. The body has a plurality of slots 10 formed in the top surface of the body for receiving the inserts. It is preferred that the body is formed as a continuous member having no gaps.

[0028]In this embodiment, the inserts 4 are formed as an inverted “L” shape. The shorter leg of the L meets the longer leg at 90° angle. The shorter leg is inserted into a slot 10 of the body 2 and fastened to the body. The...

Claims

1. Low friction inserts for marine pile guides, comprising:cylindrical sector inserts formed of thermoplastic polymer, wherein the cylindrical sector inserts are constructed and arranged for positioning within an internal area of a marine pile guide body and extending outwardly from the internal area of the marine pile guide body, the cylindrical sector inserts having an upper flange that extends from a cylindrical sector of the cylindrical sector inserts, wherein the upper flange is attached to an upper exterior of the marine pile guide body,the inserts having a radius of 75 degrees to 179 degrees, and wherein the inserts are spaced apart when attached to the internal area of the marine pile guide body.

2. Low friction inserts for marine pile guides as described in claim 1, further comprising a barrier that is positioned between a first cylindrical sector insert and a second cylindrical sector insert.

3. Low friction inserts for marine pile guides as described in claim 1, further comprising a first barrier that is positioned between a first end of a first cylindrical sector insert and a first end of a second cylindrical sector insert and a second barrier that is positioned between a second end of a first cylindrical sector insert and a second end of a second cylindrical sector insert, wherein the first barrier and the second barrier space the first cylindrical sector and the second cylindrical sector apart.

4. Low friction inserts for marine pile guides as described in claim 1, further comprising a barrier that extends upwardly from the upper exterior of the marine pile guide body and is positioned between a first cylindrical sector insert and a second cylindrical sector insert.

5. Low friction inserts for marine pile guides as described in claim 1, wherein a first cylindrical sector insert has a radius of 150 degrees to 179 degrees.

6. Low friction inserts for marine pile guides as described in claim 1, wherein a first cylindrical sector insert has a radius of 150 degrees to 179 degrees and a second cylindrical sector insert has a radius of 150 degrees to 179 degrees.

7. Low friction inserts for marine pile guides as described in claim 1, wherein the cylindrical sector inserts are formed of thermoplastic polymer having greater abrasion resistance than the material from which the marine pile guide body is formed.

8. Low friction inserts for marine pile guides as described in claim 1, wherein the cylindrical sector inserts are formed of ultra-high molecular weight (UHMW) polyethylene.

9. Low friction inserts for marine pile guides as described in claim 1, further comprising a first clip and a second clip attached to an internal area of the marine pile guide body, wherein the first clip is positioned over a first side of a lower portion of the cylindrical sector insert and the second clip is positioned over a second side of the lower portion of the cylindrical sector insert.

10. Low friction inserts for marine pile guides as described in claim 1, wherein the plurality of spaced apart inserts are formed of ultra-high molecular weight (UHMW) thermoplastic polymer and the body is formed of high density thermoplastic polymer.

11. Low friction inserts for marine pile guides as described in claim 1, wherein a first cylindrical sector has a radius of 75 degrees to 89 degrees.

12. Low friction inserts for marine pile guides as described in claim 1, wherein a first cylindrical sector insert has a cylindrical sector that is thicker than a cylindrical sector of a second cylindrical sector insert.

13. Low friction inserts for marine pile guides as described in claim 1, wherein the cylindrical sector inserts extend outwardly from the internal area of the marine pile guide body, and cover substantially an entire internal area of the marine pile guide body.

14. Low friction inserts for marine pile guides as described in claim 1, wherein the cylindrical sector inserts are formed of thermoplastic polymer having greater abrasion resistance and lower frictional properties than the material from thermoplastic polymer of which the marine pile guide body is formed.

15. Low friction inserts for marine pile guides as described in claim 1, further comprising a first clip and a second clip attached to an internal area of the marine pile guide body, wherein the first clip is positioned in a recess formed in a first side of a lower portion of the cylindrical sector insert and the second clip is positioned in a recess formed in a second side of the lower portion of the cylindrical sector insert.

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