U.S. patent application number 11/540258 was filed with the patent office on 2007-02-01 for rail and panel system for pontoon boat.
This patent application is currently assigned to Bennington Marine LLC. Invention is credited to Bradley R. Fishburn.
Application Number | 20070022938 11/540258 |
Document ID | / |
Family ID | 46326197 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070022938 |
Kind Code |
A1 |
Fishburn; Bradley R. |
February 1, 2007 |
Rail and panel system for pontoon boat
Abstract
The invention relates to boundaries used on a watercraft.
Specially, the invention relates to boundaries used on pontoon
boats. The boundaries generally include a rail and panel system
positioned around an outer periphery of the pontoon boat. The
invention also relates to a method of forming and installing the
boundaries on a watercraft.
Inventors: |
Fishburn; Bradley R.;
(Nappanee, IN) |
Correspondence
Address: |
BAKER & DANIELS LLP
300 NORTH MERIDIAN STREET
SUITE 2700
INDIANAPOLIS
IN
46204
US
|
Assignee: |
Bennington Marine LLC
|
Family ID: |
46326197 |
Appl. No.: |
11/540258 |
Filed: |
September 29, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11132483 |
May 19, 2005 |
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11540258 |
Sep 29, 2006 |
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11346835 |
Feb 3, 2006 |
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11540258 |
Sep 29, 2006 |
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Current U.S.
Class: |
114/364 |
Current CPC
Class: |
B63B 17/04 20130101 |
Class at
Publication: |
114/364 |
International
Class: |
B63B 17/00 20060101
B63B017/00 |
Claims
1. A watercraft comprising: a frame; at least one rail supported by
the frame, said rail including an extension movable from an open
receiving position to a locked position; and a non-metallic panel
supported by said rail and held in position by said extension.
2. The watercraft as set forth in claim 1, wherein said
non-metallic panel includes interlocking portions along the top and
bottom edges thereof.
3. The watercraft as set forth in claim 2, wherein said
interlocking portions of said panel are substantially perpendicular
to a main plane defined by said panel.
4. The watercraft as set forth in claim 3, including a top rail and
a bottom rail having extensions with interlocking portions
configured to mate with said interlocking portions on said
non-metallic panel.
5. The watercraft as set forth in claim 1, wherein said rail
includes a cross-section having at least two areas separated by a
stiffener.
6. The watercraft as set forth in claim 5, wherein one of the rail
areas is smaller than the other, and said extension is connected to
the smaller of the areas.
7. The watercraft as set forth in claim 1, including a top rail and
a bottom rail and at least one intermediate rail extending
therebetween, the intermediate rail having a width that is less
than the width of said top and bottom rails.
8. The watercraft as set forth in claim 7, further including at
least one rib located interstitial to said non-metallic panel and
said intermediate rail.
9. The watercraft as set forth in claim 8, wherein said rib is
attached to said non-metallic panel.
10. The watercraft as set forth in claim 9, wherein said rib
includes a pair of flanges and a raised portion.
11. The watercraft as set forth in claim 10, wherein said rib
includes flanges and a recessed area in each flange, and an
adhesive is located in said recessed areas to attach said rib to
said non-metallic panel.
12. The watercraft as set forth in claim 1, including a pair of
side rails, each having extensions, and trim members held in
position by said extensions.
13. The watercraft as set forth in claim 12, wherein said
extensions have interlocking portions, and said trim members have
interlocking portions configured to mate with said interlocking
portions on said extensions.
14. The watercraft as set forth in claim 13, wherein said trim
members are configured to include a receiving area, and side edges
of said non- metallic panel are positioned in respective receiving
areas of said trim members.
15. The watercraft as set forth in claim 14, wherein said side
edges of said non-metallic panel are loosely clamped in said
receiving area of said trim member when said extension of said
rails are in the locked position to accommodate thermal expansion
and contraction of said panel.
16. A boundary for a watercraft, the boundary comprising: at least
one rail including an extension movable from an open receiving
position to a locked position; and a panel including first and
second ends, said first end including an interlocking portion held
in position by said extension when said extension is in the locked
position.
17. The boundary for a watercraft as set forth in claim 16,
including a top rail and a bottom rail having extensions with
interlocking portions, and said second end also includes an
interlocking portion, said rail interlocking portions configured to
mate with said panel interlocking portions.
18. The boundary for a watercraft as set forth in claim 16, wherein
said rail includes a cross-section having at least two enclosed
areas, and one of said enclosed areas is smaller than the other,
and said extension is connected to the smaller of said enclosed
areas.
19. The boundary for a watercraft as set forth in claim 16,
including a top rail and a bottom rail and at least one
intermediate rail extending therebetween, and further including at
least one rib located interstitial to said panel and said
intermediate rail.
20. The boundary for a watercraft as set forth in claim 19, wherein
said rib includes recessed areas and adhesive tape is located in a
recessed area to attach said rib to said panel.
21. The boundary for a watercraft as set forth in claim 20, wherein
said panel is constructed of polycarbonate.
22. The boundary for a watercraft as set forth in claim 16,
including a pair of side rails with extensions and a pair of trim
members locked in position by respective extensions.
23. The boundary for a watercraft as set forth in claim 22, wherein
said extensions include interlocking portions, and said trim
members have interlocking portions configured to mate with said
interlocking portions on said extensions.
24. The boundary for a watercraft as set forth in claim 23, wherein
said trim members include a receiving area, and side edges of said
panel are loosely clamped in said receiving areas to accommodate
thermal movement of said panel.
25. A boundary for a watercraft, the boundary comprising: at least
one rail including an extension movable from an open receiving
position to a locked position; a non-metallic panel configured to
be attached to said rail; and cooperative interlocking members
associated with said panel and said rail, said interlocking members
configured to attach said panel to said rail.
26. The boundary for a watercraft as set forth in claim 25,
including a top rail and a bottom rail, each having one of said
interlocking members.
27. The boundary for a watercraft as set forth in claim 25, wherein
said panel is configured from a non-metallic material.
28. The boundary for a watercraft as set forth in claim 27, wherein
said rail includes a cross-section having at least two enclosed
areas.
29. The boundary for a watercraft as set forth in claim 28, wherein
one of said enclosed areas is smaller than the other, and said
extension is connected to the smaller of said enclosed areas.
30. The boundary for a watercraft as set forth in claim 26, further
including at least one intermediate rail, extending between said
top rail and said bottom rail, and at least one rib located
interstitial to said panel and said intermediate rail.
31. The boundary for a watercraft as set forth in claim 30, wherein
said rib includes flanges and recessed areas in each of said
flanges for receipt of an adhesive member.
32. The boundary for a watercraft as set forth in claim 25,
including a pair of side rails with extensions and a pair of trim
members, with one trim member held in position by each
extension.
33. The boundary for a watercraft as set forth in claim 32, further
including cooperative interlocking members associated with the
extensions on the side rails and the trim members, said
interlocking members configured to attach said trim members to said
rail.
34. The boundary for a watercraft as set forth in claim 33, wherein
said trim members include a receiving area, and side edges of said
panel are positioned in said receiving areas.
35. The boundary for a watercraft as set forth in claim 33, wherein
said panel is held in said receiving areas in a manner that
accommodates thermal movement of said panel.
Description
[0001] This Continuation-In-Part application claims the benefit of
U.S. patent application Ser. No. 11/132,483 filed May 19, 2005, and
Continuation-In-Part application Ser. No. 11/346,835 filed Feb. 3,
2006, the complete disclosures of which are hereby expressly
incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to boundaries used on a watercraft.
Specially, the invention relates to boundaries used on pontoon
boats.
BACKGROUND OF THE INVENTION
[0003] Watercraft such as pontoon boats generally include a
plurality of rails supported by the deck of watercraft. The rails
sometimes are positioned around the outer periphery of the deck to
prevent passengers from falling overboard and to provide support of
passengers. Typically, the rails cooperate with the deck or some
other area of the watercraft to enclose a panel. The rail and panel
may form a boundary around the outer periphery of the watercraft.
In general, the panels are constructed of a metal such as
aluminum.
BRIEF SUMMARY OF THE INVENTION
[0004] One embodiment of the invention includes a watercraft having
a frame; at least one rail supported by the frame, the rail
including an extension movable from an open receiving position to a
locked position; and a non-metallic panel supported by the rail and
held in position by the extension.
[0005] The non-metallic panel may include interlocking portions
along the top and bottom edges thereof. The interlocking portions
of the panel may be substantially perpendicular to a main plane
defined by the panel. A top rail and a bottom rail having
extensions may be provided with interlocking portions configured to
mate with the interlocking portions on the non-metallic panel.
[0006] The rail may include a cross-section having at least two
areas separated by a stiffener. One of the rail areas may be
smaller than the other, and the extension can be connected to the
smaller of the enclosed areas.
[0007] Another embodiment of the invention includes a watercraft
having a top rail and a bottom rail and at least one intermediate
rail extending therebetween. The intermediate rail may have a width
that is less than the width of the top and bottom rails, and the
watercraft may further include at least one rib located
interstitial to a non-metallic panel and the intermediate rail. The
rib can be attached to the non-metallic panel, and the rib may
include a pair of flanges and a raised portion. The rib may include
flanges with recessed areas, and an adhesive may be located in the
recessed areas to attach the rib to the non-metallic panel.
[0008] The watercraft may include a pair of side rails, each having
extensions, and trim members held in position by the extensions.
The extensions may have interlocking portions, and the trim members
may have interlocking portions configured to mate with the
interlocking portions on the extensions. The trim members may be
configured to include a receiving area, and side edges of the panel
can be positioned in respective receiving areas of the trim
members. The side edges of the panel can be loosely clamped in the
receiving area of the trim member when the extension of the rails
is in the locked position to accommodate thermal expansion and
contraction of the panel.
[0009] In another embodiment of the invention, a boundary for a
watercraft is provided, wherein the boundary includes at least one
rail having an extension movable from an open receiving position to
a locked position, and a panel including first and second ends, the
first end including an interlocking portion. The panel is held in
position by the extension when the extension is in the locked
position.
[0010] The boundary may include a top rail and a bottom rail having
extensions with interlocking portions, and the second end also
includes an interlocking portion, wherein the rail interlocking
portions are configured to mate with the panel interlocking
portions.
[0011] The rail may include a cross-section having at least two
enclosed areas, and one of the enclosed areas may be smaller than
the other, with the extension connected to the smaller of the
enclosed areas.
[0012] The boundary may include a top rail, a bottom rail, and at
least one intermediate rail extending therebetween, and may further
include at least one rib located interstitial to the panel and the
intermediate rail. The rib may include recessed areas and adhesive
tape located in the recessed areas to attach the rib to the
panel.
[0013] The panel may be constructed of polycarbonate. The boundary
may further include a pair of side rails with extensions and a pair
of trim members locked in position by respective extensions. The
extensions can include interlocking portions, and the trim members
can have interlocking portions configured to mate with the
interlocking portions on the extensions. The trim members can
include a receiving area, and side edges of the panel may be
loosely clamped in the receiving areas to accommodate thermal
changes in the length of the panel.
[0014] Another embodiment of the invention includes a boundary for
a watercraft that includes at least one rail including an extension
movable from an open receiving position to a locked position; a
non-metallic panel configured to be attached to the rail; and
cooperative interlocking members associated with the panel and the
rail, the interlocking members configured to attach the panel to
the rail.
[0015] The boundary for a watercraft may include a top rail and a
bottom rail, both having interlocking members. The panel can be
configured from a non-metallic material. The rail may include a
cross-section having at least two enclosed areas. One of the
enclosed areas may be smaller than the other, and the extension can
be connected to the smaller of the enclosed areas. The boundary for
a watercraft may further include an intermediate rail extending
between the top rail and the bottom rail, and at least one rib
located interstitial to the panel and the intermediate rail. The
rib may include flanges and recessed areas in each flange for
receipt of an adhesive member.
[0016] The boundary for a watercraft may also include a pair of
side rails with extensions and a pair of trim members, with one
trim member held in position by respective extensions.
[0017] The boundary may further include cooperative interlocking
members associated with the extensions on the side rails and the
trim members that are configured to attach the trim members to the
rail. The trim members may include a receiving area, and side edges
of the panel can be positioned in the receiving areas. The panel
may be held in the receiving areas in a manner that accommodates
thermal changes in the length thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above-mentioned and other features and objects of this
invention, and the manner of attaining them, will become more
apparent and the invention itself will be better understood by
reference to the following description of embodiments of the
invention taken in conjunction with the accompanying drawings,
wherein:
[0019] FIG. 1 is an elevated perspective view of a pontoon
boat;
[0020] FIG. 2 is a cross-sectional view of one prior art embodiment
of a rail used on a watercraft, such as the pontoon boat shown in
FIG. 1, the rail is shown in its preassembled configuration;
[0021] FIG. 3 is a partial cross-sectional assembly view of one
embodiment of a rail and panel system through lines 3-3 of FIG. 1,
and as shown, is configured to be used on a watercraft, such as the
pontoon boat shown in FIG. 1, the rails are shown in their
preassembled configuration;
[0022] FIG. 4 is a partial cross-sectional assembly view of the
rail and panel system shown in FIG. 3, with the rails shown in
their assembled configuration;
[0023] FIG. 5 is a partial cross-sectional assembly view of another
embodiment of a rail and panel system configured to be used on a
watercraft, such as the pontoon boat shown in FIG. 1, with the
rails shown in their preassembled configuration;
[0024] FIG. 6 is a partial cross-sectional assembly view of the
rail and panel system shown in FIG. 5, with the rails shown in
their assembled configuration;
[0025] FIG. 7 is a partial cross-sectional assembly view of another
embodiment of a rail and panel system using the rail shown in FIG.
2, the system is configured to be used on a watercraft, such as the
pontoon boat shown in FIG. 1, the rails are shown in their
assembled configuration;
[0026] FIG. 8 shows a diagrammatical view showing a method of
manufacturing the panel and rail system described;
[0027] FIG. 9 is a partial cross-sectional assembly view of another
embodiment of a rail and panel system configured to be used on a
watercraft, such as a pontoon boat, as shown in FIG. 1, the rails
are shown in their preassembled configuration;
[0028] FIG. 10 is a partial cross-sectional assembly view of the
rail and panel system shown in FIG. 9, with the rails shown in
their assembled configuration;
[0029] FIG. 11 is a perspective view of another embodiment of a
rail and panel system in accordance with the present invention;
[0030] FIG. 12 is a partial cross-sectional assembly view of the
rail and panel system through lines 12-12 of FIG. 11, and as shown,
is configured to be used on the watercraft, such as the pontoon
boat, shown in FIG. 1, the rails being shown in their preassembled
configuration;
[0031] FIG. 12A is an enlarged view of the top rail area indicated
in FIG. 12;
[0032] FIG. 12B is an enlarged view of the bottom rail area
indicated in FIG. 12;
[0033] FIG. 13 is a partial cross-sectional assembly view of the
rail and panel system shown in FIG. 12, with the rails shown in
their assembled configuration;
[0034] FIG. 14 is a partial cross-sectional assembly view of the
rail and panel system through lines 14-14 of FIG. 11, with the
rails shown in their assembled configuration;
[0035] FIG. 14A is an enlarged view of the rib area indicated in
FIG. 14;
[0036] FIG. 15 is a partial cross-sectional assembly view of the
rail and panel system through lines 15-15 of FIG. 11, showing side
trim members and side rails in their preassembled
configuration;
[0037] FIG. 15A is an enlarged view of the side rail area and trim
member indicated in FIG. 15;
[0038] FIG. 16 is a partial cross-sectional assembly view of the
rail and panel system shown in FIG. 15, with the side rails and
trim members shown in their assembled configuration;
[0039] FIG. 16A is an enlarged view of the side rail area and trim
member indicated in FIG. 16;
[0040] FIG. 17 is an end view of the rails for use with the rail
and panel system of FIG. 11 shown in the preassembled
configuration;
[0041] FIG. 18 is an end view of an intermediate rail of the rail
and panel system shown in FIG. 11;
[0042] FIG. 19 is an end view of the rib used with the rail and
panel system shown in FIG. 11; and
[0043] FIG. 20 is an end view of the side trim members used with
the rail and panel system shown in FIG. 11.
[0044] Corresponding reference characters indicate corresponding
parts throughout the several views. Although the drawings represent
embodiments of the present invention, the drawings are not
necessarily to scale and certain features may be exaggerated in
order to better illustrate and explain the present invention. The
exemplifications set out herein illustrate embodiments of the
invention in several forms and such exemplification is not to be
construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The embodiments discussed below are not intended to be
exhaustive or limit the invention to the precise forms disclosed in
the following detailed description. Rather, the embodiments are
chosen and described so that others skilled in the art may utilize
their teachings.
[0046] A watercraft, generally indicated as 10, is shown in FIG. 1,
and in this embodiment, watercraft 10 is a pontoon boat. Watercraft
10 includes a frame, generally indicated as 12, an engine,
generally indicated as 14, pontoons 16, and deck 18. Watercraft 10
also includes a plurality of rails 20 and panels 22 supported by
frame 12 and deck 18. Rails 20 are positioned above and below
panels 22 to form a boundary around an outer periphery of deck 18
to safely surround passengers on watercraft 10.
[0047] A cross-sectional view of a prior art embodiment of one
rail, generally indicated as 19, is shown in FIG. 2. Rails 19 are
used similarly to rails 20 as shown in FIG. 1 to secure panels 22
to the watercraft to form an outer boundary of the watercraft. Each
rail 19 is constructed of an extruded metallic tube and includes a
rail member 17 having a substantially square profile. Rail 19 also
includes an extension 15 coupled to one side of rail member 19.
This configuration of rail 19 is commonly called a "Q tube."
Extension 15 includes a pair of teeth 21. A receiving area,
generally indicated as 23, is formed between extension 15 and rail
member 17. In FIG. 2, rail 19 is shown in the unassembled
orientation. In use, a panel, such as panel 22 in FIG. 1, is
positioned in receiving area 23, and extension 15 is bent or
crimped toward rail member 17 to secure the panel in receiving area
23 in position. Teeth 21 engage the panel when extension 15 is
crimped.
[0048] A partial cross-sectional view of an embodiment of upper and
lower rails 20 in accordance with the present invention with one
panel 22 positioned between is shown in FIGS. 3 and 4. Upper and
lower rails 20 are identical with respect to form and function and
differ only in orientation. Panel 22 is shown in partial for
simplicity, and it should be understood that opposite ends are also
substantially identical and only differ in orientation.
[0049] As shown in FIG. 3, each rail 20 includes a rail member 24,
an extension 26, and a recess or recessed area 30. In this
embodiment, rail 20 is an extruded aluminum tube. In other
embodiments (not shown), rail 20 may be constructed of another
metallic material, a non-metallic material, or any other suitable
material. Rail member 24 has a substantially square profile and a
hollow central region. Rail member 24 includes a side, generally
indicated as 25, from which an extension 26 extends. Side 25 and
extension 26 form a receiving area, generally indicated as 29, for
receiving an end of panel 22, as will be described herein.
Extension 26 extends from side 25 of rail member 24 and includes an
interlocking or engaging portion 28, which is shown as a tab,
positioned at one end of extension 26. A recessed area or recess 30
is formed in side 25 of rail member 24. As shown in FIG. 3, in this
embodiment, recessed area 30 extends about half of the length of
side 25.
[0050] Panel 22 includes a panel member 32, which is continuous
between an upper end 31 and a lower end 33. Upper and lower ends 31
and 33 each include an interlocking or engaging portion 34, which
is shown as a tab that extends substantially perpendicularly from
panel member 32. In this embodiment, panel 22 is constructed of
polycarbonate. Polycarbonate is dent- and scratch-resistant and has
excellent thermal expansion, toughness, and forming capabilities.
Additionally, polycarbonate has heat deflection properties and can
be produced in a wide variety of colors, which may reduce the need
for further processing such as painting. Supplemental components,
such as ultraviolet blockers and stabilizers, may be added to
polycarbonate to optimize the polycarbonate for the desired
application. It should be understood that panel member 22 may be
constructed from a polymer-based material, a non-metallic material,
or any other suitable material.
[0051] It should be appreciated that FIG. 3 shows a preassembled
position, where panel 22 is shown poised for interconnection to
rails 20. In this position, upper end 31 and lower end 33 of panel
member 32 are positioned in corresponding recessed areas 30, with
respective interlocking portions 34 extending in an overlapping
manner with interlocking portions 28 of extensions 26.
[0052] Referring now to FIG. 4, rails 20 are shown with extensions
26 bent or crimped to secure panel 22 in position between upper and
lower rails 20. When extensions 26 are crimped, interlocking
portions 28 interlock with respective interlocking portions 34 to
secure panel member 32 in recessed areas 30. As shown in FIG. 1,
rails 20 and panels 22 extend along the length of watercraft 10.
Assembly of the boundary formed by rails 20 and panels 22 generally
includes the steps of positioning a panel 22 between upper and
lower rail 20, as shown in FIG. 3, and providing a roller or other
crimping device (see FIG. 8) configured to bend extensions 26 from
the position shown in FIG. 3 into a position to secure panel 22, as
shown in FIG. 4.
[0053] With reference now to FIGS. 5 and 6, another embodiment will
be described. In this embodiment, upper and lower rails, generally
indicated as 40, are provided and positioned to cooperate with a
panel, generally indicated as 52. Upper and lower rails 40 each
include a rail member 42, an extension 44, a recess or recessed
area 48, and a receiving area, generally indicated as 50. In this
embodiment, recess 48 defines a notch. Panel 52 includes a panel
member 54 and interlocking portions 56, which are shown as tabs.
Panel 52 is substantially similar to panel 22 with the exception
that the orientation of the interlocking portions is reversed
relative to the rails 40, that is, interlocking portions 56 are
facing towards rails 40 rather than away from rails 40. Rails 40
are similar to rails 20 with the exceptions that extensions 44 do
not include interlocking portions and recesses 48 are configured to
accept interlocking portions 56 of panel 52.
[0054] As shown in assembled view FIG. 6, extensions 44 are bent or
crimped, as described above, toward rail members 42 to contact
panel member 54 and secure interlocking portions 56 in recesses 48.
Interlocking portions 56 interlock with rail members 42 in recesses
48. Extensions 44, interlocking portions 56, and recesses 48
prevent panel 52 from becoming dislodged if a force is applied to
flex panel member 54.
[0055] Another alternative embodiment of the rail and panel system
is shown in FIG. 7. This rail and panel system utilizes rails 19 of
FIG. 2 and a non-metallic panel, generally indicated as 70. Rails
19 and panel 70 are shown in an assembled partial cross-sectional
view in FIG. 7. As discussed above, rail 19 includes an extension
15 having teeth 21. Non-metallic panel 70 is substantially flat and
includes ends 72, which are configured to be positioned in
receiving areas 23 (not shown) of rails 19 during assembly.
Extensions 15 are then crimped, which is described below, to secure
panel 70 in position. Teeth 21 on extensions 15 contact ends 72 of
panel 70 to secure panel 70 between rails 19. In this position,
non-metallic panel 70 directly contacts rail members 17 and
extensions 15.
[0056] With reference now to FIG. 8, a method of installing the
rail and panel system will be described. The method is shown with
the rail and panel system of FIGS. 3 and 4, but the method is
equally applicable to the embodiments of FIGS. 5, 6 and 7.
[0057] With respect to the manufacturing of the rails themselves,
the rails may be extruded from a material such as aluminum. The
cross-section of rails 20 or 40 is conducive to an extrusion
process, as all of the configuration is continuous along its entire
length. That is, for instance, in the embodiment shown, rail 20 is
designed such that all of the features, including rail member 24,
extension 26, interlocking portion 28, and recess 30, are
continuous along the entire length of the rail, which may make an
extrusion process a suitable means for producing rails 20 or
40.
[0058] Once the rails are provided, the panel is provided. In one
embodiment, panels 22, 52 may be formed by a molding or extrusion
process. The configuration of panels 22, 52 is also compatible for
either process. In either case, the panels are formed to include
the interlocking portions 34 at the upper and lower ends 31, 33 of
panel 22. It should be appreciated that the panels are formed such
that the interlocking portions are spaced apart at the proper
distance between extensions 26.
[0059] Once two rails are positioned as shown in FIG. 3, the panel
22 can be slidably received longitudinally into the receiving areas
29, until the panel 22 is fully installed. At that point, a
crimping roller, such as 60 (FIG. 8), which is rotatable about axis
A-A, can be used to crimp extensions 26 into place. For example,
roller 60 can begin at one end of rail 20 and move longitudinally
along the length of rail 20 to roll the extensions from the
preassembled position of 26-1, shown in outline form, to the
assembled position of 26-2, where interlocking portions 28 overlap
and interlock with interlocking portions 34.
[0060] Now referring to FIGS. 9 and 10, another alternate
embodiment of a rail and panel system is shown. The rail and panel
system utilizes upper and lower rails, generally indicated as 80,
respectively. Rails 80 may be an extruded aluminum tube or may be
constructed using another process or another metallic material,
non-metallic material or any other suitable material. Rail member
84 has a substantially square profile and a hollow central region.
Each rail member 84 also includes a side, generally indicated as
85, from which an extension 86 extends. Side 85 and extension 86
form a receiving area, generally indicated as 89 (FIG. 9), for
receiving an end of a panel, generally indicated as 100, as will be
described herein. Extension 86 extends from side 85 of rail member
84 and includes an interlocking or engaging portion 88, which is
shown as a tab or a lip, positioned at one end of extension 86. In
this embodiment, a recessed area or recess 90 is formed in side 85
of rail member 84. In this embodiment, recessed area 90 extends
about one-half of the length of side 85.
[0061] Panel 100 includes a panel member 102, which is continuous
between an upper end 101 and a lower end 103. Upper and lower ends
101 and 103 each include an interlocking or engaging portion 104,
which is shown as a tab or a lip that faces away from rail members
84. In the embodiment shown, interlocking portions 104 form an
acute angle with a face of panel member 102. Panel member 102 may
be constructed of a polycarbonate or may be constructed from
another polymer-based material, a non-metallic material, a metallic
material, or other suitable material.
[0062] FIG. 9 shows a preassembled position, where panel 100 is
shown poised for interconnection to rails 80. In this position,
upper end 101 and lower end 103 of panel member 102 are positioned
in corresponding recessed areas 90, with respective interlocking
portions 104 extending in an overlapping manner, with interlocking
portions 88 of extensions 86.
[0063] Referring to FIG. 10 again, rails 80 are shown with
extensions 86 bent or crimped, such as with a crimping roller 60
shown in FIG. 8, to secure panel 100 and positioned between upper
and lower rails 80. When extensions 86 are crimped, interlocking
portions 88 interlock with respective interlocking portions 104 to
secure panel member 102.
[0064] Now referring to FIG. 11, another alternate embodiment of a
rail and panel system in accordance with the present invention is
shown, generally indicated as 110. Rail and panel system 110
includes an upper or top rail 120a and a lower or bottom rail 120b.
Upper and lower rails 120a and 120b are identical with respect to
form and function and differ only in orientation. Rail and panel
system 110 also includes a panel 122, side or end rails 124a and
124b, intermediate rails 126, an auxiliary rail portion 128 (which
is known), and a support rib 130.
[0065] Referring to FIGS. 12-13 and 17, upper rail 120a and lower
rail 120b, are shown in detail in a preassembled configuration
(FIGS. 12, 12A, 12B, and 17) and as assembled (FIG. 13) with
respect to panel 122. Rails 120a and 120b each have a cross-section
with a larger enclosed area 132 and a smaller enclosed area 134.
Areas 132 and 134 are separated by a stiffener 136. Stiffener 136
may completely separate areas 132 and 134 as shown or just
partially separate the areas. An extension 138 is attached to and
extends from a corner of each area 134. Also, an interlocking
portion 140 is located on the end of each extension 138. In the
embodiment shown, interlocking portion 140 extends generally
perpendicular to extension 138; however, it should be realized that
other suitable interlocking configurations may be employed. As with
the other rail embodiments, rails 120a and 120b may be extruded
from aluminum or any other suitable material.
[0066] In addition, as shown in FIGS. 12 and 13, panel 122 includes
an interlocking portion 142 along the upper and lower edges
thereof, that is configured to mate and interlock with respective
interlocking portions 140 of rails 120a and 120b. It should be
appreciated that the panel may be constructed of a polycarbonate or
other non-metallic material, as discussed above with respect to the
previous embodiments. The side edges of panel 122 are generally
planar and do not include any interlocking portions where the panel
is attached to side rails 124a and 124b (FIGS. 15 and 16) for
reasons discussed below.
[0067] Referring to FIGS. 15-16A, and 17, it can be seen that side
rails 124a and 124b have the same configuration as upper and lower
rails 120a, 120b, and each includes an enclosed area 132 and 134
separated by stiffener 136. Side rails 124a and 124b also include
extension 138 with interlocking portion 140 at the end thereof.
Accordingly, side rails 124a and 124b are identical to one another
and to upper and lower rails 120a and 120b and differ only in
orientation.
[0068] Referring now to FIG. 18, intermediate rails 126 have a
generally rectangular cross-section, and in the embodiment shown,
do not include any extensions, interlocking portions or areas
separated by a stiffener. Intermediate rails 126 may also be
extruded from aluminum or any other suitable material. As shown in
FIG. 14, the width of intermediate rails 126 may be less than the
width of rails 120a, 120b, 124a, and 124b.
[0069] Now referring to FIG. 19, it can be seen that rib 130
includes a raised portion 150 and a pair of laterally extending
flanges 152a and 152b. Rib 130 may also be extruded from an
aluminum or other suitable material. A recess 154 is located in
each flange for receipt of an adhesive member 156, which may
include a double-sided adhesive tape or adhesive strip.
[0070] Rail and panel system 110 also includes trim members,
generally indicated as 160, as shown in FIGS. 15-16 and 20. Trim
members 160 extend for the length of side rails 124a and 124b and
may be made from a polycarbonate or other material that will not
scratch panel 122. Each trim member 160 has a generally V-shaped
configuration and includes a first leg 162 and a second leg 164
(FIG. 20). Leg 164 includes an interlocking slot 166 extending
along the length thereof and an inwardly bent lip 168 extending
along the far end of the leg. Trim member 160 also includes a
receiving area, generally indicated as 170, between legs 162 and
164 for receiving the side edges of panel 122.
[0071] To assemble rail and panel system 110, the side rails 124a
and 124b are welded or otherwise attached in a known manner to
respective top and bottom rails 120a and 120b. Intermediate rails
126 are also welded or otherwise attached in a known manner at the
top and bottom thereof to respective top and bottom rails 120a,
120b. Auxiliary rail portion 128 may also be welded or otherwise
attached to top rail 120a or side rails 124a, 124b to complete a
rail frame.
[0072] Panel 122 may be attached to upper rail 120a and lower rail
120b in a manner similar to the previously discussed embodiments.
As shown in FIGS. 12 and 13, extensions 138 are bent or crimped
towards the respective rail so that the respective interlocking
portions 140 extend in an overlapping manner with interlocking
portions 142 at the top and bottom of panel 122, as shown in FIG.
13, to secure panel 122 to rails 120a and 120b.
[0073] Then, panel 122 can be attached to respective side rails
124a, 124b using rail extensions 138 and trim members 160. As noted
above, the side edges of panel 122 are planar and do not include an
interlocking portion. Rather, extensions 138 are bent or crimped
towards the side rails so that interlocking portions 140 are
engaged in the interlocking slot 166 of the respective trim member,
as shown in FIGS. 16 and 16A. It should be appreciated as seen in
FIGS. 15 and 16 that trim members 160 are compressed when
extensions 138 are bent or crimped so that leg 164 is forced closer
to leg 162. Accordingly, the panel side edges are not interlocked
but are loosely clamped within the receiving area 170 of trim
members 160. As such, the side edges of panel 122 can move or slide
within the trim members to accommodate thermal expansion and
contraction of the panels. This prevents the panel from bulging or
buckling due to any difference in thermal expansion between panel
122 and the rails. As noted above, the trim members may be made out
of a polycarbonate or other material that will not scratch panel
122 during thermal movement. Also, it should be appreciated that
the length of the panel is sufficient that the side edges will not
slip out of the trim members regardless of the temperatures and
thermal movement to which it is subjected.
[0074] Since intermediate rails 126 are not as wide as the outer
rails, as noted above, it should be appreciated that this will
create a space between the intermediate rails and panel 122 as
shown in FIG. 14. To fill the space and buttress the panel, rib 130
is placed interstitially between the intermediate rails and panel
122. A double-sided adhesive tape or other adhesive is placed in
recesses 154 of flanges 152a, 152b so that the rib will adhere to
panel 122, as shown in FIG. 14. The raised portion 150 of rib 130
is sized such that when the rib is attached to the panel, the
raised portion abuts intermediate rails 126.
[0075] When rail and panel system 110 is thusly assembled, it can
be welded or attached with fasteners to deck 18. The assembly will
have an attractive and finished appearance, and the panel 122 will
be firmly supported between the rails and stiffened by rib 130. In
addition, as the side edges of the rails can thermally expand and
contract within trim members 160, panel 122 should not buckle or
bulge due to temperature changes.
[0076] While this invention has been described as having an
exemplary design, the present invention may be further modified
within the spirit and scope of this disclosure. This application is
therefore intended to cover any variations, uses, or adaptations of
the invention using its general principles. For example, most of
the embodiments depicted can be manufactured without a recessed
area on the rail adjacent the extension. In addition, the shape,
size and orientation of the interlocking portion or tabs on the
extension and panel can be modified to other suitable forms.
[0077] It should also be appreciated that the trim members may be
held in the top and bottom rails, and the interlocking portions may
be on the side rail and sides of the panel. Also, the extension may
be attached to the larger area of the rail cross-section, and the
stiffener may only partially close off the areas from one another.
This application is intended to cover such departures from the
present disclosure as come within known or customary practice in
the art to which this invention pertains.
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