U.S. patent application number 15/491082 was filed with the patent office on 2018-08-02 for recreational watercraft and method of assembly.
This patent application is currently assigned to Bote, LLC. The applicant listed for this patent is Bote, LLC. Invention is credited to Corey Cooper.
Application Number | 20180215447 15/491082 |
Document ID | / |
Family ID | 62949203 |
Filed Date | 2018-08-02 |
United States Patent
Application |
20180215447 |
Kind Code |
A1 |
Cooper; Corey |
August 2, 2018 |
RECREATIONAL WATERCRAFT AND METHOD OF ASSEMBLY
Abstract
In at least some embodiments, the invention is directed to a
watercraft that includes a buoyant core, an upper shell bonded to
the core and a lower shell bonded to the core, wherein at least one
of the upper shell and the lower shell includes a plurality of
bonded shell material layers, and wherein the plurality of shell
material layers include a polycarbonate-based material layer and an
acrylonitrile butadiene styrene-based material layer.
Inventors: |
Cooper; Corey; (Destin,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bote, LLC |
Fort Walton Beach |
FL |
US |
|
|
Assignee: |
Bote, LLC
Fort Walton Beach
FL
|
Family ID: |
62949203 |
Appl. No.: |
15/491082 |
Filed: |
April 19, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62452782 |
Jan 31, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/12 20130101;
B29L 2031/5272 20130101; B32B 7/12 20130101; B29C 51/266 20130101;
B32B 27/302 20130101; B32B 27/32 20130101; B29K 2069/00 20130101;
B32B 27/065 20130101; B32B 5/245 20130101; B29K 2669/00 20130101;
B32B 27/08 20130101; B32B 5/18 20130101; B29K 2655/02 20130101;
B32B 2262/101 20130101; B32B 2307/50 20130101; B32B 27/38 20130101;
B32B 2605/00 20130101; B29C 2791/001 20130101; B29L 2031/307
20130101; B32B 2266/0228 20130101; B32B 2355/02 20130101; B32B
27/365 20130101; B63B 32/00 20200201; B63B 5/24 20130101; B29C
51/08 20130101; B63B 32/57 20200201; B32B 2266/0278 20130101 |
International
Class: |
B63B 35/79 20060101
B63B035/79; B32B 7/12 20060101 B32B007/12; B32B 27/36 20060101
B32B027/36; B32B 27/08 20060101 B32B027/08; B29C 51/08 20060101
B29C051/08; B29C 51/26 20060101 B29C051/26; B29C 65/48 20060101
B29C065/48; B29C 63/04 20060101 B29C063/04 |
Claims
1. A watercraft comprising: a buoyant core having a core top, a
core bottom, and a core rail portion; an upper shell having an
upper rail portion edge, the upper shell bonded to the core top; a
lower shell having a lower rail portion edge, the lower shell
bonded to the core bottom; and a joint material between the upper
rail portion edge and lower rail portion edge; wherein the upper
rail portion edge does not overlap and is not bonded to the lower
rail portion edge; wherein at least one of the upper shell and the
lower shell includes a plurality of bonded shell material layers;
and wherein the plurality of shell material layers include a
polycarbonate-based material layer and an acrylonitrile butadiene
styrene-based material layer.
2. The watercraft of claim 1, wherein the acrylonitrile butadiene
styrene-based material layer is situated between the
polycarbonate-based material layer and the core.
3. The watercraft of claim 2, wherein a graphic is bonded between
the polycarbonate-based material layer and the acrylonitrile
butadiene styrene-based material layer.
4. The watercraft of claim 1, wherein the upper shell includes a
shell top surface integrally formed with an upper rail portion that
includes the upper rail portion edge, and the lower shell includes
a shell bottom surface integrally formed with a lower rail portion
that includes the lower rail portion edge.
5. The watercraft of claim 4, wherein the upper shell and lower
shell are bonded to the core to provide a spaced relation between
the upper rail portion edge and the lower rail portion edge as they
extend proximate the core rail portion.
6. The watercraft of claim 5, wherein the joint material is bonded
between the upper rail portion edge and the lower rail portion edge
to provide a flush relation between the upper and lower rail
portions and the joint material.
7. The watercraft of claim 6, wherein a first augmentation
substrate is positioned between the core rail portion and the upper
rail portion and lower rail portion.
8. The watercraft of claim 6, wherein a first augmentation
substrate is positioned over, and in contact with, the joint
material and the upper and lower rail portions, and not in contact
with the core rail portion.
9. The watercraft of claim 6, further including: a first
augmentation substrate positioned between the core rail portion and
the upper and lower rail portions; and a second augmentation
substrate positioned over the upper and lower rail portions
opposite the first augmentation substrate.
10. The watercraft of claim 4, wherein an offset end having an
offset end mating surface extends from a lower rail edge of the
lower rail portion, and wherein an upper shell mating surface of
the upper rail portion is secured to the offset end mating
surface.
11. The watercraft of claim 10, wherein the upper rail portion is
flush with the lower rail portion on either side of a gap formed
between the upper rail portion edge and the lower rail edge, and
the gap is filled with joint material to provide a continuous
surface between the upper rail portion and the lower rail
portion.
12. A watercraft having a rail, the watercraft comprising: a
buoyant core having a core top; a first substrate having an upper
rail portion edge, the first substrate attached to the core top;
and a second substrate having a lower rail portion edge, the second
substrate attached to the core bottom; wherein at least one of the
first substrate and second substrate includes a plurality of bonded
material layers; wherein the upper rail portion edge is spaced
apart from the lower rail portion edge and forms a seam; and
wherein an outer layer secured to the first substrate and second
substrate over the upper rail portion edge and the lower rail edge
such that there is no external seam on the rail of the
watercraft.
13. The watercraft of claim 12, wherein the plurality of bonded
material layers include a polycarbonate-based material layer and an
acrylonitrile butadiene styrene-based material layer.
14. The watercraft of claim 12, wherein each of the first substrate
and second substrate include a polycarbonate-based material layer
bonded to an acrylonitrile butadiene styrene-based material
layer.
15. The watercraft of claim 13, wherein the acrylonitrile butadiene
styrene-based material layer is bonded between the
polycarbonate-based material layer and a top of the core, and the
polycarbonate-based material layer is bonded over the acrylonitrile
butadiene styrene-based material layer and opposite the top of the
core.
16. The watercraft of claim 13, wherein a graphic is bonded between
the polycarbonate-based material layer and the acrylonitrile
butadiene styrene-based material layer.
17. A method of assembling a watercraft comprising: forming a core
comprised of buoyant material; positioning a first composite
substrate over an upper shell mold; thermo-forming an upper shell
with the first composite substrate using the upper shell mold;
trimming excess first composite substrate from the upper shell;
positioning a second composite substrate over a lower shell mold;
thermo-forming a lower shell with the second composite substrate
using the lower shell mold; trimming excess second composite
substrate from the lower shell; bonding the upper shell to the
core; bonding the lower shell to the core opposite the upper shell,
wherein the upper shell is in spaced relation to the lower shell
along a perimeter of the shells; applying a joint material between
the upper shell and lower shell along a perimeter of the shells and
finishing to provide a flush surface between the upper and lower
shells; bonding a first augmentation substrate over the joint
material and adjacent portions of the upper and lower shells along
a perimeter of the shells; and wrapping the upper and lower shells
with one or more fiberglass layers and finishing smooth.
18. The method of claim 17, wherein the first composite substrate
comprises a polycarbonate-based material and an acrylonitrile
butadiene styrene-based material bonded together.
19. The method of claim 18, wherein a graphic is situated between
the polycarbonate-based material and acrylonitrile butadiene
styrene-based material prior to thermo-forming.
20. The method of claim 18, wherein a second augmentation substrate
is bonded to the core prior to the bonding of the upper and lower
shells to the core, and wherein the second augmentation substrate
extends along the upper and lower shells, opposite the first
augmentation substrate.
21. A watercraft comprising: a buoyant core having a core top, a
core bottom, and a core rail portion; an upper shell having an
upper rail portion, the upper shell bonded to the core top; a lower
shell having a lower rail portion, the lower shell bonded to the
core bottom, wherein at least one of the upper shell and the lower
shell includes a plurality of bonded shell material layers; a joint
material between the upper shell and the lower shell; and a first
augmentation substrate positioned over, and in contact with, the
joint material and the upper rail portion and lower rail portion,
and not in contact with the core rail portion; wherein the
plurality of shell material layers include a polycarbonate-based
material layer and an acrylonitrile butadiene styrene-based
material layer.
22. The watercraft of claim 21, wherein the acrylonitrile butadiene
styrene-based material layer is situated between the
polycarbonate-based material layer and the core.
23. The watercraft of claim 22, wherein a graphic is bonded between
the polycarbonate-based material layer and the acrylonitrile
butadiene styrene-based material layer.
24. The watercraft of claim 21, wherein the upper shell includes a
shell top surface integrally formed with the upper rail portion
that includes an upper rail portion edge, and the lower shell
includes a shell bottom surface integrally formed with the lower
rail portion that includes a lower rail portion edge.
25. The watercraft of claim 24, wherein the upper shell and lower
shell are bonded to the core to provide a spaced relation between
the upper rail portion edge and the lower rail portion edge as they
extend proximate the core rail portion.
26. The watercraft of claim 25, wherein the joint material is
bonded between the upper rail portion edge and the lower rail
portion edge to provide a flush relation between the upper and
lower rail portions and the joint material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/452,782 filed on Feb. 31, 2017, the disclosure
of which is incorporated herein by reference in its entirety for
all purposes.
FIELD OF THE INVENTION
[0002] The invention relates generally to the field of watercrafts,
and more particularly to recreational watercrafts.
BACKGROUND
[0003] Various types of watercrafts are commonly used to traverse
water. Some such watercrafts include recreational watercrafts, such
as paddleboards, surfboards, canoes, kayaks, wake boards,
sailboats, etc. Recreational watercrafts are often comprised of a
foam base that is covered with epoxy resin and fiberglass, sanded
smooth and painted. A graphic and/or paint can be applied and
sealed using a clear coat. Such a configuration typically suffers
from a lack of durability and rigidity, among other things.
[0004] Additionally, it is often desired to secure ornate or
descriptive graphics to enhance the aesthetic appeal of the
watercraft. Prior constructions often use adhesive backed graphics,
or laminate the graphics to or paint the watercraft, sometimes
using an epoxy clear coat. These methods of attachment often result
in a lack of durability and aesthetic appeal of the graphic,
thereby diminishing the value of the watercraft. For example,
graphics applied directly to the surface are more susceptible to
being faded by the elements, e.g. the sun, being worn off, e.g.
during repeated use, and/or being scratched off, e.g. from being in
contact with a hard object.
[0005] As such, there is a need for a watercraft that can provide a
durable and aesthetically appealing recreational watercraft that
does not suffer from the disadvantages noted above, as well as
various other disadvantages.
[0006] It will be understood by those skilled in the art that one
or more aspects of the recreational watercraft and method of
assembly can meet certain objectives, while one or more other
aspects can lead to certain other objectives. Other objects,
features, benefits and advantages of the recreational watercraft
and method of assembly will be apparent in this summary and
descriptions of the disclosed embodiments, and will be readily
apparent to those skilled in the art. Such objects, features,
benefits and advantages will be apparent from the above as taken in
conjunction with the accompanying figures and all reasonable
inferences to be drawn therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying drawing figures, which are incorporated in
and constitute a part of the description, illustrate several
aspects of the recreational watercraft and method of assembly, and
together with the description, serve to explain the principles of
the recreational watercraft and method of assembly. The following
description is based on embodiments of the recreational watercraft
and method of assembly and should not be taken as limiting the
recreational watercraft and method of assembly with regard to
alternative embodiments that are not explicitly described herein. A
brief description of the figures is as follows:
[0008] FIG. 1 is a top front perspective view of a recreational
watercraft;
[0009] FIG. 2 is a bottom rear perspective view of the watercraft
of FIG. 1;
[0010] FIG. 3 is an exploded top front perspective view of the
watercraft of FIG. 1 prior to assembly;
[0011] FIG. 4 is an exploded bottom rear perspective view of the
watercraft of FIG. 3;
[0012] FIG. 5 is a top front perspective view of a core;
[0013] FIG. 6 is a bottom rear perspective view of the core of FIG.
5;
[0014] FIG. 7 is a top front perspective view of an upper
shell;
[0015] FIG. 8 is a bottom front perspective view of the upper shell
of FIG. 7;
[0016] FIG. 9 is a top front perspective view of a lower shell;
[0017] FIG. 10 is a bottom front perspective view of the lower
shell of FIG. 9;
[0018] FIG. 11 is a top front perspective view of a first substrate
layer and a second substrate layer of a composite substrate;
[0019] FIG. 12 is a side view of the first substrate layer and the
second substrate layer of FIG. 11 in an unbonded configuration;
[0020] FIG. 13 is a partial side view of the first substrate layer
and the second substrate layer of FIG. 11 in a bonded
configuration;
[0021] FIG. 14 is a top front perspective view of the composite
substrate after molding to form the upper shell;
[0022] FIG. 15 is a cross-sectional view of the watercraft taken
along lines 15-15 of FIG. 1;
[0023] FIG. 16A is a top front perspective view of another
embodiment of a recreational watercraft;
[0024] FIG. 16B is a cross-sectional view of the watercraft in FIG.
16A taken along lines 16B-16B;
[0025] FIG. 17 illustrates a prior art watercraft that includes a
tape covered seam;
[0026] FIG. 18 illustrates a prior art watercraft that includes a
clip; and
[0027] FIG. 19 illustrates a prior art watercraft that includes a
protruding ridge.
[0028] FIG. 20 illustrates a prior art watercraft that includes
overlapping layers of fiberglass.
[0029] In view of the many possible embodiments to which the
principles of the present invention may be applied, it should be
recognized that the embodiments described herein with respect to
the drawing figures are meant to be illustrative only and should
not be taken as limiting the scope of the invention.
DETAILED DESCRIPTION
[0030] Referring to FIGS. 1 and 2, a recreational watercraft 10 is
illustrated in a form that includes a top surface 12 juxtaposed
with a bottom surface 14 along a rail 16. The top surface 12 can
include various securements and orifices suitable for the
securement of gear, nets, ropes, etc., as well as various pads and
textures to provide suitable footing for a user of the watercraft
10. The bottom surface 14 (FIG. 2) can be shaped to include one or
more contours that can assist with providing stability of the
watercraft, as well as assist with the reduction of resistance to
movement, thereby allowing a user to operate the watercraft 10 with
minimal effort while maintaining an upright position (e.g.,
standing, sitting, or kneeling on the top surface).
[0031] The rail 16 is configured to provide a suitable portion for
abutment of the watercraft 10 with other objects and can extend
continuously around a perimeter 19 of the watercraft 10 between the
top surface 12 and the bottom surface 14, for example, extending
along a front 22, a rear 24, a first side 26, and a second side 28
of the water craft, or it can extend along lesser portions
thereof.
[0032] Referring to FIGS. 3 and 4, exploded views of the watercraft
in FIG. 1 are provided. As shown, the watercraft 10 is comprised of
a plurality of formed components. More particularly, in at least
some embodiments, the watercraft 10 includes an upper shell 30 and
a lower shell 32, each bonded to a core 34, wherein the shells 30,
32 and the core 34 can include one or more of the elements as
described herein forming at least a portion thereof. In at least
some embodiments, the upper shell 30 includes a shell top surface
13 and an upper rail portion 18, and the lower shell 32 includes a
shell bottom surface 15 and a lower rail portion 20. The upper rail
portion 18 further includes an upper rail portion edge 23 and the
lower rail portion 20 further includes a lower rail portion edge
25, wherein the upper and lower rail portion edges 23, 25, extend
one of partially, substantially, or completely around the perimeter
19 of the watercraft 10.
[0033] Referring to FIGS. 5 and 6, an embodiment of the core 34 is
illustrated. The core 34 includes a core top portion 36 and a core
bottom portion 38, with a core rail portion 37 extending
therebetween about the perimeter of the core 34. The core 34 can be
shaped and sized to accommodate various configurations and desired
use characteristics, and constitutes the general form of the
watercraft 10. More particularly, the upper shell 30 and lower
shell 32 are bonded to the core 34. The core 34 can be comprised of
one or more of various materials, such as Expanded Polystyrene
insulation (EPS), Styrofoam, Poly Urethane Foam, Extruded
Polystyrene (XPS) and/or other materials suitable to provide
buoyancy for the watercraft 10. The core 34 can be formed using a
mold, then shaped by hand and/or via the use of a CNC machine to
achieve the desired shape. In at least one embodiment, the core is
made from a one pound density Styrofoam material.
[0034] The core 34 can be covered with one or more core outer
layers of material, such as fiberglass, polycarbonate,
acrylonitrile butadiene styrene (ABS), epoxy, etc., to assist with
the desired bonding of subsequent materials thereto, as well as to
enhance strength and durability. In at least some embodiments, such
core outer layers can include multiple layers of fiberglass, which
are sanded smooth between each layer application. In at least one
embodiment, the core 34 is formed by shaping a blank made from a
buoyant material, for example, EPS, Styrofoam, etc., sealing the
blank with a blank sealer, and bonding a layer of textile, such as
fiberglass or carbon fiber thereto using an adhesive, for example
epoxy resin, then sanding and repeating again. A sealant can be
used to prevent the core 34 from absorbing adhesives. The core 34
with fiberglass can also be put into a vacuum, for example a vacuum
bag, in order to remove air bubbles trapped between the layers of
fiberglass.
[0035] FIGS. 7 and 8 provide perspective views of the upper shell
30, including the shell top surface 13, an upper shell mating
surface 40, the upper rail portion 18, and a graphic 58. FIGS. 9
and 10 provide perspective views of the lower shell 32 including
the shell bottom surface 15, a lower shell mating surface 43, and
the lower rail portion 20.
[0036] Referring now to FIGS. 11 and 12, the upper shell 30 is
formed from a composite substrate 44. In at least some embodiments,
the composite substrate 44 includes a plurality of shell material
layers, for example a first material layer 46 and a second material
layer 48. In at least some embodiments, the first material layer 46
is comprised of a polycarbonate-based material, and the second
material layer 48 is comprised of an ABS-based material. In at
least some embodiments, the first material layer 46 is comprised
substantially of a polycarbonate-based material and the second
material layer 48 is comprised substantially of an ABS-based
material, while in other embodiments, other materials and/or varied
percentages can be used for one or both material layers 46, 48,
such as polyethylene, multiple layers of a polycarbonate-based
material or other substantially clear materials with similar
properties.
[0037] ABS materials tend to be more elastic, but lighter than
polycarbonate materials. Polycarbonate materials are more rigid,
but are but less elastic than ABS materials. The use of an ABS and
polycarbonate-based composite substrate 44 allows the resulting
watercraft to ride higher out of the water because the composite
substrate is less dense than the numerous layers of epoxy resin and
fiberglass traditionally used on such watercraft. This can also
lead to a lighter watercraft, which is desirable for carrying the
watercraft to the location of use. Further, epoxy resin can have a
fractured look when impacted, thereby reducing the aesthetics of
such watercraft. The use of an ABS and polycarbonate-based
composite substrate 44 helps make the watercraft more impact
resistant. In fact, the ABS and polycarbonate-based composite
substrate 44 has a greater impact resistance than the use of an ABS
or polycarbonate material alone. The use of an ABS and
polycarbonate-based composite substrate 44 also helps give the
watercraft a more solid feel when use. For example, when a user is
standing on a watercraft, such as a paddleboard, it does not feel
like it is compressing or flexing under the feet of the user.
[0038] The first material layer 46 includes a first material top
surface 50 and a first material bottom surface 52 with a first
thickness T1 extending therebetween. The thickness T1 can vary, for
example, in at least some embodiments, it is about 0.1 millimeters,
while in other embodiments, it can range between 0.001 millimeters
to 0.5 millimeters. One or more graphics, such as graphic 58, can
be situated on, or in abutment with, the first material bottom
surface 52. In at least some embodiments, the graphic 58 is printed
on the first material bottom surface 52 using various inks, while
in other embodiments, the graphic 58 is a substrate with the
graphic pre-printed thereon, such as a fabric substrate. The use of
a polycarbonate material as the top or first material layer 46 also
provides for protection of any graphics or designs 58 because the
polycarbonate material is clear allowing such graphics or designs
58 to be placed under the polycarbonate first material layer 46 or
printed on the first material bottom surface 52. The second
material layer 48 includes a second material top surface 54 and a
second material bottom surface 56 with a second thickness T2
extending therebetween. The first material layer 46 and second
material layer 48 can be attached by a number of known means in the
art, for example heat laminating.
[0039] The thickness T2 can vary, for example, in at least some
embodiments, it is between about 1.35 millimeters and about 1.46
millimeters, while in other embodiments, it can range between about
0.5 millimeters and about 2.5 millimeters. In addition, the
combined thickness of T1 and T2 is, in at least some embodiments,
between about 1.0 millimeter and about 3.175 millimeters. The
thickness of the composite substrate 44 can vary depending on the
amount of strength desired. Increasing the thickness may also
increase the weight of the watercraft. When the watercraft is
configured to be portaged, it is desirable to keep the weight of
the watercraft within the capabilities of most users. In one
embodiment, the weight of a paddleboard could be between thirty
five and forty two pounds; however, such paddleboards could be
lighter or heavier depending on desired characteristics such as
strength, size, etc.
[0040] The second material top surface 54 is configured for bonding
to the first material bottom surface 52, and the second material
bottom surface 56 is configured for bonding to the core 34 about
the core top portion 36, understanding that one or more other
material layers can be positioned between the second material
bottom surface 56 and the core 34, such as an adhesive, epoxy,
fiberglass, etc. The composite substrate 44 as described above can
be used to form the upper shell 30 and/or the lower shell 32.
[0041] To form the upper shell 30, the composite substrate 44 is
placed over a base mold formed in the desired shape of the upper
shell and the mold and heated (thermo-formed) and raised into the
composite substrate 44. The mold can also be vacuum ported.
Thermo-forming has an additional advantage that the composite
substrate gets thinner during thermo-forming. FIG. 14 provides an
illustration of the composite substrate 44 after the molding
process, where the first material top surface 50 becomes the shell
top surface 13. As shown in FIG. 14, the composite substrate 44 now
includes the upper shell 30 and an extraneous perimeter portion 62,
which is to be cut and removed. In at least some embodiments, the
lower shell 32 is formed in the same manner as described above with
regard to the upper shell 30, using instead a base mold shaped as
desired for the lower shell 32. In at least some embodiments, the
upper shell 30 or the lower shell 32 can be formed in a different
manner. In at least some embodiments, when trimming the composite
substrate 44 to outline the upper shell 30 and lower shell 32, it
is necessary to establish a final cut size that provides a gap 45
(as discussed below) between the upper shell 30 and lower shell 32
when bonded to the core 34. Further, in at least some embodiments,
the gap 45 must not be less than zero, resulting in an overlap
condition, while in other embodiments, the gap 45 can be zero.
[0042] Referring again to FIGS. 3 and 4, the upper shell 30 and the
lower shell 32 are shown in their completed form. Prior to bonding
the upper shell 30 and the lower shell 32 to the core 34, the core
34 can be prepared using one or more various materials. In at least
some embodiments, the core 34 is blow-molded and then wrapped in
one or more layers of fiberglass and epoxy resin, while in other
embodiments, the core 34 is not further treated prior to
installation of the upper shell 30 and the lower shell 32. The core
34 could also be sealed, but is not necessary if the core is not
wrapped with fiberglass and epoxy resin and, if not, reduces the
overall weight of the watercraft 10. To provide enhanced strength
to the rail 16, a first augmentation substrate 64, such as a
combination of paraphenylenediamine and terephthaloyl chloride
(e.g., KEVLAR.RTM.) or other suitable strengthening material (e.g.,
synthetic fiber of high tensile strength), can be bonded to the
core rail portion 37 prior to bonding the upper shell 30 and the
lower shell 32 to the core 34. Bonding of the first augmentation
substrate 64 can be accomplished using one of various methods,
including placing it on the core rail portion 37 and applying an
adhesive, for example epoxy resin, thereover. The application of a
first augmentation substrate 64 helps to strengthen the core rail
portion 37 and helps prevent the upper and lower rail portions 18,
20 from being pushed inward, towards the core 34, if the rail 16
contacts a resistant surface during use.
[0043] The upper and lower shells 30, 32 can be attached to the
core 34 in a number of known means in the art. For example, the
lower shell 32 can be placed in a mold and an adhesive, e.g. epoxy
resin, is applied to the lower shell mating surface 43. The core 34
is placed into the lower shell 32 and adhesive is applied to the
core top portion 36. The upper shell 30 is placed on top of the
core 34. A mold is placed on top of the upper shell 30. The entire
assembly is then compressed and can also be vacuum ported, e.g. via
the molds, to bond the components together.
[0044] After bonding of the upper shell 30 and the lower shell 32
to the core 34, the gap 45, if present, extends substantially or
completely about the juncture of the upper and lower rail portion
edges 23, 25, proximate the core rail portion 37. The height H of
the gap 45 can vary as the gap 45 extends around the upper and
lower rail portion edges 23, 25. In at least some embodiments, the
height H must be at least about 0.5 millimeters, but cannot exceed
about 6.4 millimeters, while in other embodiments, the height H
cannot exceed about 12 millimeters, while in still other
embodiments, the height H can vary between about 3 millimeters and
about 6.4 millimeters, while in yet still other embodiments, the
height H can vary between about 0 millimeters and about 12
millimeters, while in further other embodiments, the height H can
be greater than 6.4 millimeters or lesser than about 3
millimeters.
[0045] A gap 45 can be desirable for a number of reasons. First,
trimming the extraneous perimeter portion 62 such that the
resulting upper and lower rail portion edges 23, 25 perfectly align
would be extremely difficult and result in considerable additional
time during manufacturing and, thereby, cost. Further, cores 34 may
vary depending on whether they are hand shaped or sanded after
molding or being created in a CNC machine or even on differences in
technique in molding or using the CNC machine. Over trimming the
extraneous perimeter portion 62 to ensure a gap 45 exists results
in manufacturing efficiency and reduces the opportunity for
mistakes. Second, if a vacuum ported mold or bag is used, the gap
45 can allow air to escape the watercraft. Third, having a gap 45
ensures that the proper amount of compression is applied to the
upper shell 30, core 34 and lower shell 32 because the upper and
lower rail portion edges 23, 25 will not contact each other
preventing such compression.
[0046] Referring to FIG. 15, a cross-sectional view of the
watercraft 10 in assembled form is provided. Materials, components
and/or elements may not be shown to scale and are for illustrative
purposes only. As shown, the first augmentation substrate 64 is
bonded between the core rail portion 37 and both the upper and
lower rail portions 18, 20, and can be exposed along the gap 45.
With or without the addition of the first augmentation substrate
64, the gap 45 is filled with a joint material 70 and sanded or
otherwise finished to form a flush or substantially flush surface
that extends continuously or substantially continuously between the
upper and lower rail portions 18, 20. The joint material 70 can
include one or more of various suitable materials, such as
expanding polyurethane foam, epoxy putty, silicone, extrusion,
tape, polyester putty, Room Temperature Vulcanization silicone
(RTV), etc.
[0047] In at least some embodiments, a second augmentation
substrate 72, which can be comprised of the same material as the
first augmentation substrate 64, or another material, such as
fiberglass, nylon, polycarbonate, or other sandable material to
create a smooth rail 16, is provided over the gap 45 and the upper
and lower rail portions 18, 20. In one embodiment, the use of the
second augmentation substrate 72, is only possible because the
epoxy used to adhere the second augmentation substrate 72 will bond
with polycarbonate-based material layers. Any desirable amount of a
second augmentation substrate 72 may be used as desired. In one
embodiment a six-ounce single layer of KEVLAR.RTM. may be used. The
second augmentation substrate 72 further enhances the strength of
the rail 16, as well as couples the joint material 70 and the upper
and lower rail portions 18, 20. In at least some embodiments, the
second augmentation substrate 72 can be applied over additional
portions of the upper and lower shells 30, 32. Further, in at least
some embodiments, only one of the first and second augmentation
substrates is utilized.
[0048] One or more fiberglass outer layers 76 can be wrapped around
the upper and lower shells 30, 32, along with other exposed layers,
such as the second augmentation substrate 72, if installed.
Applying the fiberglass outer layer 76 provides a workable surface
for smoothing and shaping, and can also be overlapped along the
rail to provide additional rigidity. Additional material layers can
be applied after the fiberglass to further enhance durability and
appearance, such as paint 73, lacquer clear coat, colored epoxy
resin, etc. If a design element, such as paint 73, is applied, an
enamel, epoxy clear coat or other clear protective material can be
applied over the design element to protect it. The above described
process typically involves applying an outer layer 76 on the top or
bottom, one at a time and waiting for each layer to be cured and
then sanded before moving to the other of the top or bottom.
[0049] FIG. 16A provides a view of an alternate configuration of
the watercraft 10, namely watercraft 10'. FIG. 16B illustrates a
cross-sectional view of the watercraft 10' taken along lines 16-16
of FIG. 16A. As illustrated in the FIGS. 1-16B, various elements of
the watercraft 10 and 10' are substantially similar, or the same,
in both structure and function, while other elements can provide a
similar function, but can include structural modifications. As
such, the elements of the watercraft 10' are provided with similar
element numbers, but with a prime symbol (') appended thereto, and
further, the use and engagement of various components of the
watercraft 10, as discussed above, are sufficiently applicable to
the corresponding components discussed below for the watercraft
10', absent notation otherwise, such as the bonding of the first
material layer 46 and second material layer 48 to form the shells
30, 32. In addition, elements shown in FIGS. 16A and 16B that were
not identified in FIGS. 1-15, also include a prime symbol appended
thereto for clarity.
[0050] As shown in FIG. 16B, in at least some embodiments, an upper
shell 30' and a lower shell 32' can form a lap joint along a rail
portion 16'. More particularly, an offset end 78' extends from a
lower rail edge 79' of the lower rail portion 20', and is
positioned behind an upper rail portion 18' to limit deflection of
the upper rail portion 18' when the rail portion 16' abuts an
object. The offset is sufficient to allow the upper rail portion
18' to be flush with the lower rail portion 20' on either side of a
gap 45' between an upper rail portion edge 23' and the lower rail
edge 79'. The offset end 78' includes an offset end mating surface
80' that is secured to the upper shell mating surface 40' of the
upper rail portion 18', such as by using an adhesive 81'. The gap
45' is similarly filled with a joint material 70' and can be
covered with an augmentation substrate, such as a second
augmentation substrate 72'. In at least some embodiments, a first
augmentation substrate 64' can also be provided adjacent the core
34' and offset end 78', in order to provide additional support, as
was discussed above. Lastly, one or more fiberglass outer layers
76' can be wrapped around the upper and lower shells 30', 32',
along with other exposed layers, such as the second augmentation
substrate 72', if installed, and a finishing layer, such as paint
73', can be provided thereover. The use of a gap 45, 45' allows for
increased tolerance when molding and cutting the upper and lower
shells 30', 32' and accommodation of wide variances without
compromising structural integrity.
[0051] With reference to FIGS. 17, 18, and 19, which illustrate
various prior art watercraft constructions utilizing forming top
and bottom shells that are installed over a core, but with
sub-standard results and numerous deficiencies. For example, FIG.
17 shows an upper shell AA and lower shell BB made from an ABS
material and secured to a core such that a gap DD exists
therebetween along a rail portion CC. The lower shell BB is placed
in a mold, such as a vacuum ported mold, and the interior surface
is treated with an adhesive. A core is placed in the lower shell
BB. The exposed top surface of the core or interior surface of the
upper shell AA is treated with adhesive and the upper shell placed
on the core. A mold, such as a vacuum ported mold, is then placed
on top of the upper shell AA. The molds are compressed and a vacuum
is applied to the ports to draw out any extra air. The gap DD of
the resulting watercraft is covered with tape EE to hide the gap
and to prevent water from entering the core.
[0052] Such a configuration suffers from a number of disadvantages.
First, the tape does not structurally address the weak point along
the rail portion, which is vulnerable during use. Therefore, any
impact along the rail can puncture the tape EE, penetrate or damage
the core and allow water to enter the core. Second, the tape EE can
stretch after some use and begin to pucker inwards into the gap DD
which is not aesthetically pleasing. Third, the tape EE can begin
to peel from repeated exposure to the elements, such as water, sun,
etc. or even contact with a hard object, such as a paddle blade.
Fourth, forming each shell AA, BB from a sheet of ABS material
limits the design options of the watercraft, such as one color for
each shell. Any additional graphics have to applied to the exterior
of the ABS material.
[0053] FIG. 18 shows an upper shell AA and lower shell BB secured
to a core. The end of the upper shell AA is epoxied or glued in the
top of an "H" clip or extrusion FF and the end of the lower shell
BB is epoxied or glued in the bottom the clip FF to attach the
shells together along the rail CC and fill in the gap that would
otherwise exist therebetween. Such clips FF can be made from a
polyvinylchloride material.
[0054] Such a configuration suffers from a number of disadvantages.
First, the clip FF can add weight to the watercraft and is
typically not aesthetically pleasing because the clip FF can be
seen. Second, due to the size of the clip FF, there is only a small
amount of tolerance or variance in the edges of the shells AA, BB.
If the size of the edge varies by greater than the portion of the
clip FF that is configured to hold the edge, there will be exposure
to the core and water may be able to enter the shells AA, BB. Even
if the edge of the shells AA, BB are seated in the clip FF, the
rail CC may be susceptible to damage by even slight contact with a
hard object if the edge is not within the clip FF sufficient to
provide a strong bond. Third, unless the edges of the shells AA, BB
are substantially even, when the edges are seated in the clip FF,
some portion of the edge will contact the clip while other portions
will not. This can prevent proper compression of the two shells AA,
BB to the core, which can allow the one or both of the shells to
not be in contact with the core and not provide proper support for
the user. Fourth, the clip FF extends outward from the watercraft
and can affect use characteristics of the watercraft, such as
causing additional undesired drag, could cut a user of the
watercraft or a bystander that is contacted by the clip or could
damage the paddle blade. Fifth, as discussed above, forming each
shell AA, BB from an ABS material limits the design options of the
watercraft.
[0055] Lastly, FIG. 19 shows a shell GG formed such as by
twin-sheet thermoforming. Two sheets of ABS are placed in a mold.
The ABS is heated and air is injected into the mold to force the
ABS against the side of the mold. The edges of the two sheets of
ABS enter an indent along the side of the mold and heat fuse
together to form an integral block end HH that extends
perpendicularly. The shell GG is then placed in another mold and
foam is injected into the shell to form the core.
[0056] Such a configuration suffers from a number of disadvantages.
First, the block end HH leaves a protruding ridge that is
undesirable from both an aesthetic and functional point of view.
More particularly, the ridge provides a sharp edge on both top and
bottom portion of the ridge, which can cut a user of the
watercraft, a bystander or even the paddle blade that contacts by
the ridge. Second, the block end HH cannot be trimmed off because
this is how the two sheets of ABS are connected. Third, this ridge
can affect use characteristics of the watercraft, such as causing
additional undesired drag. Fourth, such a configuration can be
difficult to properly compress because the core is being filled
inside the formed shell GG, instead of compressing shells onto a
core. Similarly, this configuration can also be hard to remove gaps
between the shell GG and core, air pockets and other voids because
there is often only one opening in the shell. These difficulties
can result in the shell GG to not being in contact with the core
and not providing proper support for the user. Fifth, forming the
shell GG from an ABS material limits the design options of the
watercraft.
[0057] FIG. 20 illustrates another prior art watercraft 82
construction utilizing layers of fiberglass and epoxy wrapped
around a core, but with sub-standard results and numerous
deficiencies. The core 84 seen in FIG. 20 is formed from a
Styrofoam blank and shaped by a computer numerical control machine.
The core 84 can then be sealed with sealant to prevent the core
from absorbing epoxy from subsequent treatments. A first layer of
fiberglass material 84 is then cut generally to the shape of the
core 84 and then epoxied to the core. The fiberglass material 86 is
then allowed to harden, typically five to eight hours and then
sanded down.
[0058] The core 84 is then flipped over and a second layer of
fiberglass material 88 is cut generally to the shape of the core 84
and then epoxied to the core. The second layer of fiberglass
material 88 generally overlaps the first layer of fiberglass
material 86 by about six inches on the rail 90 of the core. The
second layer of fiberglass material 88 is allowed to harden or cure
and then sanded. This process is generally repeated so that six
layers of fiberglass material 86, 88, 92, 94, 96, 98 are on the
core 84, three layers on each of the top and bottom of the core
84.
[0059] This process can also include the use of a vacuum bag after
each application of a fiberglass material to draw out any air
trapped thereunder. A visual element or graphic 100 can be add to
the watercraft 82 before the last layer of fiberglass is added,
e.g. the sixth layer 98. The graphic 100 is often a fabric material
that is placed on the exposed layer of fiberglass material, e.g.
the fourth layer 94. When the sixth layer of fiberglass material is
placed over the fabric graphic and epoxied, the epoxy will also
penetrate the fabric graphic 100. Paint 102 can also be applied to
the exterior layer of fiberglass, the fifth and sixth layers 96, 98
and then an epoxy resin coat 104 applied to the watercraft 82 to
protect the paint. The epoxy resin coat 104 is then sanded to
obtain a smooth exterior surface.
[0060] Although the above described configuration results in no
seam along the rail 106 of the watercraft 82, it suffers from a
number of disadvantages. First, the entire process takes a
considerable amount of time and physical labor, which results in a
significant increase in cost to manufacture the watercraft 82.
Second, the large number of steps in the process presents numerous
opportunities for error or even simply failure of a single
component resulting in an unusable or unappealing watercraft 82.
Third, the large amount of human involvement results in a large
amount of variability in the resulting watercraft 82. For example,
the amount of sealer applied to the core 84 and the amount of epoxy
applied during each layer of fiberglass material can vary depending
on which person did the application. This can result in added
expense, if a person uses more material than necessary, and
inconsistency in the functionality of the watercraft, heavier
watercrafts ride lower in the water resulting in increased drag.
Fourth, the resulting watercraft 82 is very susceptible to damage
from improper use. For example, dropping the watercraft 82 can
result in a fractured look due to the epoxy's material
characteristics.
[0061] Although the invention has been herein described in what is
perceived to be the most practical and preferred embodiments, it is
to be understood that the invention is not intended to be limited
to the specific embodiments set forth above. Rather, it is
recognized that modifications may be made by one of skill in the
art of the invention without departing from the spirit or intent of
the invention and, therefore, the invention is to be taken as
including all reasonable equivalents to the subject matter of the
appended claims and the description of the invention herein.
Further, it is to be understood that in at least some embodiments,
plurality can include one or more of an element. The term "bonded"
as used herein can include one or more of various methods for
securing elements, such as the use of adhesives, heat, positional
limitations, resins, pressure, etc.
* * * * *