Lightweight marine craft and methods thereof
09580148 ยท 2017-02-28
Assignee
Inventors
Cpc classification
International classification
B63B3/00
PERFORMING OPERATIONS; TRANSPORTING
B63H9/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A boat hull or other marine structure is made by shaping a plastic foam core and covering it with a plastic outer skin glued in place by adhesive, mechanically fastened, or applied in liquid form. Minimal sawcuts to the foam core ease manufacture. Methods for anchoring fittings, masts, pipes and shade canopies are presented. No-sew sails for the boat have corners made of plastic sheet attached using both adhesive and mechanical fastening. Lateral resistance of the hull is provided by telescoping leeboards. A suite of these boats share the same modular masts and sails. Such boat hulls offer light weight, ease of transport, and unswampable buoyancy.
Claims
1. A lightweight marine craft, comprising: a hull having a plastic foam core and covering formed of a plastic outer skin that is free of two part epoxy or polyester resins, said plastic outer skin being one of glued in place by adhesive, mechanically fastened, applied in liquid form to dry in place, or a combination thereof, further comprising attachments passing through said hull comprising at least one of a pipe sleeve, through-deck threaded rod, rope, cable or a zip-tie to attach a fitting to said hull, further comprising a deck stepped mast placed in a hole cut through a deck mounted plate.
2. The lightweight marine craft of claim 1 wherein said foam core provides a hull shape and buoyancy.
3. The lightweight marine craft of claim 2 having six or fewer saw cuts to form said hull shape.
4. The lightweight marine craft of claim 1 further comprising a plate attached to a fitting, said plate screwed to said outer skin of said hull.
5. The lightweight marine craft of claim 1 further comprising no-sew sails formed of a high density polyethylene sheet with corners reinforced with plastic sheet material.
6. The lightweight marine craft of claim 5 further comprising a hull hole formed partially through said hull and a mast inserted into said hull hole.
7. The lightweight marine craft of claim 1 further comprising a hull hole formed in said hull and a flexible pipe frame in said hull hole for a shade canopy.
8. The lightweight marine craft of claim 1 further comprising a leeboard along a side of said hull.
9. The lightweight marine craft of claim 8 further comprising a telescoping leeboard to provide deeper extension for lateral resistance when sailing to windward.
10. The lightweight marine craft of claim 9 wherein said telescoping leeboard is retractable when sailing down wind or in shallow water.
11. The lightweight marine craft of claim 1 wherein a suite of boats of various lengths is made possible by a single mast type and three or less sail types.
12. The lightweight marine craft of claim 11 wherein said suite of boats includes at least one of a single sail catboat, a two sail sloop, a three sail ketch or a multiple masted schooner.
13. The lightweight marine craft of claim 11 wherein said suite of boats further comprises a staysail schooner with two or more sails.
14. The lightweight marine craft of claim 1 wherein said lightweight marine craft is powered by a conventional marine electric motor run by batteries and/or photovoltaic panels.
15. A method of constructing a light weight marine craft, comprising the steps of: cutting a foam core to define a hull shape; applying a plastic skin to said foam core; forming a hole in said hull for attachments, wherein said attachments include at least one of a pipe sleeve, a threaded rod, a rope, or a zip-tie; and, attaching at least one fitting to a plate and applying said plate to said foam core and said plastic skin.
16. The method of claim 15 further comprising attaching corner protection plastic at seams where said plastic skins meet.
17. The method of claim 15 wherein said attachments may be used for attaching fittings, motor mount, bow spirit or solar panel.
18. The method of claim 15 further comprising applying a sail to said mast.
19. The method of claim 15 further comprising drilling at least one second hole for a shade canopy.
20. The method of claim 19 further comprising inserting shade canopy pipe into said at least one second hole.
21. The method of claim 20 further comprising attaching said shade canopy to said shade canopy pipe.
22. The method of claim 15 further comprising attaching fittings to said plate and then fastening said plate to a top surface of said hull.
23. The method of claim 15 further comprising forming mount motor holes in plates attached to said hull at a rear end of said hull.
24. The method of claim 23 further comprising mounting a battery and controller boxes to plate attached to top deck plastic skin.
25. The method of claim 24 further comprising wiring said motor to said battery and a solar panel to charge said battery.
26. The method of claim 25 further comprising using fasteners to attach a plastic skin covering wires from motor to battery.
27. A lightweight marine craft, comprising: a hull having a plastic foam core and covering formed of a plastic outer skin that is free of two part epoxy or polyester resins, said plastic outer skin being one of glued in place by adhesive, mechanically fastened, applied in liquid form to dry in place, or a combination thereof, further comprising attachments passing through said hull comprising at least one of a pipe sleeve, through-deck threaded rod, rope, cable or a zip-tie to attach a fitting to said hull, wherein said lightweight marine craft is powered by a marine electric motor run by at least one of a battery or a photovoltaic panel.
28. A lightweight marine craft, comprising: a hull having a plastic foam core and covering formed of a plastic outer skin that is free of two part epoxy or polyester resins, said plastic outer skin being one of glued in place by adhesive, mechanically fastened, applied in liquid form to dry in place, or a combination thereof, further comprising attachments passing through said hull comprising at least one of a pipe sleeve, through-deck threaded rod, rope, cable or a zip-tie to attach a fitting to said hull, further comprising a hull hole formed partially through said hull and a mast inserted into said hull hole.
Description
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
(1) The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the lightweight marine craft and method thereof will be better understood by reference to the following description of embodiments taken in conjunction with the accompanying drawings, wherein:
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DETAILED DESCRIPTION
(12) Reference now will be made in detail to embodiments provided, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation, not limitation of the disclosed embodiments. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present embodiments without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to still yield further embodiments. Thus it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
(13) Referring now to
(14) Referring now to
(15) The foam core 12 may be formed in a variety of ways and of different materials. For example, the foam core 12 may be cut from polystyrene, polyurethane or polyethylene. The foam core 12 may be easily cut with commonly used handtools, for example a hand saw. The plastic skin 11 may be applied to the core 12 either after the boat shape has been formed, or alternatively, may be applied to the foam core 12 and subsequently the core 12 and skin 11 may be cut to the desired hull shape. According to instant embodiments, the hull 10 is formed by cutting the core 12 and subsequently applying the skin 11 to the formed core 12 shape by way of mechanical fastener, adhesive or some other retaining feature or a combination thereof. The hull 10 has minimal cuts to define the shape and leaves the bottom substantially flat, according to this embodiment. However, this hull shape should not be considered limiting as others may be utilized.
(16) Referring now to
(17) At the bow 14 of the hull 10, the hull may have a step 30 having a higher elevation than a main deck 32. The step 30 may function at least in part as a splash guard. Additionally, the step allows deeper mast embedment and support if a mast is positioned therethrough. These steps 30 may vary in size from boat to boat depending upon the size of the hull 10 and the anticipated waves to be encountered based on sailing location and anticipated conditions. The step 30 may be formed of a single piece with the core defining the main deck 32 according to some embodiments. Alternatively, the step 30 may be formed of an alternate piece or pieces and either glued or fastened to the core 12 defining the main deck 32.
(18) Referring now to
(19)
(20) Referring now to
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(22) According to a first embodiment of
(23) Referring now to
(24) Referring now to
(25) Referring now to
(26) Referring now to the first corner 306, the corner 306 is spaced from the mast 304 and the fabric 302, for example TYVEK may be laminated between two layers of a thicker plastic sheet or laminate 312. The laminate 312 may be glued to the fabric 302 or alternatively mechanically fastened with fasteners 314.
(27) The corner 306 may further comprise one or more ropes 316 to provide points of attachment to the sail 300 commonly called sheets that adjust the angle of the sail 300 relative to the wind. The ropes 316 may be of a small diameter and may be formed of wire or twine based materials.
(28) Referring still to
(29) Further, at the bottom of mast 304, the third corner 310 of the sail 300 is shown. The corner 310 is again formed of the fabric 302 with a thicker laminated layer 312 to strengthen the corner 310. In the depicted embodiment, a fastener 314 extends through the layer 312 and the fabric 302, and further passes through the mast 304. Alternatively, this corner may also slide along the mast 304 with a rope downhaul providing for adjustment of sail tension along the mast 304.
(30) Referring to
(31) Adjacent to the mast 304 is the shade support 340. The shade support 340 may be formed of lightweight tubing such as crosslinked polyethylene (PEX) or polyvinyl chloride (PVC) pipes which extend through the skin 11 and into the core 12. Due to the lightweight nature of the support 340, the tube may or may not be supported by the additional layer 15. The attachment methods provide a portion of length of mast 304 inserted into a hole of same diameter is drilled in the hull 10. The outermost rigid plastic skin 11 and optional interior horizontal layers 15 provide lateral resistance for such mast 304 and support 340.
(32) Referring now to
(33) Referring now to
(34) Referring now to
(35) The mast 304 may extend through the plate 150 and into the core 12 or, as shown, may extend to a lower plate 153 which inhibits the lower edge of the mast 304 from wearing a hole in the skin 11 and the core 12. The plate 150 and the lower plate 153 provide strength and lateral support to the mast 304. This attachment method may also be used for the support 340 shown previously.
(36) Referring now to
(37) The rope or cable 160 provides a structure for retaining the leeboards 155 against the ends of the hull 10. The embodiment further provides leeboard extensions 157 which are also connected by the rope 160 and to the leeboards 155. By loosening one end of the rope 160, the leeboard extensions 157 may be telescope into or out of the water, as desired. With the leeboard 155 and extension 157 extended, the boat has a greater lateral resistance to side slippage and can make better headway when sailing to windward, yet the leeboards 155 can be retracted as needed in shallow water or in sailing downwind when the lateral resistance is not needed.
(38) Additionally, the leeboard extension 157 may also comprise a weighted structure 158 bolted, fastened, adhered or otherwise connected thereto. The weight 158 maintains some amount of stability for the leeboard extension 157. A weight 158 on the lower leaf of the leeboard extension 157 pulls the telescoping leeboard extension 157 down with a rope 160 capable of pulling the leeboard extension 157 up when desired.
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(40) According to some embodiments, a method 400 of constructing the marine craft of the various embodiments is also provided. With reference to
(41) Next, a folded plastic or corner guard is applied 430 to corner seams where the plastic skins meet. The corner guards may be folded plastic sheet or some other type of reinforced plastic to protect the seams of the skins from damage and from peeling away from the core. According to optional steps, the corner guards may be applied at all of the seams or various plastic skin seams.
(42) Next a hole, also called a hull hole, is formed 440 through the plastic skin and into the foam core hull. The hole may be formed to receive a mast or a structure which may aid to provide shade. Additionally, or alternatively, the hole may be formed in a plate which will be subsequently applied to the top deck or a step of the hull.
(43) A fitting may be attached 450 to the plate and the plate may be attached to the hull. The fitting may alternatively be applied to the plate after the plate is attached to the hull, depending in part on the method of attachment for the fitting.
(44) Finally, the mast may be attached 460 to the hull.
(45) Further, the hull may be prepared 470 for various attachments. For example, the hole forming may be by drilling or the holes may be molded in place when the foam core is formed. Additionally, the hole may be used for any of various attachments including, but not limited to, pipe sleeves, threaded rods, ropes and zip ties. The attachments may be used to attach fittings, motor mounts, bow spirits, or solar panels.
(46) Further, a sail may be positioned or applied to the mast. This may be done with cords or ropes and may or may not include halyards to raise and lower the sail.
(47) The hull may include a second hole for a shade canopy. The method may further comprise inserting a shade canopy pipe 480 into at least one second hole. Subsequently, the shade canopy is attached to the shade canopy pipe.
(48) Additionally, one or more plates may be attached to the hull at the rear of the boat. The plate may be positioned on a top deck plastic skin. At least one of a battery and controller box may be attached to another or same plate at the middle or rear of the boat. One or more holes may be formed to provide motor mounts in the plate at the rear of the boat. The motor and battery may be wired together with a solar panel to charge the battery. A plastic skin may be placed over the wires and attached by various means including, but not limited to, fasteners. Any or all of these steps may occur as shown in step 490.
(49) Further, it should be understood that these steps do not necessarily need to be performed in the order as provided but may be performed in some instance in other orders and still be within the scope of the inventive embodiments.
(50) The foregoing description of structures and methods has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the structures and methods to the precise forms and/or steps disclosed, and obviously many modifications and variations are possible in light of the above teaching. Features described herein may be combined in any combination. Steps of a method described herein may be performed in any sequence that is physically possible. It is understood that while certain forms of composite structures have been illustrated and described, it is not limited thereto and instead will only be limited by the claims, appended hereto.
(51) While multiple inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.
(52) Examples are used to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the apparatus and/or method, including making and using any devices or systems and performing any incorporated methods. These examples are not intended to be exhaustive or to limit the disclosure to the precise steps and/or forms disclosed, and many modifications and variations are possible in light of the above teaching. Features described herein may be combined in any combination. Steps of a method described herein may be performed in any sequence that is physically possible.
(53) All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms. The indefinite articles a and an, as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean at least one. The phrase and/or, as used herein in the specification and in the claims, should be understood to mean either or both of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases.
(54) It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.
(55) In the claims, as well as in the specification above, all transitional phrases such as comprising, including, carrying, having, containing, involving, holding, composed of, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases consisting of and consisting essentially of shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures.