PERSONAL WATERCRAFT CHASSIS

Abstract

The various example embodiments disclosed herein pertain to an internal support structure in a watercraft that interfaces the motor to the hull and decreases the weight of the hull, by eliminating various components. The various example embodiments add structural stability to the overall structure of the hull or body, allowing for thinner hull and deck material. This chassis consists of a metal, composite, and or plastic bent or formed tubular structure that outlines the internal dimensions of the hull. The motor is able to mount to this structure so that the body is no longer the direct point of attachment. This furthers the structural stability and reliability of the hull as it disperses forces over a larger area and mounts to a means more suitable than direct hull mounts, which often shear and break loose from the traditional fiberglass hulls. By mounting the engine to this chassis, the hull can be completely removed without disassembling and other components. This allows easier access to the motor and ease of internal maintenance, and allows for replacement hulls and decks when damaged.

Claims

1. An apparatus comprising: an internal chassis serving as a component of a personal watercraft, the chassis being formed from a plurality of rigid members coupled together in a shape conforming to an internal area of the personal watercraft defined by a body of the personal watercraft, the body including a bottom hull component and a top deck component being coupled together at a set of bond rails, the chassis including a mounting structure for coupling a motor and a drivetrain directly to the chassis, the motor not being used as a structural element of the personal watercraft, the body being completely independent of the chassis.

2. The apparatus of claim 1 wherein the chassis including mountings for driveline, electrical, propulsion, exhaust, and accessories of the watercraft.

3. The apparatus of claim 1 including the bottom hull component and the top deck component coupled at the set of bond rails, encompassing the internal chassis.

4. The apparatus of claim 1 enabling a modular design thereby enabling the body to be removed without disassembly of the chassis.

5. The apparatus of claim 1 wherein the plurality of rigid members is comprised of metal, composite, or plastic members bent or formed into a tubular structure that conforms to the internal dimensions of the personal watercraft.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] For a better understanding of the example embodiments, reference should be made to the following detailed description disclosed in conjunction with the accompanying drawings, in which:

[0021] FIG. 1 is an isometric view of a personal watercraft chassis;

[0022] FIG. 2 is a side view of a personal watercraft chassis;

[0023] FIG. 3 is a top view of personal watercraft chassis;

[0024] FIG. 4 is a bottom view of a personal watercraft chassis;

[0025] FIG. 5 is a front view of a personal watercraft chassis; and

[0026] FIG. 6 is a rear view of a personal watercraft chassis;

[0027] FIG. 7 is a perspective view of an assembled hull, top deck, and hood manufactured by the method of thermoform manufacturing according to an example embodiment; and

[0028] FIG. 8 is a top view of the assembled hull, top deck, and hood manufactured by the method of thermoform manufacturing according to an example embodiment.

DETAILED DESCRIPTION

[0029] Reference will now be made in detail to the example embodiments illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Personal watercraft chassis and personal watercraft fabrication using a thermoforming process are described herein.

[0030] The Personal Watercraft Chassis of the various example embodiments disclosed herein and shown in FIGS. 1 through 6 allows for the body to be completely independent of the chassis and for the chassis to bolt directly to the motor, but not use the motor for structural means. In the design, an internal skeletal structure fills the internal profile of the hull design, allowing for maximum dispersion of forces. The structure connects only to itself and the body. It does not rely on a frame, sub frame, sheet metal floor, roll cage or additional engine cradle for additional support. The internal profile allows for cross-torsional structural integrity as well. The design of the Personal Watercraft Chassis of the various embodiments shown in FIGS. 1 through 6 allows for the body panels to bolt on and off easily; but, also enables the bolting of body panels in a manner such that the body splits in only to places. This allows for the easiest means for sealing the structure from water making it a reliably buoyant structure. The various example embodiments disclosed herein greatly reduce manufacturing costs, decrease manufacturing time; increase part consistency, and offer better performance characteristics and durability.

[0031] The various example embodiments include a fabricated, formed, or assembled chassis, frame or structure, which assists in the structural integrity and assembly of, but not limited to personal watercraft. The chassis can be used to assist with the creation of watercraft, including, but not limited to, personal watercraft, jet boats, race dinghies, power surfboards, and other aquatic transportation vehicles.

[0032] The various example embodiments relate to a chassis or frame component for, but not limited to, personal watercraft The various example embodiments relate to a center body structure of personal watercraft, and more particularly to the mounting of drivetrain and components thereof The implementation and design of the chassis enables a means for replaceable decks or hulls as well as adding capabilities for universal mounting, whilst increasing durability and structural integrity to current hull designs.

[0033] Watercraft designs currently rely on structural integrity from fiberglass to bolt the engine in place. This rudimentary practice is time consuming, unreliable, and over time weakens the overall structure of the hull. In order for the sport and industry to progress a solution for allowing for rapid engine installation/removal is required. More importantly, a rigid sub structure that interfaces the drivetrain mounting with the hull, to decrease overall hull weights, increase durability and structural integrity, allowing for easy maintenance, flexible components and overall preservation of the hull's structural integrity.

[0034] The various example embodiments disclosed herein provide an internal support structure in a watercraft that interfaces the motor to the hull and decreases the weight of the hull, by eliminating various components. The various example embodiments add structural stability to the overall structure of the hull or body, allowing for thinner hull and deck material. This chassis consists of a metal, composite, and or plastic bent or formed tubular structure that outlines the internal dimensions of the hull. The motor is able to mount to this structure so that the body is no longer the direct point of attachment. This furthers the structural stability and reliability of the hull as it disperses forces over a larger area and mounts to a means more suitable than direct hull mounts, which often shear and break loose from the traditional fiberglass hulls. By mounting the engine to this chassis, the hull can be completely removed without disassembling and other components. This allows easier access to the motor and ease of internal maintenance, and allows for replacement hulls and decks when damaged.

[0035] Referring to FIGS. 7 and 8 in the example embodiment, the illustrated bottom hull component mold and top deck component mold include a feature used to form bond rails 6 for both the top deck component and the hull/bottom deck component on the fabricated watercraft (e.g., see FIG. 7). The bond rails 6 provide a means of mounting or bonding the thermoform-fabricated top deck component to the thermoform-fabricated bottom hull/deck component. In an example embodiment, the bond rails 6 are produced with a unique curvature downward, built into the hull (not an aftermarket add on) and providing the rider with additional handling performance. In particular, the downward curvature of the bond rails 6 act as a fin when the rider leans into a turn. The enlarged curved bond rails 6 prevent the watercraft from submerging on landings and washing the rider out of the foot tray. Because of the precision manufacturing enabled by the thermoforming process used herein, the top deck and bottom hull can be fabricated with tight tolerances, allowing for a sealable joint between the top and bottom deck. The bond rail 6 in the nose/bow of the watercraft is configured to be flat and short. This configuration allows for easy entry of the watercraft into the water, when entering the water bow first. A longer bond rail in the nose/bow of the watercraft would increase the shock/force when entering the water. In an example embodiment, the bottom hull component can be coupled to a top deck component at a set of bond rails, encompassing the internal chassis.

[0036] A primary objective of the various example embodiments is to decrease the weight of the hull, increase the performance, and provide a mounting or coupling structure for which the motor or drivetrain can be mounted as an alternative to mounting directly to the hull or body, which is the current method. Utilization of this chassis allows for a more rigid hull design, and increased structural stability of the hull, as there are no direct mounts into the hull material that would otherwise cause stress fractures or shearing. In addition the chassis allows for a more convenient means of maintenance by allowing for the first time a jetski hull to be independent of the motor, meaning the hull or body can be quickly detached for easy access to the motor. Under the same premise, this also benefits the manufacturing time allowing the factory to assemble a full jetski in less time, with higher accuracy and lower cost, as expensive, hazardous and unforgiving adhesives are now no longer needed. In one embodiment of the various example embodiments, a tubular structure is bent and welded to reflect the internal volume of a personal watercraft hull. The various example embodiments of the chassis described herein give the watercraft rigidity, where needed, increasing the impact resistance and structural strength of the watercraft. The various example embodiments of the chassis described herein make the entire watercraft modular with replacement hulls and decks. The various example embodiments of the chassis described herein provide a modular design utilizing the internal chassis, which provides more ergonomic accessibility to work on the driveline for repairs, and or the assembly of the watercraft.

[0037] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.