MODULAR BOAT CONSTRUCTION
20260116506 ยท 2026-04-30
Inventors
- Bryan Fox (Chicago, IL, US)
- Brad Mitchell (Chicago, IL, US)
- Brian Pruent (Orland Park, IL, US)
- Daniel Daugherty (Chicago, IL, US)
- Dan Nikonchik (Chicago, IL, US)
- Glen Theusch (Hainesville, IL, US)
- James Rucker (Chicago, IL, US)
- Jason Wiegand (Chicago, IL, US)
- Jeffrey Roesmann (Chicago, IL, US)
- Samuel Thetard (Chicago, IL, US)
- Stacy Snyder (Chicago, IL, US)
- Albion Wisler (Chicago, IL, US)
Cpc classification
B63B29/025
PERFORMING OPERATIONS; TRANSPORTING
B63B35/38
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A modular system for the construction of pontoon boats includes a plurality of molded components that are assembled on the upper second surface to define the living space of the pontoon boat, wherein the molded components are secured to the upper surface of the pontoon boat. The plurality of molded components includes a roto core corner seating member, a roto core long side seating member, a roto core short side seating member, and a roto core helm member.
Claims
1. A modular system for construction of boats, the boats comprising a platform including a lower first surface and an upper second surface upon which the modular system is mounted, the modular system comprising: a plurality of molded components that are assembled on the upper second surface to define a living space of the boat, wherein the molded components are secured to the upper second surface; the plurality of molded components includes a corner seating member, a long side seating member, a short side seating member, and a helm member.
2. The modular system according to claim 1, wherein the plurality of molded components includes panels.
3. The modular system according to claim 1, wherein the corner seating member, the long side seating member, the short side seating member, and the helm member are covered by pads that provide comfortable surfaces for seating, back rests, and armrests.
4. The modular system according to claim 3, wherein the modular system also includes base pads for attachment to either the corner seating member, the long side seating member, or the short side seating member.
5. The modular system according to claim 4, wherein the modular system includes top pads for attachment as a back support to either the corner seating member, the long side seating member, or the short side seating member.
6. The modular system according to claim 1, further including a first decorative exterior panel and a second decorative exterior panel that may be secured to any of either the corner seating member, the long side seating member, the short side seating member, or the helm member.
7. The modular system according to claim 6, wherein the first decorative exterior panel is a thermoformed exterior panel.
8. The modular system according to claim 7, wherein the second decorative exterior panel is an extruded aluminum panel.
9. The modular system according to claim 6, wherein the second decorative exterior panel is an extruded aluminum panel.
10. The modular system according to claim 9, wherein the second decorative exterior panel includes snap edge members shaped and dimensioned to engage snap surfaces along the corner seating member, the long side seating member, the short side seating member, and the helm member.
11. The modular system according to claim 1, wherein each of the corner seating member, the long side seating member, the short side seating member, and the helm member are manufactured via rotational molding.
12. The modular system according to claim 11, wherein each of the corner seating member, the long side seating member, the short side seating member, and the helm member include kiss off joints or fusion joints to enhance strength.
13. The modular system according to claim 11, wherein the plurality of molded components includes panels.
14. The modular system according to claim 11, wherein the corner seating member, the long side seating member, the short side seating member, and the helm member are covered by pads that provide comfortable surfaces for seating, back rests, and armrests.
15. The modular system according to claim 14, wherein the modular system also includes base pads for attachment to either the corner seating member, the long side seating member, or the short side seating member.
16. The modular system according to claim 15, wherein the modular system includes top pads for attachment as a back support to either the corner seating member, the long side seating member, or the short side seating member.
17. The modular system according to claim 11, further including a first decorative exterior panel and a second decorative exterior panel that may be secured to any of either the corner seating member, the long side seating member, the short side seating member, or the helm member.
18. The modular system according to claim 17, wherein the first decorative exterior panel is a thermoformed exterior panel.
19. The modular system according to claim 18, wherein the second decorative exterior panel is an extruded aluminum panel.
20. The modular system according to claim 1, wherein the boat is a pontoon boat.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0026] Aspects of the present disclosure are illustrated by way of example and are not limited by the accompanying figures with like reference numbers indicating like elements.
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DETAILED DESCRIPTION OF THE INVENTION
[0041] As will be appreciated by one skilled in the art, aspects of the present disclosure may be illustrated and described herein in any of a number of patentable classes or contexts including any new and useful process, machine, manufacture, or composition of matter, or any new and useful improvement thereof.
[0042] With reference to the various figures, a modular system 100 is disclosed for the construction of pontoon boats 10.
[0043] As shown with reference to
[0044] Referring to
[0045] In accordance with such a disclosed embodiment, each of the first (or port) side pontoon 12 and second (or starboard) side pontoon 14 includes a plurality of risers (not shown) attached to upper portions thereof. The first and second pontoons 12, 14 are interconnected by a plurality of cross members (not shown). The first and second pontoons 12, 14 also are interconnected by a rear platform 20 and by a forward platform 22 connected to corresponding ones of the risers 16. While a rear platform and forward platform are disclosed in accordance with an embodiment of the present boat, it is appreciated that multiple build types are known in the construction of pontoon boats and the construction of the underlying pontoon boats used in conjunction herewith may be varied as desired by manufacturers without departing from the spirit of the present invention. While the term platform is used herein to describe the upper supporting surface of boat, it is appreciated terms such as frame, deck, horizontal surface, etc. are known to be used in the art.
[0046] Each of the rear platform 20 and the forward platform 22 includes a lower first surface 20a, 22a facing the pontoons 12, 14 and an upper second surface 20b, 22b upon which the modular system 100 of the present invention is mounted so as to define the living space of the resulting pontoon boat 10.
[0047] Referring in particular to
[0048] Briefly, and as will be discussed below in more detail, the modular system 100 includes a roto core corner seating member 200, a roto core long side seating member 300, a roto core short side seating member 400, and a roto core helm member 500. The modular system 100 also includes panels 900.
[0049] The surfaces of the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500 are covered by various pads that provide comfortable surfaces for seating, back rests, and armrests. For example, the modular system 100 also includes base pads 610 for attachment to either the roto core corner seating member 200, the roto core long side seating member 300, or the roto core short side seating member 400 in a manner discussed below in greater detail. In addition, the modular system 100 includes top pads 620 for attachment as a back support to either the roto core corner seating member 200, the roto core long side seating member 300, or the roto core short side seating member 400. The base pads 610 and top pads 620 may be constructed in various ways (e.g., upholstered foam, molded plastic, etc.) with the intent of providing a comfortable surface for those using the boat. While
[0050] Further still, aesthetics are improved by the provision of a first decorative exterior panel 700 and a second decorative exterior panel 800 that may be secured to any of either the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, or the roto core helm member 500. In accordance with a disclosed embodiment, the first decorative exterior panel 700 is a thermoformed exterior panel and the second decorative exterior panel 800 is an extruded aluminum panel. It is, however, appreciated that the first decorative exterior panel 700 and the second decorative exterior panel 800 may be made from various materials and using various manufacturing techniques, and may include various colors and textures.
[0051] Each of the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500 are manufactured via rotational molding. As those skilled in the art will appreciate, rotational molding utilizes a hollow mold that is filled with powdered plastic resin. The mold is rotated in a bi-axial manner while positioned within an oven. As the mold rotates within the oven, the resin melts and coats the walls of the mold. Once all of the resin has been melted and integrated into the walls of the mold, the mold is cooled until the resin hardens into the desired shape. Kiss off joints, or fusion joints, (which are discussed below in greater detail) are created during the rotational molding process using techniques well known to those skilled in the art. The utilization of kiss off joints enhances the strength of the various components.
[0052] Considering now the details of the roto core corner member 200 as disclosed with reference to
[0053] When viewed from above, the roto core corner seating member 200 exhibits an L-shaped configuration and includes a vertical back support member 202 (which may be provided with openings to reduce weight and enhance access for wiring and other assembly issues), a horizontal seat member 204 (which may be provided with a central opening to reduce weight, enhance access for wiring and other assembly issues, and provide for storage within the roto core corner seating member 200), a substantially vertical toe kick member 206, a horizontal base member 208, an exterior back wall member 210, and end cap members 212, 214 at the lateral sides of the roto core corner seating member 200. The vertical back support member 202, horizontal seat member 204, substantially vertical toe kick member 206, horizontal base member 208, exterior back wall member 210, and end cap members 212, 214 are held together along molded edges connecting members of the roto core corner seating member 200.
[0054] Given the L-shaped configuration of the roto core corner seating member 200, each of the vertical back support member 202, horizontal seat member 204, substantially vertical toe kick member 206, horizontal base member 208, and exterior back wall member 210 have an L-shaped configuration. As such, the vertical back support member 202 includes a first back support member portion 216 and a second back wall member portion 218 that lie in planes that are substantially perpendicular to each other. The horizontal seat member 204 includes a first seat member portion 220 and a second seat member portion 222 that lie in substantially the same plane, but the longitudinal axes of the respective first seat member portion 220 and the second seat member portion 222 are perpendicularly oriented. The substantially vertical toe kick member 206 includes a first toe kick member portion 224 and a second toe kick member portion 226 that lie in planes that are substantially perpendicular to each other. The vertical back support member 202 includes a first back support member portion 228 and a second back support member portion 230 that lie in substantially the same plane, but the longitudinal axes of the respective back support member portion 228 and the second back support member portion 230 are perpendicularly oriented.
[0055] The end cap members 212, 214 include surface details enhancing the assembly process. In particular, each of the end cap members 212 is structured as an exposed surface. The end cap member 214 includes an outwardly extending projection 214p that extends about the entirety of the perimeter of the end cap member 214 with the exception of a break 214b formed adjacent to the horizontal seat member 204. The break 214b allows for the insertion of accessory receivers 110 between adjacent modular components of the system. In accordance with one embodiment, the accessory receivers 110 include an elongated housing 111 with a central slot 112 shaped and dimensioned to receive various accessories, for exam214ple, elongated mounting posts 114 that may be positioned between various seat members.
[0056] As shown in
[0057] Considering now the details of the roto core long side seating member 300 as shown with reference to
[0058] The roto core long side seating member 300 is shaped and dimensioned to function as an elongated bench and each of the vertical back support member 302, horizontal seat member 304, substantially vertical toe kick member 306, horizontal base member 308, and exterior back wall member 310 have an elongated configuration. As such, the vertical back support member 302 includes a first back support member portion 316, the horizontal seat member 304 includes a first seat member portion 318, the substantially vertical toe kick member 306 includes a first toe kick member portion 320, and the exterior back wall member 310 includes a first back wall member portion 322.
[0059] The end cap members 312, 314 include surface details enhancing the assembly process. In particular, each of the end cap members 312, 314 includes an outwardly extending projection 312p, 314p that extends about the entirety of the perimeter of the end cap members 312, 314, with the exception of a break 312b, 314b formed adjacent to the horizontal seat member 304. The break 312b, 314b allows for the insertion of accessory receivers 110 between adjacent modular components of the system.
[0060] As shown in
[0061] As to the roto core short side seating member 400 disclosed with reference to
[0062] The roto core short side seating member 400 is shaped and dimensioned to function as an elongated bench and each of the vertical back support member 402, horizontal seat member 404, substantially vertical toe kick member 406, horizontal base member 408, and exterior back wall member 410 have an elongated configuration. As such, the vertical back support member 402 includes a first back support member portion 416, the horizontal seat member 404 includes a first seat member portion 418, the substantially vertical toe kick member 406 includes a first toe kick member portion 420, and the exterior back wall member 410 includes a first back wall member portion 422.
[0063] The end cap members 412, 414 include surface details enhancing the assembly process. In particular, each of the end cap members 412, 414 includes an outwardly extending projection 412p, 414p that extends about the entirety of the perimeter of the end cap members 412, 414, with the exception of a break 412b, 414b formed adjacent to the horizontal seat member 404. The break 412b, 414b allows for the insertion of accessory receivers 110 between adjacent modular components of the system.
[0064] As shown in
[0065] Finally, and considering the roto core helm member 500 as disclosed with reference to
[0066] The helm assembly 502 includes a vertical back wall member 508, a vertical front wall member 510, a substantially vertical toe kick member 512, a horizontal base member 514, and end cap members 516, 517 at the lateral sides of the helm assembly 502. The vertical back wall member 508, the vertical front wall member 510, the substantially vertical toe kick member 512, the horizontal base member 514, and the end cap members 516, 517 are held together along molded edges connecting members of the helm assembly 502.
[0067] The helm assembly 502 is shaped and dimensioned to function as a boat helm and each of the vertical back wall member 508, the vertical front wall member 510, the substantially vertical toe kick member 512, the horizontal base member 514, and the end cap members 516, 517 have configurations to function as such. Each of the vertical back wall member 508, the substantially vertical toe kick member 512, the horizontal base member 514, and the end cap member 516 are substantially planar members shaped and dimensioned to provide ample support to the front wall member 510 to which the steering assembly, controls, and displays are mounted for engagement by a captain of the boat 10.
[0068] The side wall 506 includes a vertical back wall member 518, a vertical front wall member 520, a horizontal base member 522, and end cap members 524, 526 at the lateral sides of the helm assembly 502. The vertical back wall member 518, the vertical front wall member 520, the horizontal base member 522, and the end cap members 524, 526 are held together along molded edges connecting members of the helm assembly 502.
[0069] The side wall 506 is shaped and dimensioned to function as a boat wall and each of the vertical back wall member 518, the vertical front wall member 520, the horizontal base member 522, and the end cap members 524, 526 have configurations to function as such. Each of the vertical back wall member 518, the vertical front wall member 520, the horizontal base member 522, and the end cap members 524, 526 are substantially planar members shaped and dimensioned to provide ample support.
[0070] In accordance with a disclosed embodiment, the seating assembly 504 includes a horizontal seat member 528, a substantially vertical toe kick member 530, a horizontal base member 532, a back wall member 534, and an end cap member 536 at the lateral side of the seating assembly 504. The horizontal seat member 528, the substantially vertical toe kick member 530, the horizontal base member 532, the back wall member 534, and the end cap member 536 are held together along molded edges connecting members of the seating assembly 504. While such a seat member is provided in accordance with a disclosed embodiment, it is appreciated other seat members (or no seat member) may be integrated into the construction of the seating assembly.
[0071] The seating assembly 504 is shaped and dimensioned to function as an elongated bench and each of the horizontal seat member 528, substantially vertical toe kick member 530, horizontal base member 532, and back wall member 534 have an elongated configuration. As such, the horizontal seat member 528 includes a first seat member portion 538 and the substantially vertical toe kick member 530 includes a first toe kick member portion 540.
[0072] As discussed above, additional molded members are used in completing the modular system 100 of the present invention. For example, the base pad 610 is a generally flat member that is shaped for attachment to either the roto core corner seating member 200, the roto core long side seating member 300, or the roto core short side seating member 400. The base pad 610 includes a horizontal seat member 612, a horizontal base member 614, and a plurality of sidewalls 616a-d extending between the horizontal seat member 612 and the horizontal base member 614.
[0073] The modular system 100 includes a top pad 620 for attachment as a back support to either the roto core corner seating member 200 or the roto core long side seating member 300. The top pad 600 includes a vertical seat member 622, a vertical base member 624, and a plurality of sidewalls 626a-d extending between the vertical seat member and the vertical base member.
[0074] As to the roto core panels 900 disclosed with reference to
[0075] The roto core panels 900 are shaped and dimensioned to function as an elongated wall and/or gate, and each of the vertical interior wall member 902, a horizontal base member 908, an exterior wall member 910, a top wall member 906, and end cap members 912, 914 have an elongated configuration.
[0076] The modular system 100 also includes the first decorative exterior panel 700 and the second decorative exterior panel 800. The first decorative exterior panel 700 is adapted for positioning at various aesthetically desirable locations on the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. As such, the first decorative exterior panel 700 includes an inner surface 702 adapted for secure coupling with an exterior surface of either the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. In accordance with a disclosed embodiment, the first decorative exterior panel 700 includes snap edge members 706 shaped and dimensioned to engage snap surfaces along the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. While snap connections are disclosed herein, the first second decorative exterior panel may be secured using a variety of techniques and structures known to those skill in the art.
[0077] The first decorative exterior panel 700 also includes an outer surface 704 providing an aesthetically desirable surface along the boat. The first decorative exterior panel 700 may be formed from a variety of materials and may be manufactured using a variety of forming techniques.
[0078] The second decorative exterior panel 800 is also adapted for positioning at various aesthetically desirable locations on the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. As such, the second decorative exterior panel 800 includes an inner surface 802 adapted for secure coupling with an exterior surface of either the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. In accordance with a disclosed embodiment, the second decorative exterior panel 800 includes snap edge members 806 shaped and dimensioned to engage snap surfaces along the roto core corner seating member 200, the roto core long side seating member 300, the roto core short side seating member 400, and the roto core helm member 500. While snap connections are disclosed herein, the second decorative exterior panel may be secured using a variety of techniques and structures known to those skill in the art.
[0079] The second decorative exterior panel 800 also includes an outer surface 804 providing an aesthetically desirable surface along the boat. The second decorative exterior panel 800 is preferably extruded aluminum, although it is appreciated it may be formed from a variety of materials and may be manufactured using a variety of forming techniques.
[0080] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms a, an, and the are intended to comprise the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0081] The corresponding structures, materials, acts, and equivalents of means or step plus function elements in the claims below are intended to comprise any disclosed structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. For example, this disclosure comprises possible combinations of the various elements and features disclosed herein, and the particular elements and features presented in the claims and disclosed above may be combined with each other in other ways within the scope of the application, such that the application should be recognized as also directed to other embodiments comprising other possible combinations. The aspects of the disclosure herein were chosen and described in order to best explain the principles of the disclosure and the practical application and to enable others of ordinary skill in the art to understand the disclosure with various modifications as are suited to the particular use contemplated.
[0082] While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention.