Abstract:
A marine windshield frame for curved or straight windshield glass having a top frame rail mounted inward of the windshield glass and substantially flush with frontal surface of the windshield glass. The top frame rail is mounted onto the windshield glass edge by adhesive. The windshield frame may also include a pair of vertically oriented corner posts. The corner posts are preferably manufactured by die-cast molding. An alternate manufacturing method is to stretch-form an aluminum alloy extrusion, matching vent holes therein, and machined a taper thereon an edge.

Description:
TECHNICAL FIELD 
   The invention relates to a marine windshield frame and method of manufacture, and more specifically to a narrow adhesive mounted top frame rail, substantially flush with the frontal surface of the windshield glass and may also employ a pair of dramatically tapered corner posts. 
   BACKGROUND OF THE INVENTION 
   Mounting, trimming or finishing the edges of marine windshields has become more complex over the years as the windshield shapes have progressed from simple rectangular panes to complexly gently curved, dramatically curved and obliquely oriented windshields, some of which are segmented and also allowing access to a forward seating area through a windshield hatch. 
   The most common approach currently in use is to employ an extrusion, which is stretch-formed on a die set to the curved shape of the edge of the windshield glass to be mounted. Usually the mounting and edge trimming extrusions are formed from aluminium extrusions and usually have a windshield receiving longitudinally extending channel therein. A gasket, such as a vinyl or thermoplastic gasket, is mounted between the windshield channel in the extrusion and the glass, so as to seal and cushion the windshield edge within the assembly. 
   Typical marine windshield frame extrusions that extend along the top and bottom edge, and sometimes, corners of the windshield, are as set forth in U.S. Pat. Nos. 6,800,160; 6,647,914; 5,601,050; 4,970,946; 3,654,648 and 3,016,548. 
   Accordingly, it is an object of the present invention to provide a windshield frame and method of manufacturing, which is well suited for use as a frame for most boat windshield glass including, curved, semi-curved, straight and corner posted boat windshields. 
   Another object of the present invention is to provide a method of manufacture of a vented corner post allowing different vent hole configurations. 
   Yet another object of the present invention is to provide a method of manufacture of a vented corner post. 
   A further object of the present invention is to provide a vented corner post with added visibility through the vent holes. 
   Still a further object of the present invention is to provide a windshield frame with a significantly tapered shape for improved visibility and aesthetic values. 
   The marine windshield frame and method of manufacture of the present invention has other objects and features of advantage which will become apparent from and are set forth in more detail in, the accompanying drawings and following details. 
   DISCLOSURE OF THE INVENTION 
   The marine windshield frame and method of manufacture of the present invention is designed to be stretch or die formed so as to fit along the frontal area of a boat deck, and comprises briefly, an elongated base member, longitudinally extending along the front and somewhat along the sides of the boat deck and including a windshield mounting rail. The windshield mounting rail includes an elongated windshield glass adhesion area, as described in U.S. patent application Ser. No. 11/155,942. The windshield frame assembly includes a longitudinally extending top windshield edge receiving structural rail, which also includes an elongated windshield glass adhesion area, where this top windshield edge receiving structural rail is affixed to the top rearward edge of the glass so as to be substantially flush with the frontal glass surface. 
   The windshield assembly may also include a pair of corner posts, where the corner posts may include vent holes therein. The vent holes can also be opened or closed from the cockpit, by sliding a cover up or down if desired. The vent cover fits into slots or tracks that run up and down the length of the corner post. The top of the corner post may be covered by a continuous top rail being bent around the top corner area, or by a cap that is screwed to the top of the corner post. 
   When the windshield frame includes a hatch to access the front deck of a boat, a corner connector is used to improve rigidity of the connection of the top windshield frame rail and vertically oriented hatch rail. The connector is made of plastic or other material. The corner connector block includes tabs, where the tabs insert into both the top windshield frame rail and the vertically oriented hatch rail during assembly. 
   The design of the corner post vent holes naturally provides a negative pressure in behind the windshield to vent the cockpit area. If a positive pressure is desired, an air scoop can be provided on the frontal surface of the corner post. This can be in the form of an external air scoop or an integrated hemispherical scoop that can be rotated within a vent hole. 
   The top vent hole on the starboard side is used to mount an optional mirror, where the mirror bracket is attached using a fastener that extends through the vent hole to a bracket that spans the inside of the vent hole. The mirror bracket mounts without any modification to the corner post. 
   The windshield frame rail members are typically made using suitable aluminium alloy extrusions, which are stretch-formed to the desired shape and then cut to length. The corner post can be made of a stretch-formed aluminium extrusion, or die-cast aluminium, or die-cast plastic, such as ABS plastic. The final part can be finished by a coated, using a variety of coatings methods and types for either the metal or plastic parts, adding most any desired aesthetic finish to the part. 
   In another aspect of the present invention, the manufacturing process, where the corner post is made of an aluminium alloy extrusion. The extrusion is then stretch-formed, and trimmed to length. To finished the shape a taper is created on at least one upper edge by machining off material. This trimming process is preferably executed robotically, and is done after the stretch-forming process. Thereby allowing a complex shaped part to be relatively inexpensive for smaller manufacturing runs. 
   It should be noted that the inward shape—towards the cockpit area—of the top rail can change depending on the angle of the windshield glass and the desired appearance, without the need to change the connection area and connection means, as well as the uppermost of the frontal area—towards the windshield glass—of the top rail. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the following detailed description of an illustrative embodiment and accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein; 
       FIG. 1  is a perspective view of the preferred embodiment showing the invention mounted onto a boat deck and having a hatch segment for passage to the front deck area. 
       FIG. 2  is a perspective view of an alternate windshield assembly having vented corner post, showing the invention mounted onto a boat deck. 
       FIG. 3  is a segmented cross-sectional view of the top rail of the windshield frame taken along line A from  FIG. 1  and as taken along line B from  FIG. 2 . 
       FIG. 3   a  is a segmented cross-sectional view of an alternate top rail of the windshield frame taken along line A from  FIG. 1  and as taken along line B from  FIG. 2 . 
       FIG. 4  is a segmented cross-sectional view of an alternate top rail of the windshield frame taken along line C from  FIG. 2 . 
       FIG. 5  is a segmented perspective view as viewed from above the cockpit area showing a continuous top rail. 
       FIG. 6  is a segmented perspective view as viewed from above the cockpit area showing the top rails and corner post, with a corner post cap in place, and showing the vent cover open. 
       FIG. 7  is a segmented perspective view as viewed from above the cockpit area showing the top rails and corner post, with the corner post cap in place, and showing the vent cover closed. 
       FIG. 8   a  is a segmented perspective view as viewed from above the cockpit area showing the top rails and corner post, with the corner post cap removed. 
       FIG. 8   b  is a perspective view showing the corner post cap, away from attaching frame members. 
       FIG. 9  is a perspective frontal view of a corner post extrusion after stretch-forming and trimming, and before machining. 
       FIG. 10  is a perspective frontal view of a finished corner post with vent holes. 
       FIG. 11  is a cross-sectional view of the corner post extrusion. 
       FIG. 11   a  is a cross-sectional view of an alternate corner post. 
       FIG. 12  is a segmented cross-sectional view of the top rail of the windshield frame taken along line A from  FIG. 1  and as taken along line B from  FIG. 2 , showing an alternate ribbed surface of top frame rail that extends the adhesive contact surface area. 
       FIG. 13  is a perspective frontal view of a windshield assembly showing an air scoop attached rearward of the corner vent holes. 
       FIG. 14  is a perspective frontal view of a windshield assembly showing a mirror attached to the upper corner vent hole and a hemispherical vent is shown attached within the lower corner vent hole. 
       FIG. 15  is a sectional perspective frontal view of the windshield assembly taken from circle F 15  in  FIG. 13  showing a corner connector block attached. 
       FIG. 15   a  is a perspective frontal view showing a corner connector block unattached. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The marine windshield frame is generally referred to as  10  as shown in a perspective view in  FIG. 1 . A boat is shown in partial view where a deck  12  has windshield  10  mounted thereon deck  12 , by means of windshield base frame rail  14 . Windshield  10  is segmented, dramatically curved and swept back along the front sides of a cockpit area  16 . 
   Windshield  10  includes windshield glass  18 , where windshield glass  18  includes peripheral sections  18   a ,  18   b , and  18   c . Windshield section  18   b  is attached to a hatch door  20 , where hatch  20  allows access to the front deck seating area  22 . On top of glass sections  18   a ,  18   b  and  18   c  is longitudinally extending top windshield frame rail  24 . 
   Alternate marine windshield frame as shown in a perspective view in  FIG. 2 , is generally referred to as  110 . A boat is shown in partial view where a deck  112  has windshield  110  mounted thereon. Windshield  110  is segmented, gently curved and swept back along the front sides of a cockpit area  116 . 
   Windshield  110  as shown in  FIG. 2 , where windshield glass  118  includes peripheral sections  118   a ,  118   b ,  118   c ,  118   d  and  118   e . Windshield section  118   c  is attached to hatch door  120 , where windshield section  118   c  and hatch door  120  allows access to the front deck seating area  122 . On top of glass sections  118   b ,  118   c ,  118   d  and  118   e  is longitudinally extending top windshield frame rail  124 . 
   As shown in  FIG. 3  a partial cross-sectional view taken along line A from  FIG. 1 , and also an identical section as taken along line B from  FIG. 2 , where the elongate top frame rail  24  is shown mounted substantially flush with windshield glass  18 &#39;s exterior surface  19 . The windshield glass  18  is shown adhesively fastened, or glued, where adhesive fastener  25  is shown between top rail  24 &#39;s adhesive application surface  24   a  and windshield glass  18 &#39;s interior surface  26 . Also, a double adhesive strip  25   a  is used where double adhesive strip  25   a  is applied during assemble to control adhesive spread, thereby creating a clean glue edge on the interior surface  26  of windshield glass  18 . 
   Also shown in  FIG. 3  is a pliable strip  28 , where strip  28  is attached to form a clean transition of upper glass edge  29  with the top rail  24 , therefore creating a substantial flush seam between the front exterior surface  19  of windshield glass  18  and the upper surface  24   b  of top rail  24 . 
   As shown in  FIG. 3   a  the top rail  24  includes a lip  24   c , where lip  24   c  creates a substantial flush seam between the front exterior surface  19  of windshield glass  18  and the upper surface  24   b  of top rail  24 . 
   Also, as best viewed in  FIG. 2 , alternate windshield frame  110  includes a pair of vertically oriented corner posts  132   a  and  132   b , where corner posts  132   a  and  132   b  mate with base frame rail  114  and top frame rail  124 . 
   As shown in  FIG. 4  a partial cross-sectional view taken along line C from  FIG. 2  of windshield frame  110 , where an alternate rearward top frame rail  130  is utilized to reduce protrusion of top rail inner edge  130   b  towards cockpit area  116 , on the lesser sloped peripheral rearward windshield sections  118   a.    
   As shown in  FIG. 5  a partial perspective view of windshield frame  110  as viewed from just above the cockpit area  116 , showing a continuous top rail  124 . 
   As shown in  FIG. 6  a partial perspective view of windshield frame  110  as viewed from just above the cockpit area  116 , where right-hand corner post  132   a , mates with base frame rail  114 , top frame rail  124  and alternate rearward top frame rail  130 . Corner post is shown having vent holes  134  and vent hole cover  138 , where vent hole cover  138  includes vent hole cover handle  138   a . In this view vent cover  138  is in the open position. 
   As shown in  FIG. 7  a partial perspective view of windshield frame similar to  FIG. 5 , where in this view vent hole cover  138  is in the closed position. 
   As shown in  FIG. 8   a , a partial perspective view of windshield frame  110  as viewed from just above the cockpit area  116 , right-hand corner post  132   a  is shown with corner cap  136  removed. As shown in  FIG. 8   b , cap  136  is shown away from corner post  132   a . Corner post cap  136  may include alignment pins  136   a  and  136   b , to support alignment of cap  136  with top frame rail  124  and alternate top frame rail  130 . Corner post cap  136  may also screw holes  136   c  and  136   d.    
   As shown in  FIG. 9  in a perspective view, corner post  132   a  is shown after stretch-forming and trimming, and before machining. 
   As shown in  FIG. 10  in a perspective view, corner post  132   a  is shown finished, including with an outward upper edge taper  135 , and with vent holes  134  therein. 
   Shown in  FIG. 11  is a cross-section of corner posts  132   a  and  132   b . Corner posts  132   a  and  132   b  include a pair of screw chases  144   a  and  144   b  and where external area of screw chases  144   a  and  144   b  include slots  146   a  and  146   b , for vertical sliding of vent cover  138 , to open and close vent cover  138 . Corner posts  132   a  and  132   b  also includes a pair of windshield glass receiving slots  148   a  and  148   b , and outward upper edge  135 . 
   In  FIG. 11   a , a cross-sectional view shows an alternate corner post, where no glass receiving slots are required. This is employed when adhesive is used to attach the corner post to the windshield glass. 
   As shown in  FIG. 12  a partial cross-sectional view taken along line A from  FIG. 1 , and also an identical section as taken along line B from  FIG. 2 , where the elongate top frame rail  24  is shown mounted substantially flush with windshield glass  18 &#39;s exterior surface  19 . The windshield glass  18  is shown adhesively fastened, or glued, where adhesive fastener  25  is shown between top rail  24  and windshield glass  18 &#39;s interior surface  26 , and where an alternate ribbed surface  24   a ′ of top frame rail  24  is used to extend the adhesive contact surface area. 
   As shown in  FIG. 13  in a perspective frontal view of a windshield assembly, an air scoop  150  is attached over the corner vent holes. 
   As shown in  FIG. 14  in a perspective frontal view of a windshield assembly, a mirror bracket  152  is attached using the upper vent hole. 
   Also shown in  FIG. 14 , a hemispherical vent  139  is attached within the bottom vent hole, where the vent can be open or closed by rotation of the hemispherical vent  139  to provide a stream of air to the cockpit area. 
   As shown in  FIG. 15  in a segmented perspective frontal view of the windshield assembly taken from circle F 15  in  FIG. 13 , shows a corner connector block  119  attached to the top windshield frame rail and the vertical oriented hatch door rail  121 . 
   As shown in  FIG. 15   a  is a perspective frontal view showing a corner connector block  119  unattached. Corner connector  119  includes tabs  119   a  and  119   b . Where tab  119   a  inserts into top windshield frame rail  118   b  and tab  119   b  inserts into vertically oriented hatch rail  121 . 
   The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. These modifications may include forming the base members separately and reversing male and female members. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. 
   It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.