Abstract:
A modular pontoon boat including a modular deck and modular pontoons is described. The modular deck includes interlocking portions. Each modular pontoon includes interlocking sections having locks and keys. The modular pontoon boat enables the length of the boat to be selected at the time of assembly, rather than fabrication.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates generally to pontoon boats and, more particularly, to modular pontoon boats.  
           [0002]    Typical pontoon boats include two pontoons having a fixed length. That is, once the pontoon is fabricated, the pontoon length cannot be altered. A deck which extends over the pontoons also has a fixed length. Due to consumer preferences, a variety of pontoon boats having different lengths are fabricated and sold. A pontoon boat fabricator therefore must have a variety of molds and also must build, for inventory, many different length pontoons and decks. In addition to the costs associated with maintaining an inventory of different length pontoons and decks, a large work area is required to assemble the boats due to the length of the pontoons and decks.  
           [0003]    It would be desirable to provide pontoons and decks which can have lengths selected at the time of assembly rather than fabrication. It also would be desirable to provide pontoon boats which can be quickly and easily assembled in a small area.  
         BRIEF SUMMARY OF THE INVENTION  
         [0004]    These and other objects may be attained by pontoon boats including modular pontoons and modular decks assembled from pontoon sections and deck sections that form pontoons and decks of selected lengths. More particularly, and in an exemplary embodiment, the modular deck includes a bow section, a stern section, and a plurality of center sections. The bow, stern and center sections are interconnected by a flange and groove arrangement. The length of the deck can be altered by varying the number of center, or intermediate, sections.  
           [0005]    The modular pontoons also include a bow section, a stern section, and a plurality of center, or intermediate, sections interconnected by a lock and a key arrangement. As with the deck, the pontoon length can be altered by varying the number of center sections.  
           [0006]    During assembly, a pontoon bow section is connected to a pontoon center section by positioning the pontoon center section lock over the pontoon bow section key. The pontoon center section is lowered so that the bow section key fits into the center section lock. Another pontoon is assembled in a similar manner. A deck bow section is then connected to the pontoon bow sections and center sections by locating the deck bow section over the pontoon sections. The deck bow section is lowered so that flanges of the pontoon sections extend into a saddle area formed in a bottom of the deck bow section. The pontoon sections are then secured to the deck bow section.  
           [0007]    A pontoon center section is added to the assembled portion of each pontoon by fitting the lock of the center section onto the key of the adjacent assembled pontoon sections. The deck center section is located over the pontoon center sections and a flange of the deck center section is positioned within a groove of the adjacent assembled deck section. The deck center section is lowered so that flanges of the pontoon sections extend into a saddle area formed in a bottom of the deck center section. The deck center section is then secured to the pontoon sections. The deck center section is also secured to the adjacent assembled deck section.  
           [0008]    Additional pontoon center sections and deck center sections are added to the assembled portion of the pontoons and deck until the assembled portion reaches a selected length. A pontoon stern section is then positioned onto the assembled portion of each pontoon and a deck stern section is positioned onto the pontoon portions. The deck stern section is secured to the adjacent deck center section and to the pontoon stern sections.  
           [0009]    The modular deck sections and the modular pontoon sections enable a boat dealer and others, to assemble pontoons and decks of various lengths selected at the time of assembly, rather than requiring that pontoons and decks of fixed lengths be stored in inventory. In addition, the pontoons and decks can be easily and quickly assembled.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a partially exploded view of a modular deck and a modular pontoon for a modular pontoon boat.  
         [0011]    [0011]FIG. 2 is a bottom perspective view of a deck bow section of the modular deck shown in FIG. 1.  
         [0012]    [0012]FIG. 3 is a top view of the deck bow section shown in FIG. 2.  
         [0013]    [0013]FIG. 4 is a top view of a stern section of the modular deck shown in FIG. 1.  
         [0014]    [0014]FIG. 5 is a side view of a stern section of the modular pontoon shown in FIG. 1.  
         [0015]    [0015]FIG. 6 is an end view of a center section of the modular pontoon shown in FIG. 1.  
         [0016]    [0016]FIG. 7 is a side view of a portion of the modular deck shown in FIG. 1 being assembled.  
         [0017]    [0017]FIG. 8 is a top view of an assembly track.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]    [0018]FIG. 1 illustrates a partially exploded view of a modular pontoon boat  10  including a modular deck  12  and a plurality of modular pontoons  14 . Modular deck  12  includes a top  16  and a bottom  18  which extend from a port side  20  to a starboard side (not shown in FIG. 1) of boat  10 . Modular deck  12  further includes a bow section  22 , a plurality of deck center sections  24 , and a stern section (not shown in FIG. 1).  
         [0019]    Modular pontoon  14  includes a bow section  26 , a plurality of pontoon center sections  28 , and a stern section (not shown in FIG. 1). Modular pontoon  14  further includes a top  30  and a bottom  32 . Top  30  of pontoon bow section  26  includes a first flange  34 . In addition, top  30  of pontoon center sections  28  and the pontoon stern section each include a second flange  36  and a third flange  38 .  
         [0020]    Top  16  of deck bow section  22  and deck center sections  24  each include an interlock portion  40 . Bottom  18  of deck center sections  24  and the deck stern section each include an interlock portion  42 . Top interlock portion  40  includes a groove  44  adjacent a flange  46  on top  16  of deck bow section  22  and deck center sections  24 . Bottom interlock portion  42  includes a flange  48  adjacent a groove  50  on bottom  18  of deck center sections  24  and the deck stern section. Each bottom interlock portion  42  is configured to engage a respective top interlock portion  40 .  
         [0021]    A plurality of interlock openings  52  extend through bottom interlock portion  42  in deck center sections  24  and the deck stern section. A plurality of fasteners (not shown) extend through openings  52  and secure interlock bottom portion  42  to interlock top portion  40  as described below in greater detail.  
         [0022]    Deck bottom  18  includes saddle openings  54  which extend through a first saddle area  56  and a second saddle area (not shown in FIG. 1). Two pontoon openings  58  extend through each of first flange  34 , second flange  36 , and third flange  38 . In one embodiment, flanges  34 ,  36  and  38  include one, three, or more pontoon openings. Pontoon openings  58  align with saddle openings  54  when pontoon sections  26  and  28  engage deck bottom  18 . Pontoon openings  58  and saddle openings  54  are circular openings. In an alternative embodiment, pontoon openings  58  and saddle openings  54  are oval or elliptical, depending on the fastener utilized therewith.  
         [0023]    Pontoon bow section  26  and pontoon center sections  28  each include a key  60  formed on a ledge  61  extending from a bottom  32  of an aft portion of pontoon sections  26  and  28 . Pontoon center sections  28  and the pontoon stern section each include a lock  62  formed in a forward portion of center sections  28  and the stern section. Pontoon center sections  28  and the pontoon stern section also each include a notch  63  on bottom  32  of the forward portion. Each ledge  61  and key engage a respective notch  63  and lock  62 , respectively, when modular pontoon  14  is assembled, as described below in greater detail.  
         [0024]    Pontoon key  60  includes a wedge shaped protrusion having a base  64  and a top  66 . Base  64  includes a length  68  and a width  70  and top  66  includes a length  72  and a width  74 . Width  70  and length  68  of base  64  are larger than width  74  and length  72  of top  66 . Pontoon key  60  extends from pontoon ledge  61  towards pontoon top  30 . Pontoon lock  62  includes a wedge shaped opening having a base  76  and a top  78 . Lock base  76  includes a length  80  and a width  82  and lock top  78  includes a length  84  and a width  86 . Length  80  and width  82  of lock base  76  are larger than length  84  and width  86  of lock top  78 . Pontoon lock  62  diminishes in size as lock  62  extends from notch  63  towards top  30 .  
         [0025]    In an alternative embodiment, pontoon key  60  has other shapes that permit pontoon key  60  to fit within pontoon lock  62  and lock adjacent pontoon sections in a fore and aft direction. In addition, pontoon key  60  is shaped to locate vertically within pontoon lock  62 .  
         [0026]    Pontoon center sections  28  and the pontoon stern section further include a channel  88 . Channel  88  separates second pontoon flange  36  from third pontoon flange  38 .  
         [0027]    Modular pontoon  14  is assembled by positioning pontoon center section lock  62  over pontoon bow section key  60 . Pontoon center section  28  is lowered so that key  60  fits into lock  62  and ledge  61  fits within notch  63 . A second pontoon is assembled in a similar manner. Deck bow section  22  is then located above pontoon bow sections  26  and center sections  28 . Deck bow section  22  is lowered so that flanges  34  and  36  of pontoon sections  26  and  28 , respectively, extend into saddle area  56  of deck bow section  22 . Pontoon sections  26  and  28  are then secured to the deck bow section  22  with a pair of bolts  90  (only one bolt  90  is shown) and a pair of nuts  92  (only one nut  92  is shown).  
         [0028]    Pontoon center sections  28  are connected to the assembled portion of each pontoon  14  by fitting lock  62  of center section  28  onto key  60  of an adjacent center section  28 . Deck center section  24  is located over pontoon center sections  28  and flange  48  of deck center section  24  is positioned within groove  44  of deck bow section  22 . Deck center section  24  is lowered so that adjacent flanges  38  and  36  of pontoon sections  28  extend into saddle area  56  in bottom  18  of deck center section  24  Deck center section  24  is then secured to pontoon sections  28  with bolts  90  and nuts  92 . Deck center section  24  is also secured to deck bow section  22  with a plurality of fasteners (not shown). The fasteners extend through openings  52  in deck center section  24  and into a plurality of openings (not shown) in deck bow section  22 . Additional pontoon center sections  28  and deck center sections  24  are added to the assembled portion of pontoons  14  and deck  12  until the assembled portion reaches a selected length. A pontoon stern section (not shown in FIG. 1) is then positioned onto the assembled portion of each pontoon and a deck stern section (not shown in FIG. 1) is positioned onto the pontoon stern portions. The deck stern section is secured to adjacent deck center section  24  with fasteners (not shown). The deck stern section is secured to the pontoon stern sections with bolts  90  and nuts  92 .  
         [0029]    [0029]FIG. 2 illustrates a bottom view of deck bow section  22  including a starboard side  94  and a bow  96 . Bow  96  is located between port side  20  and starboard side  94 . Deck bottom  18  of bow section  22  includes first saddle area  56  on port side  20  and a second saddle area  98  on starboard side  94 . Saddle areas  56  and  98  each include four saddle openings  54 . In an alternative embodiment, saddle areas  56  and  98  each include two, six, or more saddle openings. Saddle openings  54  are arranged in pairs such that a single bolt  90  (shown in FIG. 1) can extend through two saddle openings  54 .  
         [0030]    Deck bow section  22  is attached to a first pontoon bow section  26  (shown in FIG. 1) and center section  28  (shown in FIG. 1) by inserting pontoon flanges  34  and  36  into first saddle area  56 . Deck bow section  22  is also attached to a second pontoon bow section  26  and center section  28  by inserting pontoon flanges  34  and  36  into second saddle area  98 . Pontoon openings  58  are aligned with saddle openings  54  as flanges  34  and  36  are inserted into saddle areas  56  and  98 . Bolts  90  and nuts  92  (shown in FIG. 1) secure deck bow section  22  to pontoon bow sections  26  and center sections  28 .  
         [0031]    [0031]FIG. 3 illustrates top  16  of deck bow section  22  further including a plurality of top interlock openings  100  which extend through top interlock portion  40  at groove  44 . Top interlock openings  100  are circular openings which align with bottom interlock openings  52  (shown in FIG. 1) when top interlock portion  40  engages bottom interlock portion  42  (shown in FIG. 1). In an alternative embodiment, top interlock openings  100  can be any shape such as square, oval, or elliptical. Groove  44  and flange  46  form top interlock portion  40  which extends from port side  20  to starboard side  94  in deck top  16 . Fasteners (not shown) extend through openings  52  and  100  to secure deck bow section  22  to center section  24  (shown in FIG. 1).  
         [0032]    In an alternate embodiment, the top interlock openings extend partially through top interlock portion  40 . Fasteners then extend through openings  52  and into the top interlock openings to secure deck bow section  22  to center section  24 .  
         [0033]    [0033]FIG. 4 illustrates a deck stern section  150  including top  16 , a front  152 , and a back  154 . A notch  156  extends from back  154  towards front  152 , and includes a first side  158 , a second side  160 , and a notch front  162 . Sides  158  and  160  are angled from back  154  to notch front  162  and notch  156  is larger at back  154  than at notch front  162 . Notch  156  receives a motor mount (not shown) and a motor (not shown) as is well known in the art.  
         [0034]    Groove  50  and flange  48  form bottom interlock portion  42  which extends from port side  20  to starboard side  94  of deck bottom  18 . Bottom interlock portion  42  includes bottom interlock openings  52 , which are circular openings. In an alternative embodiment, bottom interlock openings  52  can be any shape such as square, oval, or elliptical. Bottom interlock openings  52  align with top interlock openings (not shown) in an adjacent deck center section  24  (shown in FIG. 1) when bottom interlock portion  42  engages top interlock portion  40 . Fasteners (not shown) secure deck stern section  150  to center section  24 .  
         [0035]    [0035]FIG. 5 illustrates port side  20  of a pontoon stern section  200  including a ladder  202  extending from pontoon top  30  towards pontoon bottom  32 . Pontoon stern section  200  further includes a forward end  204  and an aft end  206 . Ladder  202  slopes towards aft end  206  as it extends from pontoon top  30  towards pontoon bottom  32 .  
         [0036]    Second flange  36  and third flange  38  of pontoon stern section  200  engage a saddle area (not shown) of deck stern section  150  (shown in FIG. 4) when deck stern section  150  is positioned onto pontoon stern section  200 . Pontoon openings  58  align with saddle openings  54  (shown in FIG. 1) when flanges  36  and  38  engage the saddle area. Pontoon lock  62  engages a pontoon key  60  (shown in FIG. 1) of an adjacent pontoon center section  28  when pontoon stern section  200  is assembled onto pontoon center section  28 . Notch  63  accommodates ledge  61  (shown in FIG. 1) of pontoon center section  28  when lock  62  engages key  60  of center section  28 . Bolts  90  (shown in FIG. 1) and nuts  92  (shown in FIG. 1) are utilized to secure pontoon stern section  200  to deck stern section  150  (shown in FIG. 4) after pontoon stern section  200  is locked onto pontoon center section  28 .  
         [0037]    [0037]FIG. 6 illustrates an alternative embodiment of a pontoon center section  250  including a forward end  252 , a first rubber trim insert  254 , a second rubber trim insert  256 , a first side flange  258  and a second side flange  260 . Pontoon center section  250  also includes a first groove  262  adjacent first side flange  258  and a second groove  264  adjacent second side flange  260 . Pontoon center section  250  further includes a first central flange  266 , a second central flange  268 , and a channel  270  separating flange  266  from flange  268 . Central flanges  266  and  268  each include a pair of openings  272 . In an alternative embodiment, central flanges  266  and  268  each include one, three, or more openings  272 .  
         [0038]    Prior to attaching pontoon center section  250  to pontoon boat  10  (shown in FIG. 1), first rubber trim insert  254  is positioned on first side flange  258  and within first groove  262 , and second rubber trim insert  256  is positioned on second side flange  260  and within second groove  264 . Rubber trim inserts  254  and  256  provide styling to pontoon section  250  and also reduce the amount of water that enters channel  270 . Channel  270  extends along a length of pontoon center section  250  and is utilized to carry wiring and other elements below modular deck  12  (shown in FIG. 1).  
         [0039]    Pontoon center section  250  is attached to deck center section  24  (shown in FIG. 1) by positioning deck center section  24  above pontoon center section  250  and aligning openings  272  with saddle openings  54  (shown in FIG. 1). Deck center section  24  is then lowered onto pontoon center section  250  and fasteners (not shown) are positioned through openings  272  and  54  to secure pontoon center section  250  to deck center section  24 .  
         [0040]    [0040]FIG. 7 illustrates deck bow section  22 , deck center section  24 , and deck stern section  150  being assembled into modular deck  12  (shown in FIG. 1). Deck sections  22  and  24  are assembled by engaging top interlock portion  40  of deck bow section  22  with bottom interlock portion  42  of deck center section  24 . Specifically, flange  46  of bow section  22  is inserted into groove  50  of center section  24  while flange  48  of center section  24  is inserted into groove  44  of bow section  22 . Fasteners (not shown) secure deck bow section  22  to center section  24 .  
         [0041]    Additional deck center sections  24  are attached to deck  12  until a selected length is attained. Deck stern section  150  is then attached to an adjacent deck center section  24  by engaging top interlock portion  40  of deck center section  24  with bottom interlock portion  42  of deck stern section  150 . Fasteners (not shown) secure deck center section  24  to stern section  150 .  
         [0042]    [0042]FIG. 8 illustrates an assembly track  300  for assembling modular pontoon boat  10  (shown in FIG. 1). Assembly track  300  includes a first row of rollers and a second row of rollers  304 . First row  302  is substantially parallel to second row  304 . A first pontoon bow section  26  is positioned on first row  302  and a second pontoon bow section  26  is positioned on second row  304 . A first pontoon center section  28  is locked onto first pontoon bow section  26  as first pontoon center section  28  is placed on first row of rollers  302 . A second pontoon center section  28  is locked onto second pontoon bow section  26  as second pontoon center section  28  is placed on second row of rollers  304 .  
         [0043]    A deck bow section  22  is positioned above assembled pontoon sections  26  and  28 . Deck bow section  22  is lowered onto pontoon sections  26  and  28  so that flanges  34  and  36  of sections  26  and  28  extend into saddle areas  56  and  98  (shown in FIG. 2) of deck bow section  22 .  
         [0044]    Deck bow section  22  is then attached to pontoon sections  26  and  28  by aligning pontoon openings  58  (shown in FIG. 1) with saddle openings  54  (shown in FIG. 1). Nuts  90  (shown in FIG. 1) and bolts  92  (shown in FIG. 1) are utilized to secure deck bow section  22  to pontoon sections  26  and  28 .  
         [0045]    The assembled sections  26 ,  28 , and  22  are then rolled forward on track  300  and a first additional pontoon center section (not shown) is locked onto assembled pontoon center section  28  as the additional pontoon center section is positioned on first row of rollers  302 . A second additional pontoon center section (not shown) is locked onto assembled pontoon center section  28  as the second additional pontoon center section is positioned on second row of rollers  304 .  
         [0046]    A deck center section (not shown) is positioned above assembled pontoon sections  28  and adjacent deck bow section  22 . The deck center section is lowered onto pontoon sections  28  so that the flanges (not shown) of pontoon sections  28  extend into saddle areas (not shown) of the deck center section. The deck center section is then attached to pontoon sections  28  with nuts  90  (shown in FIG. 1) and bolts  92  (shown in FIG. 1).  
         [0047]    Additional pontoon center sections (not shown) and additional deck center sections (not shown) are assembled in a similar manner until a selected length is attained, A pontoon stern section (not shown) is then attached to each assembled pontoon portion and a deck stern section (not shown) is then attached to the assembled pontoon sections.  
         [0048]    In one embodiment, pontoon bow section  26  and the pontoon stern section have a length of about three feet. Pontoon center section  28  has a length of about 2 feet. In addition, deck bow section  22  and the deck stern section have a length of about two to about four feet, and deck center section  24  has a length of about two feet. Modular decks and modular pontoon can thus be fabricated having various lengths. The lengths of both the deck and the pontoons will vary in two feet increments.  
         [0049]    Three pontoon molds, a pontoon bow mold, a pontoon center mold, and a pontoon stern mold, are utilized for the molding of the pontoon sections. Additionally, three deck molds, a deck bow mold, a deck center mold, and a deck stern mold, are utilized for the molding of the deck sections.  
         [0050]    Modular deck  12  and modular pontoon  14  are fabricated by rotational molding utilizing polyethylene. The method for rotational molding the sections includes the step of adding polyethylene pellets to the molds. The molds are then heated to a temperature of about 400° F. for about 20 minutes. Thereafter, the molds are cooled, for example with cooling fans or with water mist. The molded section is then removed from the mold and the method is repeated.  
         [0051]    A modular pontoon boat is fabricated utilizing three deck sections, bow, center, and stern, and three pontoon sections, bow, center, and stern. Boats of various lengths can be fabricated from these sections simply by altering the number of center sections of both the deck and the pontoons. The boat manufacturer can thus reduce fabrication costs by stocking only six sectional components that can be utilized to fabricate virtually any length pontoon boat. In addition, due to the rotational molding of the sections, the pontoon sections can be utilized for storage. In one embodiment, the pontoon stern section is utilized as a fuel tank, and the pontoon bow section is utilized as a fresh water tank.  
         [0052]    From the preceding description of various embodiments of the present invention, it is evident that the objects of the invention are attained. Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is intended by way of illustration and example only and is not to be taken by way of limitation. Accordingly, the spirit and scope of the invention are to be limited only by the terms of the appended claims.