Valve structure, bladder, and hull portion for inflatable boats

A valve structure includes a valve body on which is mounted a first valve and a second valve. The first valve traverses the valve body at a first position and the second valve traverses the valve body at a second position spaced apart from the first position. The first valve may comprise a fill valve and the second valve may comprise a pressure relief valve. Alternatively, a single valve structure may incorporate both the fill and pressure relief functions. The valve structure may be incorporated with a bladder made of a flexible and elastic material. In this arrangement, the valve body is positioned in a valve receiving opening in the bladder material and is sealed to the bladder material around the periphery of the valve receiving opening so as to define a sealed bladder interior with the bladder material. Such a valve and bladder combination may be used together with a hull tube to form a portion of an inflatable hull for a boat.

TECHNICAL FIELD OF THE INVENTION

The invention relates to a valve structure and valve structure/bladder combination for use in inflatable boats such as rigid inflatable boats and inflatable rafts. The invention also encompasses a hull portion or hull for such inflatable boats and rafts.

BACKGROUND OF THE INVENTION

Small boats and rafts have commonly used inflatable elements for buoyancy and for other purposes. Rafts using inflatable elements may include no rigid structure and rely on the inflatable elements to form a desired hull shape. Other boats include both a rigid hull and an inflatable collar commonly positioned around the top of the front and sides of the rigid hull portion. Boats including both a rigid hull portion and an inflatable collar are commonly referred to as rigid inflatable boats (also commonly abbreviated to “RIB boats”).

Prior RIB boats utilize an inflatable collar in which the collar material is required to both contain the gas pressure for inflation, and to provide a tough and durable exterior. A problem with current RIB boat collars is that specialized materials and assembly techniques are required to produce collars that are capable of retaining gas pressure and providing the desired durable exterior surface. Another problem with current RIB boat collars is that a single puncture to the collar material will allow the entire collar to deflate unless air-tight dividers are used within the collar to form separate pressure cells along the length of the collar. Although such dividers do solve the problem of having the entire collar deflate in response to a single puncture, the dividers are difficult to form.

SUMMARY OF THE INVENTION

The present invention provides a valve structure that can be used to form a two-piece inflatable hull portion for an inflatable boat or raft. The invention encompasses the valve structure itself, a bladder formed with the valve structure, and an inflatable hull portion that includes the bladder and an outer hull tube. As used in this disclosure and the accompanying claims, the term “boat” will include both rafts and boats such as RIB boats.

A valve structure embodying principles of the invention includes a valve body on which is mounted a first valve and a second valve. The first valve traverses the valve body at a first position and the second valve traverses the valve body at a second position spaced apart from the first position. In one form of the invention, the first valve is a fill valve and the second valve is a pressure relief valve. In other forms of the invention, a single valve structure may incorporate both the fill and pressure relief functions.

One preferred valve structure includes both a first flange and a second flange extending from the valve body around the periphery of the valve body. The first flange extends generally in a plane transverse to a longitudinal axis of the first valve, and the second flange extends generally parallel to the first flange. The two flanges extend in a spaced apart relationship to define a valve body positioning structure. The valve body and each flange may have a generally oval peripheral shape.

In accordance with one aspect of the invention, the valve structure made up of the valve body and the fill and pressure relief valves is incorporated with a bladder made of a flexible and elastic material. The valve body is positioned in a valve receiving opening in the bladder material and is sealed to the bladder material around the periphery of the valve receiving opening so as to define a sealed bladder interior with the bladder material. The lower or inner flange of the double flange structure may be used to provide an extensive surface for providing a durable seal between the valve structure and bladder material.

A valve and bladder combination according to the present invention may be used together with a hull tube to form a portion of an inflatable hull (an inflatable hull portion) for a boat. The hull tube includes at least a portion made of a readily bendable sheet material, preferably a fiber reinforced plastic material. An access opening is formed at an access location in the flexible hull tube material. The preferred double flange arrangement included in the valve structure may be used to maintain the position of the valve in the access opening.

An inflatable hull portion according to the present invention uses the bladder to receive and retain inflation gas pressure for the hull portion, and uses the hull tube material for providing a tough and durable exterior surface. This allows the hull tube material to be selected without regard to its ability to hold gas pressure. The bladder material may be selected solely for its gas pressure holding properties and for its relatively greater flexibility and elasticity as compared to the hull tube material. Although the flexible bladder must be inserted into the hull tube, the hull tube access opening provides ready access for bladder insertion and also cooperates with the valve structure to retain the valve structure at the desired location to provide easy access to the fill and pressure relief valves or valve.

These and other advantages and features of the invention will be apparent from the following description of the preferred embodiments, considered along with the accompanying drawings.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 through 3show a valve structure100for use in boats having an inflatable hull portion. Valve structure100includes a valve body101, a first valve102traversing the valve body at a first position, and a second valve103traversing the valve body at a second position spaced apart from the first position.

As shown inFIG. 3, valve body101includes a first opening106for receiving first valve102and a second opening107for receiving second valve103. First opening106includes a flange portion108to which first valve102is secured. Second opening107includes a threaded insert109in for receiving second valve103.

The illustrated preferred first valve102is a fill valve (also called a topping valve) that allows air or other gas or fluid to be pumped into a bladder as will be described further below. As shown inFIG. 3, this preferred first valve102includes a top portion111and a bottom portion112. Top portion111includes a threaded section113and top flange114, while bottom portion112includes a corresponding threaded section115and bottom flange116. Valve102further includes a plunger118slidably mounted through an opening120through the valve top portion111. A lower portion of plunger118carries a sealing surface121that is adapted to form a seal against a valve seat surface122on the valve top portion. A spring124biases plunger118upwardly in the drawing to bias sealing surface121against valve seat surface122to form a seal. Valve top portion111threads together with valve bottom portion112to pull top flange114towards bottom flange116with flange portion108there between to secure first valve102to valve body101and form a seal against the valve body material. An o-ring126acting between valve top portion111and valve bottom portion112provides a seal between those two components. The illustrated first valve102operates by providing a seal in the position shown inFIG. 3and by allowing a suitable gas to pass through openings in the valve top portion111when plunger118is displaced downwardly in the drawing to unseat sealing surface121from valve seat surface122.

The illustrated preferred second valve103is a pressure relief valve that allows fluid to escape from the bladder once a certain fluid pressure is achieved in the bladder. As also shown inFIG. 3, this preferred second valve103includes a housing130with an opening there through in which is mounted a plunger131. Plunger131carries a sealing element132which is adapted to seat against a valve seat133formed on housing130. A spring134biases plunger131downwardly inFIG. 3to pull sealing element132into contact with valve seat133. Plunger131also includes an actuating surface135that causes sealing element132to unseat from valve seat133once a certain pressure is applied to the actuating surface to overcome the force of spring134. Housing130includes a threaded section137that threads into the correspondingly threaded insert109in second valve body opening107.

The specific valves shown inFIG. 3for valves102and103are merely preferred forms and any other suitable form may be used in a valve structure according to the present invention. For example, both valves102and103may be molded with the material forming valve body101, thus obviating the top and bottom structure of the illustrated valve102and the threading associated with valve103, as well as the flange portion108and threaded insert109. In one preferred form of the invention, a fill valve used in place of valve102includes a one-piece body with an outer thread by which the valve may be secured to valve body101. This alternate preferred fill valve requires a threaded insert molded into the valve body for receiving the threaded fill valve, similar to threaded insert109used in the illustrated form of the invention for attaching valve103to valve body101. In any case, the various valve components included in valves102and103may be made form any suitable material including preferably hard plastics or corrosion resistant metals. The valves may also include many other features not apparent from the present figures. For example, a fill valve such as valve102preferably includes a locking mechanism that allows the valve to be locked in an open position. Locking the valve in the open position facilitates deflating or draining a bladder in which the valve body is secured as will be described below.

As shown best inFIG. 3but also somewhat inFIGS. 1 and 2, valve structure100further includes a first flange140and a second flange141. First flange140extends from valve body101around the periphery of the valve body. First flange140also extends generally in a plane transverse to a longitudinal axis A1of first valve102and a longitudinal axis A2of second valve103. Second flange141extends from valve body101around the periphery of the valve body, generally parallel to first flange140and spaced apart from the first flange to define a valve body positioning structure or groove142between the two flanges140and141.

The illustrated preferred valve body101has a generally oval peripheral shape in a plane generally parallel to first flange140. The illustrated first flange140and second flange141also each have a generally oval peripheral shape. Other preferred forms of the valve structure according to the present invention may include a circular peripheral shape or a polygonal peripheral shape rather than the illustrated oval shape. Also, the peripheral shape of the flanges140and141need not correspond to the peripheral shape of valve body101, or to each other.

Valve body101and flanges140and141are preferably molded in one piece from a suitable rubber or plastic material such as a suitable Neoprene compound or fiber reinforced Neoprene. Also, as mentioned above, some preferred forms of the invention may include valves102and103integrally formed with the valve body101.

FIG. 4shows an inflatable bladder400according to the invention for use in boats having an inflatable hull portion. As shown inFIG. 4, bladder400includes a bladder portion or bladder material401and a valve structure such as valve structure100shown inFIGS. 1 through 3. The manner in which the illustrated valve structure100attaches to bladder material401is shown particularly inFIG. 5. As best indicated inFIG. 5, bladder material401is made of a flexible sheet material and includes a valve receiving opening500(shown only inFIG. 5) at a valve location. In particular, valve receiving opening500is defined by bladder material edges501shown inFIG. 5. Valve structure100has a portion traversing valve receiving opening500as shown best inFIG. 5and is sealed to the bladder material401around the periphery of the valve receiving opening so as to define a sealed bladder interior with the bladder material. This sealed bladder interior is indicated generally at504inFIG. 5. Bladder400according to the present invention also includes first valve102traversing valve body101at a first position within the area defined by valve receiving opening500and second valve103traversing valve body101at a second position within the area defined by the valve receiving opening500.

As best shown inFIG. 5, bladder material edges501are sealed to an inner surface505of first flange140. A backing material506is attached to the an outer surface507of first flange140and is also attached to the bladder material401around the bladder material edges501. Any suitable adhesive or welding technique may be used to form the desired seal between bladder material401and valve structure100.

Bladder material401preferably comprises a sheet of material such as a thin polyester film having opposite edged rolled up to a point at which the two edges of the sheet overlap and may be sealed together with adhesive or a suitable material welding technique to form a tube shape. Outwardly convex end sections of the bladder material or perhaps a different material may then be secured by adhesive or by a suitable welding technique to the ends of the tube formed sheet material to form generally an enclosure, open only at the valve receiving opening500.

It will be appreciated that the sheet material401used to form bladder400is preferably quite flexible or bendable in directions transverse to the plane of the sheet material and preferably does not have sufficient rigidity to stand on its own in the cylindrical shape or convex shapes described in the preceding paragraph. Thus, the bladder400collapses to the shape shown inFIG. 4when deflated. However, when the bladder is filled with fluid under a sufficient pressure through valve102in valve body101, the bladder will naturally take on a cylindrical shape with outwardly convex ends.

FIGS. 6 through 9may be used to describe one preferred form of an inflatable hull portion for a boat according to the present invention. The inflatable hull portion includes a hull tube601shown particularly inFIGS. 6 and 7. At least a portion of hull tube601is made of a sheet material that is readily bendable, that is, bendable in directions transverse to the plane of the sheet material. Hull tube601includes an access opening602formed at an access location in the material making up the hull tube. By “readily bendable” it is meant that the hull tube material does not have sufficient rigidity to retain its shape without being held in position by some structure separate from the sheet material. The hull tube shapes shown particularly inFIGS. 6 and 7show the shape as if it was being so supported. It will be appreciated that without support, the readily bendable hull tube material will collapse generally to the shape of the collapsed bladder shown inFIG. 4.

The sheet material used to form hull tube601may be pieced together in any suitable fashion. In one preferred form of the invention, rectangular sheets of readily bendable hull tube material are secured or seamed together by any suitable technique to form the desired tube shape. Suitable bendable hull tube material includes fabric reinforced plastic or rubber sheeting. For example suitable material includes a polyester fabric coated with polyurethane. It will be noted that the particular materials used for the hull tube sheeting may be selected purely for its strength and resistance to abrasion without regard to whether an airtight enclosure may be formed with the material. This is because unlike prior art RIB boats, the hull tube601is inflated to the desired shape using the airtight inner bladder such as bladder400shown inFIG. 4. In preferred forms of the invention, the bladder used inside hull tube601to inflate the hull tube to the desired shape is made at least partially of a bladder sheet material that is relatively more elastic or stretchable in the plane of the material than the hull tube bendable sheet material. With this relative elasticity between the hull tube material and bladder material, the bladder material may expand within the hull tube601as bladder400is inflated to press against the inner surface of the hull tube material and take up space within the hull tube until the hull tube takes on the desired inflated shape.

As indicated inFIG. 7, bladder400is rolled up lengthwise (rolled parallel to its longitudinal axis) to allow it to be inserted into the interior of hull tube601through hull tube access opening602. Preferably, a suitable lubricant such as soapy water may be applied to the exterior surface of the bladder400to allow the bladder to be inserted through opening602more readily. Once the bladder400is completely inserted through opening602, the end of the bladder nearest the opening is pulled back in interior of hull tube601in the direction opposite to the direction in which the bladder was inserted until the valve body101aligns with hull tube access opening602. At this point, the valve body101may be pulled to the position shown inFIG. 8. In this position shown inFIG. 8and in section inFIG. 9, valve receiving opening500(FIG. 9) is aligned at least partially with the hull tube access opening602. In this position also at least a portion of the valve structure100traverses the hull tube access opening602with at least the fill valve102being accessible from outside the hull tube. Preferably both the fill valve102is accessible from outside the hull tube601and the pressure relief valve103is aligned with the hull tube access opening602so that pressure may be released as desired from bladder400through the hull tube access opening. As best shown inFIG. 9, in the properly inserted position, sections of the hull tube material901surrounding hull tube access opening602are captured in the positioning structure or groove142(labeled only inFIG. 3) defined between flanges140and141of the illustrated preferred valve structure.

It will be noted that in order to insert the bladder400into the interior of hull tube601through hull tube access opening602as described above with reference toFIGS. 8 and 9, the flanges140and141on valve100must be flexible. That is, the material from which flanges140and141are formed must be sufficiently flexible to allow the flanges to be flexed so as to fit through the relatively smaller hull tube access opening602.

An inflatable hull according to the present invention may include only a singe hull tube access opening602and use only a single bladder400. Some preferred forms of the invention, however, include an elongated single hull tube that includes multiple hull tube access openings along its length, each different hull tube access opening receiving a respective bladder400. This multiple hull tube access opening and multiple bladder arrangement is illustrated inFIG. 6. In these multiple bladder arrangements, if one bladder should fail, the remaining bladders provide the desired function around the remainder of the periphery of the inflatable boat. Furthermore, some preferred forms of the invention, include a single continuous hull tube601formed to fit around the entire periphery of the inflatable boat or around a large portion of the periphery such as the bow together with the port and starboard sides. In any case, the multiple bladder embodiments of the invention preferably use the same valve and bladder structure described above and the same bladder insertion technique for each respective bladder.

The position of valve structure100along the length of bladder400may be varied greatly within the scope of the invention. AlthoughFIG. 4shows valve structure100positioned generally midway along the length of bladder400, the valve structure may in fact be positioned anywhere along the length of the bladder, in the middle position shown inFIG. 4, or near either end. Also, there may be some forms of the invention in which valve structure100may be located on the piece of bladder material making up an end of the bladder. Of course, the position of valve structure100on bladder400generally dictates the location of the hull tube access openings602.FIG. 10provides a diagrammatic representation showing the relationship between the respective valve structure100, bladder400, and hull tube access opening602in one preferred form of the invention where the valve structures are positioned in a mid-section of each bladder.FIG. 11provides a diagrammatic representation showing the relationship between the respective valve structure100, bladder400, and hull tube access opening602in an alternate form of the invention in which the valve structure100is located near an end of the respective bladder. It will be noted that with the valve position shown inFIG. 11, the entire valve100need not be inserted through hull tube access opening602to reach the properly installed position. Rather, only the lower or first flange140(FIGS. 3,5, and9) together with the lower portion of valve body101must be inserted through hull tube access opening602. Thus, with the form of the valve100shown inFIGS. 3,5, and9, only the first or lower flange140must be sufficiently flexible to bend so that it may pass through hull tube access opening602and reach the installed, operating position shown inFIGS. 8 and 9. Regardless of the position of the valve structure100in a bladder400according to the present invention, the valve structure performs the function of locating or positioning the bladder with respect to the hull tube.

It should also be noted that since the hull tube601in the present invention is not required to be airtight or watertight, the hull tube need not form a complete cylindrical tube. Rather, a structure for receiving a bladder according to the invention may be formed from a rigid structure along one side with a readily bendable material as described above along the opposite side as shown in the section view ofFIG. 12(with the section taken along a line generally perpendicular to the longitudinal axis of the bladder. In this example, a rigid material1201forms a portion of a hull tube or bladder receiving area and a readily bendable material1202forms the remainder of the circumference of the hull tube/bladder receiving area. A bladder400as described above resides in the area defined by rigid material1201and readily bendable material1202and, when inflated as shown in the figure, causes the readily bendable material to maintain the desired shape. It will be appreciated that the space between the material of bladder400and the material1202inFIG. 12is exaggerated to clearly indicate that the materials are separate. In practice, the material of bladder400would press up against the inner surface of material1202when the bladder is fully inflated.

Some forms of the invention combine the fill and pressure relief functions of the illustrated valves102and103into a common valve structure. When using a hybrid fill valve/pressure relief valve, it will be appreciated that the valve body would require only a single opening and associated structure (such as a threaded insert) for receiving the valve. In forms of the invention utilizing a single valve structure secured in the valve body as opposed to the multiple valve arrangement shown particularly inFIGS. 1 through 3, the valve body still performs the function of providing a surface to which the bladder material may be sealed and also performs the function of positioning the bladder with respect to the hull tube in which the bladder is installed.

As used herein, whether in the above description or the following claims, the terms “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, and the like are to be understood to be open-ended, that is, to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of,” respectively, shall be closed or semi-closed transitional phrases, as set forth, with respect to claims, in the United States Patent Office Manual of Patent Examining Procedures (Eighth Edition, August 2001 as revised May 2004), Section 2111.03.

The above described preferred embodiments are intended to illustrate the principles of the invention, but not to limit the scope of the invention. Various other embodiments and modifications to these preferred embodiments may be made by those skilled in the art without departing from the scope of the following claims. For example, although the illustrated hull tube601includes hull tube access openings602oriented with their long axis extending transverse to the length of the hull tube, the hull tube access openings may be in any other suitable orientation. In particular, a hull tube access opening602may be oriented with its respective long axis aligned with the longitudinal axis of the hull tube.