PONTOON/TRITOON WATERCRAFT WITH COMPOSITE CHASSIS

A watercraft includes: a watercraft body; and a pontoon frame system coupled with the watercraft body, the pontoon frame system including: a plurality of pontoons spaced apart from one another and including a forward end, a rearward end, a first outboard pontoon, and a second outboard pontoon; and a chassis coupled with and at least partially supporting the watercraft body, the chassis supported by and coupling together the plurality of pontoons, the chassis including a composite body coupled with the first outboard pontoon and the second outboard pontoon at the forward end and the rearward end.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to boats using two or more pontoons, and, more particularly, to the chassis of such boats.

2. Description of the Related Art

Certain boats (which can be referred to herein as watercraft) may include two or more pontoons as floatation devices. Boats that use two pontoons are herein referred to as pontoon boats, and boats that use three pontoons are herein referred to as tritoon boats. Pontoons are tubes (which can be referred to as floatation tubes) or hulls that are airtight and hollow so that they are able to float, and they are made of known materials.

Existing pontoon/tritoon watercraft experience problems with their chassis design. More specifically, existing pontoon/tritoon watercraft chassis designs require at least 100 man-hours to construct, suffer from poor tolerances in the construction, and experience excessive twisting of the pontoon frame system under high speed and/or rough water conditions. Such twisting results in weakening of the connective fasteners attached to the flotation tubes and the chassis, as well as of the connections between the chassis, the flooring, the furniture, the helm, the railings, the trim, the motor mounts, and other structures mounted above the chassis. Additionally, such twisting creates an unpleasant ride for the passengers, thus diminishing the ride experience.

Such chassis designs have a plurality of transverse beams coupled with each of the pontoons. Each beam extends transversely across, and thus perpendicular to, the pontoons. The pontoons extend longitudinally running fore to aft. Further, a forward-most transverse beam is attached to the forward end of the pontoons, a rearward-most transverse beam is attached to the rearward end of the pontoons, and a plurality of transverse beams are spaced apart between these forward-most and rearward-most transverse beams.

What is needed in the art is an improved, cost-effective way to mitigate the aforementioned problems associated with pontoon/tritoon watercraft.

SUMMARY OF THE INVENTION

The present invention provides a pontoon/tritoon chassis including a composite structure with various attachment features.

The invention in one form is directed to a pontoon frame system of a watercraft including a watercraft body, the pontoon frame system being coupled with the watercraft body, the pontoon frame system including: a plurality of pontoons spaced apart from one another and including a forward end, a rearward end, a first outboard pontoon, and a second outboard pontoon; and a chassis configured for being coupled with and for at least partially supporting the watercraft body, the chassis supported by and coupling together the plurality of pontoons, the chassis including a composite body coupled with the first outboard pontoon and the second outboard pontoon at the forward end and the rearward end.

The invention in another form is directed to a watercraft including: a watercraft body; and a pontoon frame system coupled with the watercraft body, the pontoon frame system including: a plurality of pontoons spaced apart from one another and including a forward end, a rearward end, a first outboard pontoon, and a second outboard pontoon; and a chassis coupled with and at least partially supporting the watercraft body, the chassis supported by and coupling together the plurality of pontoons, the chassis including a composite body coupled with the first outboard pontoon and the second outboard pontoon at the forward end and the rearward end.

The invention in yet another form is directed to a method of using a watercraft, the method including the steps of: providing that the watercraft includes: a watercraft body; and a pontoon frame system coupled with the watercraft body, the pontoon frame system including: a plurality of pontoons spaced apart from one another and including a forward end, a rearward end, a first outboard pontoon, and a second outboard pontoon; and a chassis coupled with and at least partially supporting the watercraft body, the chassis supported by and coupling together the plurality of pontoons, the chassis including a composite body coupled with the first outboard pontoon and the second outboard pontoon at the forward end and the rearward end; and floating the watercraft.

An advantage of the present invention is that it provides for making a pontoon/tritoon watercraft chassis with considerably lower cost and ease of build.

An advantage of the present invention is that it provides a pontoon/tritoon watercraft chassis that is easier to maintain.

Yet another advantage of the present invention is that it provides a pontoon/tritoon watercraft chassis that is more rigid and stable under rough water and/or high-speed operation. The chassis provides stability to an entire platform, eliminating twisting and flexing associated with known pontoon/tritoon watercraft.

DETAILED DESCRIPTION OF THE INVENTION

The terms “forward”, “rearward”, “left” and “right”, when used herein in connection with the watercraft and/or components thereof, are usually determined with reference to the direction of forward operative travel of the watercraft, but they should not be construed as limiting. The terms “longitudinal” and “transverse” are determined with reference to the fore-and-aft direction of the watercraft and are equally not to be construed as limiting. The terms “downstream” and “upstream” are analogous to “rearward” and “forward,” respectively.

Referring now to the drawings, and more particularly toFIG.1, there is shown a watercraft100(which can be referred to herein as a boat100) which generally includes a watercraft body102and a pontoon frame system104coupled with the watercraft body102(such as by way of fasteners324, discussed below). The watercraft body102is shown schematically and can include the parts of the watercraft mounted primarily atop the pontoon frame system304; these parts can include, by way of example and not limitation, a floor, decking, a platform, railings, furniture, a helm, and any other structures that are mounted on top of the floor. Though shown relatively small inFIG.1, watercraft body102can span at least the entire longitudinal and transverse extent of chassis108.

Pontoon frame system104incudes a plurality of pontoons106and a chassis108. Pontoons106are spaced apart from one another in a transverse direction and extend in a longitudinal direction of watercraft100. As is known, watercraft100with pontoons106typically includes two pontoons106(a pontoon boat) or three pontoons106(a tritoon boat). Though the figures show watercraft100of the present invention formed as a tritoon boat, it can be readily appreciated that the watercraft of the present invention can be formed as a pontoon boat in the figures by removing the middle pontoon (as well as features of watercraft100associated with the middle pontoon106). Pontoons106include a forward end110, a rearward end112, a first outboard pontoon114, and a second outboard pontoon116. Regarding a tritoon boat (as shown), the outboard pontoons114,116are the transverse side pontoons106. It can be appreciated that if the watercraft has only two pontoons106(a pontoon boat), then the two pontoons106can still be deemed to be first and second outboard pontoons, respectively. Pontoons106include risers120attached thereto.

Chassis108of pontoon frame system104is coupled with and at least partially supports watercraft body102. Chassis108can be coupled with watercraft body102in any suitable manner, though one way is shown and discussed below with respect to fasteners324in conjunction withFIGS.3-6. Further, chassis108is supported by and couples together pontoons106. Chassis108includes a composite body118(which can include a matrix material (such as a resin) with fibrous material embedded therein and can be referred to as a unibody) coupled with each pontoon106at forward end110and rearward end112of pontoons106. Composite body118can have any suitable shape, such as a slab (shown) or the like. Composite body118can be made of any suitable material and in any suitable way. Such materials include, but are not limited to, fiberglass, carbon fiber, polymers, plastics, other composites, castable metals, and/or the like. By way of example and not limitation, one option for the material is a carbon fiber-based product, made by Vectorply of Phenix City, Alabama, the product being marketed as a VECTORULTRA™ with a product code of C-QX2300. Composite body can be molded, formed, and/or cast, for example.

To couple together composite body118with pontoons106, a plurality of risers120attached to pontoons106can be slidably received in corresponding slots122formed in composite body118. Risers120can be made of any suitable material, such as a metal (such as aluminum, or steel), a polymer, carbon fiber, and/or fiberglass, and can be made in any suitable manner. Risers120are coupled with pontoons106in any suitable manner, such as by way of brackets, fasteners, and/or welding, and any devices making these connections can be made of any suitable material, such as aluminum, steel, carbon fiber, fiberglass, and/or the like. A single riser120can be attached to a respective platoon106and run substantially the length of the respective pontoon106from forward end110to rearward end112of the pontoon106. Alternatively, rather than a single, long riser120, a plurality of risers120—shorter in their longitudinal extent—can be attached to and spaced longitudinally apart from one another along the length of the respective pontoon106from forward end110to rearward end112of the pontoon106. Each riser120can be formed with a right-angle and thus have substantially an L-shape. Further, composite body118can include slots122which matingly receive respective risers120. Slots122, as shown, can thus have a right-angle and thus have substantially an L-shape. These slots122can be formed in composite body118when composite body118is, for example, molded, or can be cut or machined into composite body118subsequent to molding of composite body118. During assembly of pontoon frame system104, risers120can be slidably received by slots122, either before or after risers120are attached to pontoons106.

Referring now toFIG.2, there is shown a bottom, perspective view of chassis108of watercraft100, with portions broken away. Chassis108is thus shown by itself, without risers120connected thereto. Chassis108is shown to include composite body118with three slots122corresponding to three pontoons106. Each slot122, as shown, can extend the longitudinal extent of composite body118. Each slot122, with its right-angle formation, is configured to matingly receive risers120. During assembly, risers120can be inserted into a respective slot122at either end of composite body118. Securing risers120within slots122can occur in any suitable manner, such as by way of a press fit, an interference fit, using an adhesive, or the like.

Referring now toFIG.3, there is shown a top, perspective view of another embodiment of the chassis of watercraft100, according to the present invention. Certain prior reference numbers with respect to the chassis are increased by a multiple of 100 and are substantially similar to the structures and function of the embodiments shown inFIGS.1-2, unless otherwise shown and/or described. Thus, the chassis and composite body are now labeled308and318, respectively, inFIG.2. One substantial difference between chassis108and chassis308is that composite body318includes a plurality of fasteners324attached thereto, which can be made of any suitable material, such as aluminum, steel, carbon fiber, fiberglass, and/or the like. More specifically fasteners324are embedded in the composite material of composite body318; such fasteners324can be referred to as captivated machine screw nuts324, and inFIG.3fasteners324are embedded in a top portion of composite body318. Alternatively, rather than being screw nuts, fasteners324can be screws, bolts, or the like. Fasteners324serve to mount all or portions of watercraft body102. Thus, by way of example, fasteners324can serve to mount the floor, helm, railings, furniture, and/or any other structures that are required to be mounted on top of the floor.

Another substantial difference is that composite body318includes a high-voltage battery pack326embedded therein. Pack326is thus captured within composite body318, which is thick enough to embed such a pack326. In this way, pack326, being under the floor (part of watercraft body102), is isolated from passengers above the floor. Access can be had to pack326in any suitable manner. Further, though pack326is shown inFIG.3relatively small and placed between fasteners324, this is done only for illustrative purposes; it can be appreciated that pack326can be larger than what is shown inFIG.3(as large as needed) and can be positioned under and/or above fasteners324. Pack326can be formed of any suitable material, and may include a substantially rigid shell or enclosure. Pack326can be used, for example, as part of an all-electric boat design (a boat powered by electricity). Pack326can include therein one or more batteries as is suitable for the intended use. Further, any or all high voltage and high current cables can be at least partially contained or encapsulated within pack326and/or routed underneath the flooring of watercraft body102as well, eliminating the risk of accidental electrocution. Any such cables may route to an inverter and/or an outboard motor. Further, any such cables, if not in pack326, can be routed in composite body318and/or within recesses528(below). It can be appreciated that pack326can be included in any of the embodiments of the present invention shown herein.

Referring now toFIG.4, there is shown a bottom, perspective view of chassis308ofFIG.3. Chassis308is shown to include composite body318with three slots122corresponding to three pontoons106. Each slot122, as shown, can extend the longitudinal extent of composite body318. Further, additional fasteners324are embedded on a bottom portion of composite body318, similar to how fasteners324are embedded on the top portion of composite body318, though the positions of the fasteners324on the bottom portion of composite body318can be in locations which do not correspond to the positions of the fasteners324on the top portion, as shown when comparingFIGS.3and4. These fasteners324on the bottom portion are configured to mount various structures, for example, trim pieces, motor supports, and any other suspended structures that require attachment to the bottom of composite body318.

Referring now toFIG.5, there is shown a top, perspective view of another embodiment of the chassis of watercraft100, according to the present invention. Certain prior reference numbers with respect to the chassis are increased by a multiple of 100 and are substantially similar to the structures and function of the embodiments shown inFIGS.1-4, unless otherwise shown and/or described. Thus, the chassis and composite body are now labeled508and518, respectively, inFIG.5. Composite body518includes slots122and fasteners324embedded therein. One substantial difference between chassis308and chassis508is that composite body518includes at least one recess528configured for receiving and, as is necessary, routing a device530therein (device530is shown schematically).FIG.5shows three such recesses formed in the top portion of composite body518. Device530can be any suitable device, including, but not limited to cooling lines, electrical conduits, lighting cables or tubing, stereo cables or tubing, and/or any other cabling or tubing that requires routing. Recesses528are thus configured for receiving and routing therein any such device530.

Referring now toFIG.6, there is shown a bottom, perspective view of chassis508ofFIG.5. Chassis508is shown to include composite body518with three slots122corresponding to three pontoons106. Each slot122, as shown, can extend the longitudinal extent of composite body518. Further, additional fasteners324are embedded on the bottom portion of composite body518. The bottom portion of composite body518also includes, like the top portion, recesses528, which can be located in different positions relative to recesses528in the top portion of composite body518. Recesses528on the bottom portion are configured for receiving and, as is necessary, routing therein device530, as described above.

In sum, the present invention has been made in view of the complexity, material cost (typically) aluminum, and man-hours required to measure, cut, drill, and mount all of the required hardware to attach pontoons106(the floatation tubes) on the bottom of chassis508, including splash pans, motor mounts, conduit and piping and other structures under the flooring, as well as the furniture, railings, trim pieces, motor mounts, helm and all other fixtures mounted on top of the floor (summarized as watercraft body102and/or device530, depending upon whether fasteners324or recesses528are used).

In use, during manufacture, chassis108,308,508can be formed including a formed, molded, or cast (or other suitable way of manufacturing) structure, namely, composite body118,318,518. Composite body118,318,518can be molded, for example, to include slots122and recesses528therein, and to embed fasteners324. Any suitable manufacturing process can be used, such as any suitable forming process, molding process, or casting process, for example. Risers120can be slid into slots122, either before or after attaching risers120to pontoons106. Further, any additional structures associated with watercraft body102and/or device530can be connected to fasteners324and stored or routed in recesses528, respectively. Devices530stored or routed in recesses528can be attached to composite body518in any suitable manner. Upon assembling watercraft100, watercraft100can be floated or otherwise used on a body of water.

Referring now toFIG.7, there is shown a flow diagram showing a method740of using watercraft100. Method740includes the steps of: providing742that the watercraft100includes: a watercraft body102; and a pontoon frame system104coupled with the watercraft body102, the pontoon frame system104including: a plurality of pontoons106spaced apart from one another and including a forward end110, a rearward end112, a first outboard pontoon114, and a second outboard pontoon116; and a chassis108,308,508coupled with and at least partially supporting the watercraft body102, the chassis108,308,508supported by and coupling together the plurality of pontoons106, the chassis108,308,508including a composite body118,318,518coupled with the first outboard pontoon114and the second outboard pontoon116at the forward end110and the rearward end112; and floating744the watercraft100. The plurality of pontoons106can include a plurality of risers120attached thereto, the composite body118,318,518including a plurality of slots122which slidably receive the plurality of risers120. The composite body318,518can include a plurality of fasteners324embedded therein. The composite body518can include at least one recess528configured for receiving a device530therein. The composite body118,318,518can include fiberglass, carbon fiber, and/or a polymer. The composite body318can include a high-voltage battery pack326therein.