Double seal kayak hatch

The present invention provides a sealing device for an opening. The device includes a body that has a first side and a second side. A passageway is formed through the body such that the passageway has a first end adjacent to the first side and a second end that is adjacent to the second side. A sealing member is provided that includes an outer gasket and an inner gasket. The outer gasket is positioned adjacent the first side and the inner gasket is positioned adjacent the second side. A seal connector connects the inner gasket and the outer gasket and the seal connector passes through the passageway. In this way, the inner gasket and the outer gasket are mechanically attached to the ring. The sealing device is configured for use in such applications as sealing the cargo opening on the deck of a kayak.

FIELD OF THE INVENTION

The invention relates generally to a sealing system to a cargo area and more specifically to a system for sealing, i.e. providing a hatch for, a cargo area of a kayak.

BACKGROUND OF THE INVENTION

The watercraft market has seen a significant growth over the last decade. In particular, in more recent times the growth of kayak (sometimes spelled: kayak) sales has spiked dramatically. Along with this growth, the competition for sales has generated new and better vessels. While these vessels generate large sales dollars, they can also create substantial costs. In some cases, much of the costs are associated with production of the tools to create new and improved features on these vessels.

Features are very important in the kayak industry. However, unlike other industries, the focus for product development is function first, aesthetics second. One of the functions that is often addressed is keeping the storage compartments of the vessel dry. One problem with conventional kayaks is that it has always been a challenge to keep various zones of the boat dry. As a result, great effort and dollars have been expended on seals and gaskets for hatches. Stretchable, rubber-like designs, o-rings, and die cut sealing materials are but some of the conventional methods to seal cargo areas. One problem with these conventional methods is that they do not operate consistently. In this regard, stretchable, rubber-like designs, o-rings, and die cut sealing materials have a tendency to shift and change shape. A conventional method for maintaining seal position is to glue the seals to a supporting structure or body or the deck. But seals can move even when glue is used to affix them to the hatch body or deck.

The present invention provides a means for insuring consistent dimensional stability at a reasonable cost by employing a new and unique manufacturing method.

SUMMARY OF THE INVENTION

The present invention provides a sealing system that addresses the above problems by providing a main body that has a seal surrounding it for contacting a deck and a cover that contacts a second seal. The positions of the surrounding seal and the second seal relative to each other and to the main body are maintained by connectors that extend through the body between the two seals. In this way the seals are mechanically linked to the body such that the seals are resistant to deformation and shifting.

According to one embodiment of the present invention, there is provided a sealing device for an opening. The device includes a body that has a first side and a second side. At least one hole is formed through the body such that the at least one hole has a first end adjacent to the first side and a second end that is adjacent to the second side. A seal set that includes an outer seal, an inner seal, and at least one bridge is positioned such that the outer seal is positioned adjacent the first side and the inner seal is positioned adjacent the second side. The outer seal is connected to the inner seal by the at least one bridge that extends from the outer seal through the hole to the inner seal.

According to one aspect of the present invention, the body is formed of a first material and the seal set is formed of a second material and the first material is stiffer than the second material.

According to another aspect of the present invention, the device also includes a flange that defines at least a portion of the first surface, and an outer wall that extends away from the flange and defines at least a portion of the second surface.

According to another aspect of the present invention, a bottom wall and an inner wall that together with the outer wall define a channel.

According to another aspect of the present invention, the body is a ring.

According to another aspect of the present invention, the outer gasket is attached to the flange and the inner gasket is attached to the channel.

According to another aspect of the present invention, the device also includes a cover that is configured to engage the ring such that a portion of the cover depresses a portion of the inner gasket.

According to another embodiment of the present invention, there is provided a hatch system that includes a ring, an outer seal, and an inner seal. The ring defines an outer surface and an inner surface. The outer seal is attached to the outer surface and an inner seal is attached to the inner surface. At least one passageway is defined through the ring from a first end adjacent to the outer surface to a second end that is adjacent to the second surface. A cover is configured to engage the ring such that the cover is sealingly engaged with the inner seal. A connector extends through each passageway such that the connector is joined to the outer seal and the connector is joined to the inner seal.

According to one aspect of the present invention, the outer seal, the inner seal, and the connector are composed of a first material and the ring is composed of a second material and the second material is stiffer than the first material.

According to another aspect of the present invention, the system also includes a flange that defines at least a portion of the outer surface. And an outer wall that extends away from the flange and defines at least a portion of the second sealing surface.

According to another aspect of the present invention, a bottom wall, an inner wall and the outer wall define a channel.

According to another aspect of the present invention, the outer seal is attached to the flange and the inner seal is attached to the channel.

According to another aspect of the present invention, the ring is attached to a boat.

According to another aspect of the present invention, the boat includes a deck that has an opening formed in it and the ring is positioned near the opening such that an upper surface of the deck is separated by the ring and the cover from a lower surface of the deck.

According to another aspect of the present invention, a portion of the ring extends into the opening.

According to another aspect of the present invention, a portion the ring extends over the surface of the deck around the opening.

According to another aspect of the present invention, the boat is a kayak.

According to another embodiment of the present invention, there is provided a device for providing flexible surfaces for sealing openings, the device produced by a method that includes the following steps: A) providing a first mold that defines a first space of predetermined first shape; B) introducing a first material that has a predetermined stiffness when cured into the first space to form a body that has the predetermined first shape which includes a passageway that has a first end on a first side of the body and second end on a second side of the body; C) removing the body from the first mold; D) providing a second mold that defines a second space that has a second predetermined shape; E) introducing the body into the second space such that a third space that has a third predetermined shape is defined by the body and the second mold; F) introducing a second material that when cured, is less stiff then the first material when cured, such that the second material passes through the passageway; F) connecting the first side of the body to the second side of the body with the second material; and G) removing the second mold to provide a sealing ring.

According to another aspect of the present invention, the method for producing the device including the further step of attaching the sealing ring to a deck that has an upper surface and a lower surface such that the sealing ring is near an opening formed through the deck such that the upper surface is fluidly connected to the lower surface.

According to another aspect of the present invention, the method for producing the device including the further step of providing a hatch configured to sealingly engage with the ring such that the upper surface of the deck is not fluidly connected to the lower surface of the deck.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention are directed to a hatch system10, in which a removable hatch cover20and a sealing ring body30is provided. In the illustrated embodiment, sealing ring30is configured to engage a deck14of a boat (now shown) such that an opening16within deck14is sealed by ring body30and cover20.

Referring toFIGS. 1 and 2, in accordance with an embodiment of the invention, a hatch system10for sealing a cargo opening16in a deck14includes a cover20, a ring body30, and a seal set70. In the illustrated embodiment cover20and body30are generally round but it should be appreciated that they can be some other suitable shape as well. Cover20includes a shell22that extends to an outer rim26. A hatch wall27extends from shell22near the outer rim26of cover20. Cover20also includes a means for engaging ring30. In the illustrated embodiment, means for engaging ring30includes a closure actuator24positioned on shell22and mechanical fasteners25. In the illustrated embodiment, actuator24and mechanical fasteners25are part of a cam arm locking system. By way of example and not limitation, the means for engaging ring30can include the following: threaded closures, snap-fit closures, interlocking tabs, a hinge and clasp system, and a combination thereof. Outer rim26defines an outer rim surface28and hatch wall27defines a sealing ridge tip end29for engaging with seal set70as will be discussed further below.

Continuing to refer toFIG. 1, seal ring30has at least one fastener indents31defined therein that are each configured to receive a corresponding mechanical fastener25. Extending from sealing ring30is a flange32. Flange32defines an outside land area34. Flange32also defines a flange deckside surface37and an outer edge39. As seen inFIGS. 1, 3 and 4sealing ring30also includes an annular channel41. Annular channel41includes an outer wall43, a channel bottom45, and an inner wall46. Together, outer wall43, bottom wall45, and inner wall46define a channel surface47. Inner all46extends upward from bottom wall45to define an inner land area49.

As seen inFIGS. 5, 6, and 7, a plurality of ports are defined through ring body30in the form of holes52. Each hole52extend from a first side opening53to a second side opening56. Each opening53is adjacent to deckside surface37and opening56is adjacent to channel surface47. Stated another way, each hole52runs through body ring30from the deckside surface37to channel surface47.

Referring now toFIGS. 5-8, seal set70includes an outer seal73and an inner hatch seal81. Outer flange seal73is positioned adjacent the deckside surface37of ring30. Inner seal81is positioned adjacent channel surface47. In the illustrated embodiment, seal set70includes a plurality of connector bridges91connect outer seal73to inner seal81. Each connector bridge91extends through a hole52from outer seal73to inner seal81. In this manner, outer seal73is mechanically locked to ring body30and inner seal81is locked to ring body30.

Outer seal73has a vertical seal portion72at is configured to engage an edge of opening16and outer wall43of ring30. In this manner, the outside of ring30is sealed from water on deck14even if flange32is not positioned such that outer seal73is sealingly compressed against deck14. It should be appreciated that in some embodiments Outer seal73does not include a vertical portion72and only seals between flange32and deck14and in other embodiments vertical portion72is the only seal provide between ring30and the deck.

Continuing to refer toFIGS. 5-8, outer seal73defines a flange surface75which is configured to contact deckside surface37of ring30. Outer seal73also defines a deck surface77that is configured to contact deck14. Inner hatch seal81is positioned within channel41and includes a hatch seal outer wall83, a hatch seal bottom85, and a hatch seal inner wall87. Inner hatch seal81is adjacent annular channel surface47. Thus inner hatch seal81and outer seal73are positioned against opposite sides of ring30.

In the illustrated embodiment, body30is formed of a generally rigid material such as glass or talc filled polypropylene, acrylonitrile butadiene styrene (ABS), polycarbonate, or the like. The rigid materials of body30cannot, on their own, seal off against the intrusion of water. Therefore seal set30is formed of flexible materials. In the illustrated embodiment, seal set30is formed of a synthetic rubber thermoplastic polymer (TPE). By way of example and not limitation, seal set30can be formed of one of the following: Polyethylene, urethane, rubberized polypropylene and a combination thereof.

Referring toFIGS. 1 and 3, in use, hatch system30is attached to deck14by fasteners17. Fasteners17are configured to compress seal set70between the deck and components of hatch system10. More specifically outer seal73is compressed between flange32and deck14thus sealing any gaps that might otherwise exist between flange surface37and deck surface18. Inner seal73is compressed such that gaps between cover20and channel41are sealed when cover20is moved toward ring30by operation of closure actuator24and mechanical fastener25.

Ring30is secured to deck14by a plurality of fastening means17. In the illustrated embodiment, the fastening means is a screw. By way of example and not limitation, the fastening means can include one of the following: a bolt and nut, bolts with cam locks, a tab and slot system, a threaded closure system, and a combination thereof.

Referring now to the operation of the cover, tip29of hatch wall27is configured to engage and compress hatch seal bottom85. Inner contact surface23of hatch wall27is configured to engage and compress hatch seal inner wall87. It is believed that this double sealing configuration provides a robust closure that will resist leaks even when rugged use or improper closure causes tip29not to be firmly engaged with hatch wall27.

The present invention can be better understood by a description of the manufacture thereof which results in the seal set70being mechanically attached to the ring30. Primary parts of hatch system10are injected molded of a generally rigid material as indicated above. The process of injecting melted plastic material between metal dies that have specific gaps between the metal portions is called injection molding. Referring now toFIGS. 9 and 10, dies are provided to mold hatch system10in two steps. Ring30is molded in the first step and a sealing ring mold first block92is configured to be joined to sealing ring mold second block93such that voids are defined by mold block92and mold block93that defines the shape of ring30. As shown inFIG. 9, in one embodiment, flange32includes a downward lip33that is configured to further retain outer seal73of seal set70in position. In an additional molding step, sealing set70is added to ring body30by the process of overmolding. In this process ring30formed in the first molding step is placed in the second mold, for the seal set, as defined by seal set mold first block94and seal set mold second block95and the liquid material97for seal set70is introduced. The liquid material is allowed to flow through holes52to form seal connectors91, outer seal73and inner seal74such that outer seal73and inner seal74are mechanically locked together by connectors91. In addition seal set70is adhered to ring30by the process of overmolding.

In more detail, ring30and seal set70are produced by a method that includes the following steps: A) providing a first mold made up of seal set mold first block94and seal set mold second block95that defines a first space of predetermined first shape; B) introducing a first material that has a predetermined stiffness when cured into the first space to form ring body30that has the predetermined first shape which includes a passageway or hole52that has a first end on a first side of ring body30and a second end on a second side of ring body30; C) removing ring body30from the first mold; D) providing a second, gasket or seal set, mold that defines a second space that has a second predetermined shape; E) introducing ring30into the second space such that a third space that has a third predetermined shape equivalent to seal set70is defined by body30and the second mold; F) introducing a second material that when cured, is less stiff then the first material when cured, such that the second material passes through the passageway, hole52; F) connecting the first side of the body to the second side of the body with the second material via seal connector91; and G) removing the second mold to provide a sealing ring.

The method for producing the device including the further step of attaching sealing ring30to deck14that has an upper surface and a lower surface such that the sealing ring is near opening15that is formed through deck14such that the upper surface is fluidly connected to the lower surface.

According to another aspect of the present invention, the method for producing the device including the further step of providing a hatch or cover20configured to sealingly engage with ring30such that the upper surface of deck14is not fluidly connected to the lower surface of deck14.

The invention is applicable to any type of water tight closure that requires sealing surfaces that are resistant to shifting and movement such that the sealing surfaces remain properly aligned. While the present invention has been illustrated and described with reference to preferred embodiments thereof, it will be apparent to those skilled in the art that modifications can be made and the Invention can be practiced in other environments without departing from the spirit and scope of the invention, set forth in the accompanying claims.