Abstract:
A personal watercraft having one or more decorated, and preferably painted, multifunction components, such as the grab handle, shroud, splashguard, hood, rub rails, sponsons, and/or mirror portions of a personal watercraft. The components are fabricated from engineering plastics in a manner suitable to provide an optimal combination of both structural characteristics and the ability to be painted, in a manner sufficient to permit these materials to provide one or more multifunction components within a watercraft. A plurality of different multifunctional components can be fabricated, for use in different portions of the watercraft, thereby permitting some or all of those components to be decorated or painted in a matching or complementary manner.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention is related generally to personal watercraft. More specifically, the present invention is related to the ability to decorate, including to paint, the various structural, decorative, and multifunction components used to assemble personal watercraft.  
         DESCRIPTION OF RELATED ART  
         [0002]    Personal watercraft (PWC) have become increasingly popular in recent years. A personal watercraft, also known as a “jet ski” typically has a bottom hull, handle bars for steering, a tunnel within the bottom hull, a jet pump located within the bottom tunnel, and an engine within the hull under the top deck for driving the jet pump. The jet pump typically pulls in water from the front of the tunnel under the boat, and discharges the water at high velocity through a steerable nozzle at the rear of the boat. The handlebars are typically coupled to the nozzle, which is the steering mechanism for the personal watercraft. The watercraft commonly has a straddle-type seat and foot wells disposed on either side of the seat.  
           [0003]    Personal watercraft typically have a top deck affixed to a bottom hull. The PWC has a shroud mounted in front of the driver on top of the top deck to house the steering column and some instruments. A front portion of the top deck includes a hinged cover or “hood.” The underside of the hood can include a gasket or a grommet that attempts to provide a watertight seal between the hood and the top deck. The hood typically covers either a storage bin or an engine access port. Often, the PWC also includes the use of a handle, often referred to as the “grab handle” which extends rearward of the seat and allows a person to grab the handle and pull themselves onto the watercraft in the course of operation.  
           [0004]    Typically, the various components making up a watercraft can be considered as having either largely decorative functions (such as the windshield and gauge housing) or largely structural and/or mechanical functions (such as the top deck, engine, and engine compartment).  
           [0005]    Those portions having decorative functions are typically used in exterior applications, where they are visible to the rider and others, and are not generally required to be as strong or durable as structural parts. Hence, they can instead focus on aspects of texture, shape, and color. The materials used to provide decorative portions, in turn, must provide physical characteristics sufficient for their intended use, but are particularly chosen for their ability to be decorated (e.g., textured, shaped and/or painted). As a result, many such components are often prepared using relatively non-structural and often thereby less expensive materials, such as ABS/styrene blends, that are typically not sufficient for use as structural components.  
           [0006]    By comparison, structural/mechanical components are typically not intended to be decorative so much as they are intended to reliably perform their intended function. In turn, such materials are often not amenable to being decorated, though they are occasionally provided with protective or functional coatings of one sort or another. At best, the ability to design an aesthetically appealing component of this sort is secondary to ensuring that it will reliably perform its desired function.  
           [0007]    Relatively few portions of a watercraft have both decorative and structural functions, and these will be referred to herein as “multifunction” components. Key examples of such components include the grab handle and shroud. While these components are an important aspect of the overall appearance of the watercraft, they are also subjected to relatively rigorous use and performance standards. To date, therefore, such components are typically formed of materials such as high density polyethylene or high impact polypropylene, which tend to provide a variety of desirable structural features, but are not amenable to being painted.  
           [0008]    Regardless of its potential decorative aspects, the various structural and performance aspects of a multifunction component typically predominate, and therefore limit, the selection of materials that might be used in fabricating such parts. As such, multifunction components have tended to be fabricated from the same sorts of materials that are used to fabricate structural components themselves, and hence tend to be less amenable to decoration.  
           [0009]    On a separate topic, a vast array of engineering polymers are available to serve a corresponding array of purposes. GE and others, for instance, manufacture and sell many such polymeric materials. See, for instance, the GE Plastics website at http://www.geplastics.com/resins/index.jsp, which provides a wealth of information regarding these various products, many of which can be used or adapted for particular purposes. Included within the families of polymers available, are products sold or available under the tradenames Cycolac(® ABS resin, Cycoloy® PC/ABS resin, Enduran™ PBT resin, Geloy® ASA resin, Lexan® EXL and PC resins, Noryl® GTX PPE/PA resin, and Noryl® PPO resin, as well as “specialty resins” that include those sold under the tradenames Supec® PPS resin, Ultem® PEI resin, Valox® PBT resin, and “weatherables” sold under the tradenames Xenoy® PC/PBT Resins. The GE site includes a “GE Plastics Painting Guide” released August 1998, which describes the manner and extent to which certain of their engineering plastics might be painted.  
           [0010]    Finally, a variety of patents and applications describe automotive or other parts adapted to be decorated or painted, see for instance, US 2001/0055671 A1 (Pickett et al); and U.S. Pat. Nos. 4,739,994 (Lewis, Jr.); 4,743,038 (Myers et al.); 5,046,652 (Shanok et al.); 5,449,305 (Kobayashi et al.); 5,509,665 (Hansen); 5,537,948 (Kobayashi et al.); 5,836,640 (Hurayt et al.); 5,915,329 (Watkins, et al.); 5, 947,540 (Pariseau et al.); 6,050,579 (Selland et al.); and 6,152,504 (Dickson et al.).  
           [0011]    To date, however, it would appear that multifunction components used to prepare watercraft continue to be manufactured using structural materials, and hence tend not to be decorated, or particularly painted. This, in turn, limits the design options available to manufacturers and purchasers alike. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0012]    [0012]FIG. 1 is a side view of a personal watercraft of the present invention.  
         [0013]    [0013]FIG. 2 is a front view of a personal watercraft of the present invention.  
         [0014]    [0014]FIG. 3 is an isolated top view of the grab handle of the watercraft of FIGS. 1 and 2.  
         [0015]    [0015]FIG. 4 is an isolated top view of the rear view mirror of the watercraft of FIGS. 1 and 2.  
         [0016]    [0016]FIG. 5 is an isolated front view of the splash guard of the watercraft of FIGS. 1 and 2.  
         [0017]    [0017]FIG. 6 includes isolated side and rear views of the shroud of the watercraft of FIGS. 1 and 2.  
         [0018]    [0018]FIG. 7 includes isolated bottom, side, and top views of the grab handles of the watercraft of FIGS. 1 and 2. 
     
    
     SUMMARY OF THE INVENTION  
       [0019]    In one embodiment, the present invention provides a watercraft having one or more decorated, and preferably painted, multifunction components. Surprisingly, Applicant has discovered the manner in which various engineering plastics can be used to provide an optimal combination of both structural characteristics and the ability to be painted, in a manner sufficient to permit these materials to provide one or more multifunction components within a watercraft. Even more surprisingly, the materials can be used to fabricate a plurality of multifunctional components, for use in different portions of the watercraft, thereby permitting some or all of those components to be decorated or painted in a matching or complementary manner.  
         [0020]    In a particularly preferred embodiment, the multifunction portion is selected from the group consisting of the grab handle, shroud, splashguard, hood, rub rails, sponsons, and/or mirror portions of a personal watercraft. Optionally, the multifunction portion is formed to provide, or separately provided with, one or more reinforcing features and/or components in order to provide added strength. With a grab handle, for instance, it is preferred to provide reinforcement by including design elements such as ribs and/or gussets, while optionally also providing a suitable radius to sharp corners.  
         [0021]    The grab handle, in turn, is provided as the portion of the personal watercraft that extends rearward of the seat and includes a handle portion to allow a person to grab the handle and pull themselves onto the boat. With respect to the shroud, personal watercraft typically have a top deck affixed to a bottom hull. In turn, the PWC has a shroud mounted in front of the driver on top of the top deck to house the steering column and some instruments. A front portion of the top deck includes a hinged cover or “hood.” The underside of the hood can include a gasket or a grommet that attempts to provide a watertight seal between the hood and the top deck. The hood typically covers either a storage bin or an engine access port.  
       DETAILED DESCRIPTION  
       [0022]    Preferred engineering plastics for use in the present invention include amorphous plastics, crystalline plastics, and thermoplastic copolymers and alloy blends. Thermoplastic alloy blends are particularly preferred, such as those selected from the group consisting of acrylonitrile-butadiene-styrene/polycarbonate (ABS/PC) blends, such as the Cycoloy® line of resins available from GE Plastics); polycarbonate/polyester (PCT/PE) blends, such as the Makroblend® also referred to as Macroblend) line of amorphous resins available from Bayer Polymers, and the polyurethane/acrylonitrile-butadiene-styrene (PU/ABS) blends such as those available from Dow under the AMPLIFY® tradename. The AMPLIFY® alloys are a blend of engineering thermoplastic polyurethanes (ETPU) and MAGNUM* acrylonitrile butadiene-styrene (ABS) resins. The ETPU resins contribute high flow, chemical resistance and dimensional stability to the blend, while MAGNUM ABS resins provide toughness and improved processability.  
         [0023]    An example of a suitable thermoplastic polymers and copolymers is the Centrex® line of resins, including acrylonitrile-styrene-acrylate (ASA), acrylonitrile-EPDM-styrene (AES), and ASA/AES copolymers, which provide improved weatherability over many other useful materials.  
         [0024]    Particularly preferred thermoplastic alloy blends for use in the present invention include polycarbonate/polyester resins, and more preferably polycarbonate/poly(butylene terephthalate) (PC/PBT) resins, such as those available under the Xenoy® line of resins from GE Plastics. The amorphous polycarbonate provides impact resistance and toughness, while the crystalline PBT structure provides enhanced chemical resistance and thermal stability. Suitable polymers and blends can optionally be reinforced (e.g.,. glass fiber reinforced) and provide an optimal combination of properties for their intended use, including the ability to be painted, adhesion, chemical resistance, impact performance, and scratch resistance. Further desired properties include various aspects of strength, weatherability, dimensional stability, and chemical stress cracking resistance.  
         [0025]    Suitable resins are commercially available, such as those available from GE Plastics under the Xenoy® tradename, including those available under the Xenoy 1000 series resin grades, for instance, grades identified as Grades 1, 2, 5, 6 or X, and within Grade 1, those products identified as product numbers 1102, 1200, 1402B, 1731, 1732, 1760 and 1760E.  
         [0026]    Such resins can be selected to provide a desired combination of properties such as mechanical properties (e.g., tensile strength, tensile elongation, flexural strength, flexural modulus, compression strength, shear strength, and hardness), impact properties (such as Izod impact, notched and unnotched at varying temperatures), thermal properties (e.g., heat deflection temperature (“HDT”), coefficient of thermal expansion (“CTE”), relative thermal index), and physical properties (e.g., specific gravity, solid, specific volume, water absorption, and mold shrinkage). Even more preferred are those that provide UV weatherable characteristics.  
         [0027]    Various desired combinations of particular properties (e.g., chemical resistance, dimensional stability, and mechanical performance) can be achieved by those skilled in the art, for instance, by judicious balancing of the PC and PBT components of the blend, including in forms that are either unreinforced or reinforced, and UV stabilized. Particularly within such materials, Applicant&#39;s have found that increased HDT (as achieved by increasing crystalline content over that available in commercial formulations) generally correlates well with improved dimensional stability, and in turn, to stable part geometry. GE product information generally describes their commercial materials as being characterized by their chemical resistance, high temperature dimensional stability and mechanical strength.  
         [0028]    In a particularly preferred embodiment, the multifunction component is fabricated from a thermoplastic resin, of the type described herein, by a process selected from the group consisting of injection molding, blow molding, and thermoforming.  
         [0029]    The multifunction component can be painted in any suitable fashion, and is preferably provided as an “in mold” color. See, for instance, “Painting Guide”, GE Plastics (document no. Paint Eng/2M/0898), the entire disclosure of which is incorporated herein by reference. In turn, the word “paint” and inflections thereof, will refer to any coat or coating positioned upon the multifunction component in order to add or improve color or its retention. Such coating can be in the form of a primer layer, a paint layer, and/or in the form of a clear protective coating added to a colored piece.  
         [0030]    The multifunction component can be colored at the stage of its raw materials, or as a formed part, including by pre-treating the piece. Components can be pretreated by cleaning, prior to any secondary painting operation, in order to remove unwanted contamination. Such pretreatment can be accomplished, for instance, by power-washing, surface activation, flaming, low pressure plasma, or corona treatment, as well as UV treatment, fluorination, sanding and sandblasting.  
         [0031]    The particular method of painting, or coating of a colored component, is not critical, so long as it provides a component having a suitable combination of the desirable properties described herein. A variety of suitable paints are available and can be used, including acrylic, alkyd, epoxy, polyester, and polyurethane based paints. Particular for use with the preferred amorphous resins of the present invention, it is important that the paint solvent formulation be selected to correspond with the particular substrate, including in terms of the production method and solubility of the resin in the paint, the rheological behavior of the paint, the evaporation behavior of the solvents, and their effect on the substrate itself.  
         [0032]    Using the preferred polycarbonate/PBT polymer blends described herein, the polycarbonate provides both heat resistance and improved paintability, while the PBT provides chemical resistance and other desirable properties. The optional use of impact modifiers can further improve the mechanical performance of the part, and ensure good low temperature impact performance. Such materials can be used with any suitable combination of water-based and/or solvent-based primers, or in a solvent-based primerless fashion, to provide any suitable combination of primer, basecoat metallic layer, basecoat colored layer, colored topcoat, or clear coat.  
         [0033]    In one preferred embodiment, for instance, the multifunction component is molded as a black, or pre-colored, piece. It is then processed in a robotic painting system that lays down the an initial base coat of a desired color, followed by a suitable top coat, e.g., a clear coat that itself might include metallic flakes or other suitable ingredients. In an optional embodiment, the polymeric resin used to form the part is itself provided in the desired color, and after being formed into final shape is then coated with a clear coat or other suitable additional (e.g., protective) layer. A preferred painting process includes the following steps, using acrylic urethane base paint and clear coats:  
         [0034]    Washing in phosphate solution  
         [0035]    De-ionized water rinse  
         [0036]    Dry-off oven  
         [0037]    Base paint first coat  
         [0038]    Oven flash  
         [0039]    Base paint second coat  
         [0040]    Oven flash  
         [0041]    First clear coat  
         [0042]    Oven flash  
         [0043]    Second clear coat  
         [0044]    Oven flash  
         [0045]    Cure oven  
         [0046]    Forced cool down  
         [0047]    The quality of the painted surface can be evaluated using any suitable means, and is preferably evaluated using conventional tests such as a cross-cut test for evaluating the adhesion of single- or multi-coat systems. In such a test, a lattice pattern is formed in the coated surface or file with an appropriate tool, cutting to the substrate. Suitable tools and materials for performing such a test are available commercially, for instance, as the BYK-Gardner paint inspection gauge (PIG, BYK-Garnder Catalog No. AB-3410), for use in adhesion testing by means of ASTM D 3359; DIN 151. The patterned surface is brushed in a diagonal direction five times each, using a brush pen or tape over the cut, and removing with suitable tape (e.g., Permacel brand). The grid area is examined using an illuminated magnifier and adhesion is rated in accordance with a conventional scale as provided below. For use in the present invention, suitable paint and clear coats provide results adhesion test results at a level of at least ISO Class 2 in quality.  
                                           ISO Class 0   ASTM Class 5B   The edges of the cuts are completely smooth, none of the               squares of lattice are detached.       ISO Class 1   ASTM Class 4B   Detachment of small flakes of the coating at the               intersections of the cuts. A cross-cut area not significantly               greater than 5% is affected.       ISO Class 2   ASTM Class 3B   The coating has flaked along the edges and/or at the               intersections of the cuts. A cross-cut area significantly               greater than 15% is affected.       ISO Class 3   ASTM Class 2B   The coating has flaked along the edges of the cuts partly or               wholly in large ribbons, and/or it has flaked partly or               wholly on different parts of the squares. A cross-cut area               significantly greater than 15%, but not significantly greater               than 35%, is affected.       ISO Class 4   ASTM Class 1B   The coating has flaked along the edges of the cuts in large               ribbons and/or some squares have detached partly or               wholly. A cross-cut area significantly greater than 35%,               but not significantly greater than 65%, is affected.       ISO Class 5   ASTM Class 0B   Any degree of flaking that cannot even be classified by               classification 4.                  
 
         [0048]    In other embodiments, the invention provides a personal watercraft having one or more painted multifunction components, as well as a method of providing a personal watercraft with one or more painted multifunction components.  
         [0049]    [0049]FIG. 1 illustrates a personal watercraft  20  having generally a front or bow  22  and a rear or stern  24 . Personal watercraft  20  includes a top deck  26  secured to a bottom hull  28  along an overlapping portion covered with a rub rail  30  in the embodiment illustrated, forming a hull. A hood  32  with a rear view mirror  34  attached thereto may also be seen. At a forward position of the top deck  26  a splash guard  36  is provided. The hull formed by the bottom hull  28  and top deck  26  define a compartment sized to contain an internal combustion engine  38  for powering the watercraft, and may also include one or more storage compartments, depending upon the size and configuration of the watercraft.  
         [0050]    The deck portion  26  also has a raised, longitudinally extending seat  40  adapted to accommodate one or more riders seated in straddle fashion. A grab handle  42  is disposed transversely across the rear of the seat  40 . Engine  38  powers ajet propulsion unit  44 , typically mounted in a tunnel at the bottom rear portion of the watercraft, all shown in phantom in FIG. 1. Jet propulsion unit  44  includes a steerable water discharge nozzle  46  that is operatively connected to a set of handlebars  48  to facilitate steering of the watercraft by the operator. Handlebars  48  typically mount through a top portion of a shroud  50 . The connection between handlebars  48  and discharge nozzle  46  may be of any suitable type, and typically includes mechanical linkages including a control cable. If desired, an electronic connection could also be utilized.  
         [0051]    [0051]FIG. 2 is a front view of a jet-propelled personal watercraft, showing sponsons  31  together with various other components. As can be seen, hood  32  is provided with a pair of rear view mirrors  34  and is positioned adjacent the shroud  50  on the left and rights sides of the watercraft  20 . Splash guard  36  is positioned adjacent the shroud  50  on the top deck  26 .  
         [0052]    [0052]FIG. 3 is a top view of a hood  32  for use in constructing the PWC of FIGS. 1 and 2.  
         [0053]    [0053]FIG. 4 is a top view of a rear view mirror provided on the right side of the PWC illustrated in FIGS. 1 and 2.  
         [0054]    [0054]FIG. 5 is a front view of the splashguard used in constructing the PWC of FIGS. 1 and 2.  
         [0055]    [0055]FIG. 6 a  is a side view of the shroud  50  used in constructing the PWC of FIGS. 1 and 2, while FIG. 6 b  is a rear view of the shroud  50  used in constructing the PWC of FIGS. 1 and 2.  
         [0056]    [0056]FIG. 7 a  is bottom view of the grab handle  42  used in constructing the PWC of FIGS. 1 and 2, while FIG. 7 b  is a side view of grab handle  42  used in constructing the PWC of FIGS. 1 and 2, and FIG. 7 c  is a top view of grab handle  42  used in constructing the PWC of FIGS. 1 and 2.