Abstract:
A cowling for an outboard marine engine includes an upper motor cover and a lower motor cover that cover an engine, and a gear case that houses a drive mechanism. The upper motor cover detachably mates with the lower motor cover along corresponding edges. At least one mating edge on one side of each cover has a non-linear profile for assisting with cover alignment during assembly. The lower motor cover is configured to be assembled to one of a plurality of upper motor covers depending on engine size, and each upper motor cover is configured to be assembled to one of a plurality of top caps depending on whether the engine uses an electric starter or a pull starter.

Description:
This application claims priority from U.S. provisional application Nos. 60/371,495 filed Apr. 11, 2002 and 60/375,400 filed Apr. 26, 2002, both of which are incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to outboard marine engines. In particular, this invention relates to the cover or cowling for such an engine. 
   2. Description of Related Art 
   Outboard marine engines are generally self contained engines that have a propulsion device, such as a propeller, a turbine, or a jet propulsion unit, that is powered by an internal combustion engine or electric motor, for example. Outboard engines are generally mounted on small to midsize watercraft to provide driving power to the watercraft. The degree of sophistication of such engines varies widely from basic pull start engines to high-end electronically controlled engines, which can include an electric starting mechanism. 
   Outboard engines typically have three main sections: the top portion; the middle portion; and, the lower portion. 
   The top portion, known as the upper motor cover, houses at least a top portion of the engine. The upper motor cover may be made from a single piece of material or it may have a separate top known as the top cap. The top cap can have an opening therethrough to accommodate a pull rope to be used to start the engine. 
   The upper motor cover usually has an opening that functions as the air intake for the engine. This intake opening must be configured to prevent water from entering into the engine. To prevent entry of water, a tortuous conduit is generally provided in the upper motor cover to define an indirect path between the opening and the engine. 
   The middle portion is known as the lower motor cover. This portion houses the bottom of the engine, the exhaust housing, and the vertically oriented driveshaft. This portion also functions as the exhaust conduit. Exhaust gases are channeled from the engine to the exhaust housing, where they are exhausted to the atmosphere through a gasket or directly into the water through the gear case. The lower motor cover is typically made of two halves attached to each other along a vertical plane of the motor. 
   The lower motor cover is attached to the upper motor cover by fitting the upper motor cover onto the top of the lower motor cover. Conventionally, the joint between the upper motor cover and the lower motor cover is horizontally oriented and forms a straight line. The upper motor cover is secured to the lower motor cover by one or more locks with a seal therebetween. The locks are usually positioned at the front and/or the back of the cowling. 
   The lower portion is known as the gear case and includes the propeller. The gear case houses the propeller shaft and the transmission. The transmission consists of two bevel gears facing each other on the propeller shaft and a third bevel gear disposed between the first two bevel gears at the end of the driveshaft. The third bevel gear has an axis perpendicular to the propeller shaft. A mechanism is used to selectively engage one or the other of the bevel gears on the propeller shaft with the bevel gear on the driveshaft to control the direction of rotation of the propeller. 
   Prior art outboard engine cowlings are difficult to close when the engine is mounted on a watercraft. Since the joint is straight and horizontal, it is hard for an operator standing in a watercraft, especially when the watercraft is floating in a body of water, to align the upper motor cover with the lower motor cover to lock them together. Therefore, there is a need for an outboard engine with an upper motor cover that is easily closed and locked to the lower motor cover. 
   Prior art outboard engine cowlings are also difficult to lock once they are closed. Locks located at the back of the cowling are hard to reach from inside the watercraft, and locks located at the front of the cowling are hard to reach from behind the watercraft, when the watercraft is mounted on a trailer for example. Further, traditional upper motor cover locks are configured with a hook mounted on the lower motor cover and a hook-engaging member attached to the upper motor cover. If the upper motor cover is not perfectly aligned with the lower motor cover, it is difficult to latch the upper motor cover onto the lower motor cover and obtain a secure connection. Accordingly, there is a need for a cowling that provides an upper motor cover that is more easily locked onto the lower motor cover. 
   As there are two common versions of small to mid-size outboard engines, the electric starter type and the pull starter type, most outboard engines are available with two different upper motor covers, depending on the type of starter mechanism for that particular engine. The same is also true for large size outboard engines (more than 90 hp), although it is less common to have such engines with pull starters. However, the other parts of the engine, especially the other parts of the cowling, may be the same. This is also true for engines that are available, for example, as two-cylinder or three-cylinder versions of the same engine, which require different height covers. To accommodate this, manufacturers must have interchangeable upper motor covers for different versions of essentially the same engine, which adds to manufacturing and distribution costs. There is a need for reducing the added costs incurred by engines that are offered in different versions. 
   Another problem with conventional outboard engines is the lack of a light source. Large boats generally have electrical systems and accordingly have light sources. In fact, watercraft above a certain length are required by the U.S. Coast Guard to have lights. However, outboard engines are often used on small watercraft, typically small boats, especially without an on-board electrical system. Thus, these boats have no lighting, except for the U.S. Coast Guard required hand held flashlight. Some attempts have been made at incorporating lights to outboard engine cowlings, but these require that the cowling be specially molded to incorporate the light, which can be expensive and inconvenient for those who would like to retrofit their current outboard engine cowling. This poses at least an inconvenience when operating a boat in dark or dim lighting or when additional lighting would be desirable for making repairs or preparing for fishing, for example. At worst, this poses a hazard while operating the boat as there is no indication to other watercraft of the boat&#39;s presence. Thus, there is a need to provide an auxiliary light source for watercraft. 
   SUMMARY OF THE INVENTION 
   Therefore, one aspect of embodiments of this invention provides an outboard engine cowling that is easy to close by an operator in various positions. 
   An additional aspect of embodiments of the present invention provides a cowling that is easily and reliably locked. 
   A further aspect of embodiments of the present invention provides an outboard engine that is more economical to manufacture and requires fewer parts. 
   An additional aspect of embodiments of the present invention provides a family of engine cowlings having common parts. 
   Another aspect of embodiments of the present invention provides a light or reflector on an outboard engine. 
   An additional aspect of embodiments of the invention provides a stable support surface to safely rest the outboard engine on a support surface when dismounted from a watercraft. 
   In summary, this invention is directed to an outboard engine assembly comprising an engine, a vertically oriented driveshaft operatively coupled to the engine, a drive mechanism operatively coupled to the driveshaft, and a gear case that houses at least a portion of the drive mechanism, and a cowling disposed around the engine. The cowling includes an upper motor cover that surrounds at least part of the engine, and a lower motor cover that houses the remainder of the engine. The upper motor cover has a lower edge having a contoured vertical profile and the lower motor cover has an upper edge having contoured vertical profile that mates with the contoured edge of the upper motor cover. The invention is also directed solely to the cowling. 
   The invention is also directed to an outboard engine assembly comprising an engine, a vertically oriented driveshaft operatively coupled to the engine, a drive mechanism operatively coupled to the driveshaft, a gear case that houses at least a portion of the drive mechanism, and a cowling disposed around the engine. An electroluminescent light source is mounted on the cowling. The invention additionally covers the cowling per se with the electroluminescent light source. 
   Further, the invention is directed to an outboard engine assembly comprising an engine, a vertically oriented driveshaft operatively coupled to the engine, a drive mechanism operatively coupled to the engine, a gear case that houses at least a portion of the drive mechanism, and a cowling disposed around the engine. An illuminator is removably mounted on the cowling. 
   Also, the invention is directed to a cowling having a front, a rear, and a pair of sides. The cowling comprises an upper motor cover configured to surround at least a part of an engine, a lower motor cover that mates with the upper motor cover configured to house at least part of an engine, and a removably mounted illuminator. 
   According to another aspect of the invention, a method of manufacturing an engine cowling for an outboard engine that has a lower motor cover and an upper motor cover with a top cap comprises the steps of selecting an engine with a particular starter, surrounding at least a portion of the outboard engine with a lower motor cover, selecting an upper motor cover, and selecting a top cap from a plurality of top caps, each formed with an identical lower edge and being designed to accommodate the particular starter of the engine. The method further comprises securing the selected top cap to the upper motor cover by attaching the lower edge of the top cap to an upper edge of the upper motor cover, and mounting the selected upper motor cover on the lower motor cover by mating a lower edge of the upper motor cover with an upper edge of the lower motor cover. 
   According to another aspect of the invention, an engine cowling has an upper motor cover having an upper edge, and a top cap selected from a family of top caps, each with a different configuration. Each top cap of the family has a lower edge configured to mate with the upper edge of the upper motor cover. 
   Additionally, another aspect of the invention is directed to a cowling assembly comprising an upper motor cover having an exterior cowling. surface, a lower motor cover having an exterior cowling surface, wherein the lower motor cover mates with the upper motor cover, and a latch handle mounted on one of the upper motor cover and the lower motor cover. A raised shoulder is positioned adjacent to the latch handle protruding outwardly from the exterior cowling surface of one of the upper motor cover and the lower motor cover. The raised shoulder has a flat, level support surface that forms a support surface for the cowling assembly. 
   The invention encompasses a cowling with each of the features above taken alone and in all possible combinations. The invention encompasses the combination of the cowling and its various features in combination with an outboard engine assembly. 
   These and other aspects of this invention will become apparent upon reading the following disclosure in accordance with the Figures. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     An understanding of the various embodiments of the invention may be gained by virtue of the following figures, of which like elements in various figures will have common reference numbers, and wherein: 
       FIG. 1  is a rear perspective view of a cowling for an outboard engine in accordance with a preferred embodiment of the invention; 
       FIG. 2  is a side view of the cowling of  FIG. 1  in combination with an outboard engine; 
       FIG. 3  is front exploded perspective view of the cowling of  FIG. 1 ; 
       FIG. 4  is a rear view of the cowling of  FIG. 1  with an alternate lamp configuration; 
       FIG. 5  is a top view of the cowling of  FIG. 1 ; 
       FIG. 6  is a partial exploded side view of an embodiment of the cowling in accordance invention showing the locking mechanism; 
       FIG. 7  is an enlarged exploded perspective view of the locking mechanism in accordance with the invention; 
       FIG. 8  is an exploded perspective view showing the interior of the lower motor cover with the details of an embodiment of the illuminator of this invention and an embodiment of the top cap of the upper motor cover in accordance with another embodiment of the invention; 
       FIG. 9  is a side view of the lower motor cover with a handle shoulder; and 
       FIG. 10  is a partial side view in perspective of the lower motor cover seen in FIG.  9 . 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   The invention is described with reference to a marine outboard engine for use on any type of watercraft. Of course, the outboard engine and the features of this invention can be used on any type of cowling assembly. 
   Referring to the Figures,  FIG. 1  is a back perspective view of primary components of the cowling assembly  10  in accordance with the invention, while  FIG. 2  is a side view of the cowling assembly  10  in combination with an outboard engine assembly  12 . 
   The general construction of the outboard engine assembly  12  includes cowling assembly  10  that surrounds and protects an engine  14 , shown schematically. Engine  14  can be a conventional internal combustion engine, such as a two-cylinder or three-cylinder engine. Engine  14  could also be an electric motor. The type of engine  14  is not critical to the invention and may take any conventional form. 
   The engine  14  is coupled to a vertically oriented driveshaft  16  that is coupled to a drive mechanism  18 , which typically includes a transmission and a propelling device, such as a propeller  20  mounted on a shaft  22 . The drive mechanism  18  could also be a jet propulsion device, turbine or other know propelling mechanism. Other known components of an engine assembly would be included within the cowling, such as an exhaust manifold  24 . As these components would be readily recognized by one of ordinary skill in the art, further explanation is not necessary. 
   A mounting support  26  is connected to through the cowling assembly  10  to components within the cowling assembly  10  for mounting the outboard engine to a watercraft or other support. The mounting support  26  can take various forms, the details of which are conventionally known. The outboard engine assembly does not require the mounting support  26  to operate. 
   A steering mechanism  28 , such as a tiller, or other control systems, such trim control, may be provided to allow the driving mechanism to be turned to facilitate directional control of the watercraft or adjusted to affect the orientation of the engine. 
   The cowling assembly  10  includes several primary components, including an upper motor cover  30  with a replaceable top cap  32 , and a lower motor cover  34 . A lowermost portion, commonly called the gear case  36 , is attached to the exhaust housing (not shown in  FIG. 1 ) which is surrounded by the lower motor cover  34 . The upper motor cover  30  preferably encloses the top portion of the engine  14 . The lower motor cover  34  surrounds the remainder of the engine  14  and can include the exhaust manifold  24 . The gear case  36  encloses the transmission and supports the drive mechanism  18 , in a known manner. The propeller shaft  22  extends from the gear case  36  and supports the propeller  20 . 
   The upper motor cover  32  and the lower motor cover  34  are made of sheet material, preferably plastic, but could also be metal, composite or the like. The sheet material is preferably weather resistant, moisture proof, and can withstand impacts. Suitable plastics include ABS (acrilonitrile-butadiene-styrene) or Zeloy, which is manufactured by DuPont™. The lower motor cover  34  or other components of the cowling assembly  10  can be formed as a single piece or as several pieces. For example, the lower motor cover  34  can be formed as two lateral pieces that mate along a vertical joint. The lower motor cover, which is also made of sheet material, is preferably made of composite, but can also be plastic or metal. One suitable composite is fiberglass. 
   The upper motor cover  30  has a lower edge  38  that has a contoured vertical profile, preferably with a curved side wall. The lower edge  38  when viewed from the side is generally convex. The lower motor cover  34  has an upper edge  40  that has a contoured vertical profile in a complementary shape to the lower edge  38  of the upper motor cover  30 . That is, the upper edge  40  when viewed from the side is curved and generally concave. The lower edge  38  and the upper edge  40  mate together in a sealing relationship when the upper motor cover  30  is attached to the lower motor cover  34 . Preferably, a seal  42  is disposed between the upper motor cover  30  and the lower motor cover  34  to form a watertight connection, as seen in FIG.  4 . As shown in  FIG. 6 , the seal  42  can be secured to the upper motor cover  30  to provide a protective surface to the lower edge  38  of the upper motor cover  30  when the upper motor cover  30  is removed from the cowling assembly  10 . 
   The curved, complementary edges  38 ,  40  provide a self-aligning function when placing the upper motor cover  30  on the lower motor cover  34 . In operation, when the upper motor cover  30  is placed over the lower motor cover  34 , the curved edges  38 ,  40  will naturally line up to form an accurate mating relationship. This facilitates assembly without precise alignment by an operator. This self aligning function is especially convenient when attempting to place the upper motor cover  30  on the lower motor cover  34  when the outboard engine assembly  12  is mounted on a watercraft that is afloat. 
   Such contoured edges, which provide the self-aligning function, can be provided on each edge or on other edges alone or in combination. Additionally, a contoured edge means that the edge can be configured as any type of curved line, such as a S-shaped line; a pattern of straight lines, such as a wedge; or a combination of the two types of lines, any of which can be used to achieve a similar result. 
   A locking mechanism  44  is provided on at least one of the sides of the cowling assembly  10 . Preferably, a locking mechanism  44  is provided on each side of the cowling assembly  10 . The locking mechanism  44  is shown in detail in  FIGS. 6 and 7 . The locking mechanism  44  is formed of a first part, which is a hook  46  and a second part, which is a movable latch  48 . Preferably, the hook  46  is formed as a tab  50  with a groove  52  formed in one end. The hook  46  is secured to the upper motor cover  30  by any conventional means such as by bonding, welding or a fastener. The latch  48  is formed as a handle  54  attached to a lever  56  at a pivot bar  58 . The end of the lever  56  includes a locking rod  60  with an enlarged head. The locking rod  60  releasably engages with the groove  52 . 
   In operation, when the upper motor cover  30  is positioned on the lower motor cover  34 , the handle  54  is pivoted about pivot bar  58  to move lever  56  so as to engage the locking rod  60  in the groove  52  of the hook  46 . To unlock the upper motor cover  30 , the handle  54  is pivoted downwardly to move the locking rod  60  out of the groove  52  and disengage the hook  46 . By this preferred positioning and ergonomic design, with the pivot  58  positioned toward the rear of the cowling assembly  10  and the locking mechanism  44  on each side, an operator can easily access the lock from any position and operate with the mechanism comfortably. 
   Of course, the hook  46  and the latch  48  could be reversed with the hook  46  attached to the lower motor cover  34  and the latch attached to the upper motor cover  30 , if so desired. 
   Referring back to  FIG. 1 , an illuminator  62  is provided on the cowling assembly  10 . The illuminator  62  is shown positioned on the lower motor cover  34  but could also be positioned on the upper motor cover  30  or top cap  32 . Moreover, one illuminator  62  is shown on the back of the cowling assembly  10 . However, any number of illuminators  62  may be provided in various positions on the cowling assembly  10 , if desired. 
   The illuminator  62  may be a simple reflector or a light source, also called a lamp. The illuminator  62  can be retained within an opening in the cowling assembly  10 , especially an opening in the lower motor cover  34  or secured to the outer surface of the cowling. The illuminator  62  can be electrically powered through the electrical system normally associated with the engine  14 . As seen in  FIG. 8 , the illuminator  62  can be an electrically powered lamp with a pair of electrical connectors or wires  68  connected to an ECU of the engine  14 . The ECU can control power to the lamp  62  using the power source of the engine  14  or a battery and can be programmed to selectively light the lamp  62 , based on a light sensor for example. 
   Preferably, the lamp  62  is an electroluminescent light source, which can be obtained from Durel Corporation. (See, www.durel.com) this type of light source is easily seen in the dark, relatively inexpensive, can be made in any shape, and is waterproof. Additionally, electroluminescent light sources are easy to assemble as they are essentially stickers with electrical wires for connection to a power source. Therefore any cowling can be retrofitted with such an electroluminescent light source, since a person only needs to apply the sticker to the cowling and connect the wires to an electrical source. The wires could pass through holes made in the cowling or simply pass between lower and upper edges  38 ,  40 . The lamp  62  could also be a removable, battery operated lamp that is preferably rechargeable. 
   Referring to  FIG. 4 , an illuminator  62  in the form of an electric or a battery operated flexible flashlight  64 , such as Black &amp; Decker®&#39;s SnakeLight®, is shown retained on the upper motor cover  30 . The flexible flashlight  64  can be removably clamped to the cowling assembly  10  or can be secured at one end to the cowling assembly  10 . A charging receptacle can be provided so that the electrical system of the engine  14  recharges the light  64 , if desired. 
   In this assembly, the illuminator  62  provides illumination to the outboard engine assembly  12 . This is particularly beneficial for watercraft without running lights. The light  64  also provides an auxiliary light source that can be redirected or removed from the cowling assembly  10  to assist in engine repair or other tasks associated with the engine or watercraft. 
   Another aspect of this invention relates to the top cap  32  of the upper motor cover  30 . Unlike the prior art, the upper motor cover  30  is formed with two parts, i.e. with a replaceable top cap  32 , rather than as a single cover. As seen in  FIG. 1 , the upper motor cover  30  includes an air intake portion  70  formed as a recessed portion on the rear of the cowling assembly  10 . The air intake portion  70  is configured to prevent water from entering the interior of the cowling assembly  10  and accordingly reaching the engine  14 . Such configuration can include a tortuous path. The top cap  32  fits over the upper motor cover  30  in a sealing relationship and preferably defines a portion of the air intake portion  70 . Alternatively, the air intake portion  70  can be wholly formed in the upper motor cover  30  or even the lower motor cover  34 . 
   The top cap  32  shown in  FIGS. 1-6  is designed for an outboard engine assembly  12  with an electric starting mechanism or some other type of automatic starter. With this type of engine, the top cap  32  is formed as a substantially solid plate. The top cap  32  can be formed of any rigid sheet material, preferably plastic, but could also be metal or composite. The edge  72  of the top cap  32  mates with the upper motor cover  30  in a sealing relationship. As seen in  FIG. 3 , the upper motor cover  30  has a pair of longitudinal channels  67  formed adjacent the upper edge  69  of the top of the upper motor cover  30 . The top of the upper motor cover  30  also has several openings formed therein including an air inlet  71  and an optional starter assembly opening  73 , which may be used for example to provide access to the starter handle. The top cap  32  is assembled to the upper motor cover  30  by securing the lower edge  72  in the channel  67 , with an adhesive for example. Once assembled, the channels  67  provide a drainage path for any water or moisture that enters the cowling assembly  10  under the top cap  32 , through the air intake portion  70  for example. 
   Referring now to  FIG. 8 , the top cap  32  may be replaced with alternative style top cap  74 . The alternative top cap  74  has an edge  76  with the same configuration as the edge  72  of top cap  32  so that it may mate in the same way to upper motor cover  30 . Like top cap  32 , top cap  74  can define a portion of the air intake. As seen in  FIG. 8 , top cap  74  is designed to accommodate a pull type starter mechanism  78 , which includes a handle  80  and a shaft or rope  82  that protrudes through an opening  84  in the top cap  74 . Preferably, the opening  84  is designed to prevent the entry of water and contaminants into the interior of the cowling assembly  10  through a baffle system. The top cap  74  is also designed to be larger to accommodate the pull type starter  78 . 
   The upper motor cover  30  can also be designed in several different sizes with the same edge configurations as above. Different size upper motor covers  30  can accommodate engines having different numbers of cylinders, for example. 
   By this configuration, the same cowling assembly  10  can be used for various different types of engines. To accommodate a manual pull starter  78 , for example, the top cap  74  can be used rather than the top cap  32 , which is designed for an electric starter. Other top caps can be replaced and used with variously sized upper motor covers  30  to accommodate other variations, such as engines having different numbers of cylinders. For example, an outboard engine assembly  12  having a three-cylinder engine can be provided with a larger upper motor cover than an upper motor cover designed for a two-cylinder engine. Similarly, the top cap  32  or top cap  74  can be chosen to connect to either size upper motor cover  30 . By merely replacing one of the components, such as the top cap instead of the whole upper motor cover, manufacturing costs can be reduced. The various possible combinations create a family of engine cowlings for outboard engines, the cowlings having common parts. Distribution costs can also be reduced as fewer parts and smaller parts are required for different models. 
     FIGS. 9 and 10  show a lower motor cover  34  with the handle removed to illustrate a modification of the cowling assembly  10  in which a raised shoulder  90  is provided at least partially around the depression  92  in which the handle (not seen in  FIG. 9 ) is disposed. The raised shoulder  90  delineates the locking mechanism  44  (not seen in FIG.  9 ), which is aesthetically pleasing, and provides a level flat surface  94 . This surface  94  functions as a support surface for the cowling  10  when it is removed from the watercraft. Typically, posts extend from the sides of an outboard engine to rest the engine against when placing it on the ground. However, the posts allow the engine to rock and tip over, which can damage the exterior cowling surface, the handles and possibly the engine. 
   In this case, when the outboard engine with the cowling  10 , or just the lower motor cover  34 , is placed on a surface, such as the ground, the raised shoulder  90  stably supports the assembly above the support surface. This prevents the exterior cowling surface from resting on the ground or other rough or unclean support, which could damage the exterior surface. This also protects the handles and locking mechanism from damage. 
   The surface  94  can extend entirely around the locking mechanism or partially around, as seen in  FIGS. 9 and 10 . The roughly pentagonal shape seen in  FIG. 9  ensures that the cowling assembly  10  will not tip to one side as each side of the pentagon offers support. However, the shape can take any form, including circular, rectangular or triangular, in whole or part, if desired. Also, although the raised shoulder  90  is shown protruding from the exterior surface of the lower motor cover  34 , the shoulder  90  could also be provided on the upper motor cover with the same effect. Further, the raised shoulder  90  can be provided merely in the vicinity of the locking mechanism, rather than surrounding it, with a similar effect. 
   Although the above description contains specific examples of the present invention, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given.