The present invention relates generally to systems for reinforcing boat hulls. More particularly, the present invention relates to fiberglass stringer systems for reinforcing fiberglass boat hulls.
Boat hulls can be manufactured from a number of different materials including materials such as fiberglass reinforced resin, aluminum and wood. To improve performance and durability, it is common for a boat hull to be reinforced with a grid or framework of reinforcing/support members positioned within the hull. The framework typically includes longitudinal support members that extend along the length of the hull. These types of supports are often referred to as stringers. The framework also includes support members that extend across the width of the hull. These type of support members are typically referred to as bulkheads. Example hull reinforcing systems are disclosed in U.S. Pat. Nos. 3,848,284; 6,367,406; and 6,286,448.
One inventive aspect of the present disclosure relates a system for reinforcing a hull, the system including longitudinal supports that define channels having open sides that face in an upward direction, and bottom walls that are bonded to the hull.
Another inventive aspect of the present disclosure relates to a reinforcing system including longitudinal supports that are interconnected by a bridge structure that extends along at least 50 percent of the length of each of the longitudinal supports.
A further inventive aspect of the present disclosure relates to a hull reinforcing system including first and second longitudinal supports interconnected by a middle support that extends along at least 50 percent of the length of each of the first and second longitudinal supports. The middle support defines at least one transverse slot in which a cross-brace is positioned.
Examples of a variety of inventive aspects in addition to those described above are set forth in the description that follows. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive aspects that underlie the examples disclosed herein.
As used herein, the term “longitudinal” refers to a direction that extends generally along or generally parallel to the keel of a boat. Also, the term “transverse” refers to a direction that extends across or generally perpendicular to the keel of a boat. Further, the terms “inner” and “outer” are specified relative to the keel of a boat.
Referring now to
Referring still to
A. Longitudinal Supports of Stringer Unit
The longitudinal supports 36L, 36R of the stringer unit 31 can also be referred to as “stringers” or “longitudinal reinforcing structures.” The left longitudinal support 36L is positioned between the keel line 22 and the port side 24 of the boat 20, and the right longitudinal support 36R is positioned between the keel line 22 and the starboard side 26 of the boat 20. Each of the longitudinal supports 36L, 36R extends from the stern 30 to the bow 28 of the boat 20, and has a length that is generally parallel to the keel line 22.
Referring to
The bottom wall 70 includes inner and outer ends 70i and 70o. The inner wall 72 is connected to the inner end 70i of the bottom wall 70, and extends from the bottom wall 70 upwardly away from the port side 24 of the hull 35. The outer wall 74 is connected to the outer end 70o of the bottom wall 70 and extends from the bottom wall 70 upwardly away from the port side 24 of the hull 35. The hull 35 and stringer unit 31 are symmetrical about the keel line 22. Thus, while not depicted in
B. Middle Bridge Structure of Stringer Unit
The middle bridge structure 40 of the stringer unit 31 structurally couples the left longitudinal support 36L to the right longitudinal support 36R. As shown in
The middle bridge structure 40 has a length L in a longitudinal direction that is preferably greater than the width W. In a preferred embodiment, the middle bridge structure 40 extends along at least 50 percent of the length of each of the longitudinal supports 36L, 36R, thereby providing inner support along a majority of the length of each of the longitudinal supports 36L, 36R. As depicted in
Referring to
The middle bridge structure 40 can also be referred to as an “intermediate support structure” or a “middle support structure” or a middle floor-support structure.” The middle bridge structure 40 extends over an open “flood chamber” region 140 (see
C. Port and Starboard Floor Supporting Portions of Stringer Unit
The port floor support structure 50 of the stringer unit 31 extends from the left longitudinal support 36L to the port side 24 of the hull 35. A port flange 51 extends from the port floor support structure 50 upwardly along the inside surface of the hull 35 (see FIG. 4). The port flange 51 can be bonded to the inner surface of the port side 24 of the hull 35 at a location above a port side chine 120.
The starboard floor support structure 52 extends from the right longitudinal support 36R to the starboard side 26 of the hull 35. A starboard flange 53 extends upwardly from the starboard floor support structure 52 along the inside surface of the starboard side of the hull 35. The starboard flange 53 can be adhesively bonded to the starboard side of the hull 35 at a location above a starboard side chine.
Preferably, the supports structures 50, 52 each have lengths in the longitudinal direction that extend along at least 50 percent of the lengths of the longitudinal supports 36L, 36R so as to provide outer support along a majority of the length of each longitudinal support 36L, 36R. As shown in
In the above-described embodiment, the flanges 51, 53 are connected to the hull at locations above the chines. It will be appreciated that in lower profile embodiments, the flanges can be connected to the hull below the chines.
D. Front Nose of Stringer Unit
As shown in
E. Unitary Construction of Stringer System
The term “unitarily connected” means that two parts are connected by a seamless connection without requiring the use of fastening structures such as adhesive or fasteners. In a preferred embodiment, the stringer unit 31 has a unitary construction in which the port floor support structure 50 is unitarily connected to the left longitudinal support 36L, the starboard floor support structure 52 is unitarily connected to the right longitudinal support 36R, and the middle bridge structure 40 is unitarily connected to both the left and right longitudinal supports 36L, 36R. In one example unitary construction, the port floor support structure 50, the left longitudinal support 36L, the middle bridge structure 40, the right longitudinal support 36R and the starboard floor support structure 52 are all formed from a continuous, uninterrupted layer of fiber reinforced resin. Example fibers for reinforcing the resin include glass fiber, carbon fiber, Kevlar or other fibrous material. In other embodiments, the stringer unit can have a non-unitary construction.
F. Cross-Braces
Referring to
Referring still to
Referring to
It will be appreciated that the stringer unit 31 and the cross-braces 90 need not be made of the same type of material. For example, in one embodiment, the stringer unit 31 is manufactured from fiber-reinforced resin, and the cross-braces 90 are manufactured from a material such as linear foam.
When mounted within the notches 92, the cross-braces 90 extend from the middle portions 94 of the notches, through the channels 75 of the left and right longitudinal supports 36L, 36R to the port and starboard portions 96, 98 of the notches 92.
G. Floor Structure
In addition to supporting the hull to minimize flex points, the reinforcing system also provides a base for supporting the floor structure 43 of the boat 20. The floor structure 43 can be a floor, or a subfloor that supports a floor or supports any other type of structure for supporting a floor (e.g., a structural framework). In the example embodiment, the floor structure 43 is a subfloor that extends generally from the stern 30 to the bow 28. The subfloor is bonded (e.g., with adhesive) to the top surface of the middle bridge structure 40 as well as to the top surfaces of the port and starboard floor support structures 50, 52. Thus, the floor structure 43 is supported by the middle bridge structure 40 and the port and starboard support structures 50, 52, and extends over the top sides of the open channels 75 of the longitudinal supports 36L, 36R.
Adjacent the bow 28 of the boat 20, an additional framework of support members (not shown) can be provided above the floor structure 43 to support the front casting platform 36 of the boat 20. A similar framework can be provided adjacent the stern for supporting the rear casting platform 39.
Referring to
The floor structure can be made of any number of different types of material. Example materials include linear foam, wood, polymeric materials, fiber reinforced resin, composite materials as well as other materials. The floor structure 43 and the stringer unit 31 need not be made of the same type of material. For example, in one embodiment, the stringer unit 31 can be made of fiber-reinforced resin, and the floor structure can be made of linear foam.
H. Example Manufacturing Method
An example technique for manufacturing the boat 20 is described in the following paragraphs. It will be appreciated that the method is for illustration purposes, and that other methods could also be used.
Initially, the hull 35 is formed by applying a layer of fiber-reinforced resin to the inner surface of a first open mold. The inner surface of the first open mold has the contour and design of the outer surface of the particular boat hull, desired to be manufactured.
Fiber-reinforced resin is also applied to a second open mold. The second open mold has an inner surface that matches the shape and contour of the stringer unit 31. The layer of fiber-reinforced resin is applied to the mold to form the edge flanges 51, 53, the port and starboard floor supporting structures 50, 52, the longitudinal supports 36L, 36R, the middle bridge structure 40, and the front nose portion 56. Thus, the various components of the stringer unit 31 are integrally molded as a single, integral/unitary piece made of fiber-reinforced resin. After the resin has cured, the cross-braces 90 are inserted into the notches 92. Preferably a bonding material is used to secure the cross-braces 90 within the notches 92. Example bonding materials include fiber reinforced resins, adhesives, bonding compounds, cements, or other materials having like characteristics.
After the cross-braces 90 have been mounted within the notches, the floor structure 43 is preferably bonded to the topside of the stringer unit 31 to form a reinforcing insert. For example, the floor structure 43 can be bonded (e.g., with adhesives, resins, epoxies, or other materials having like bonding characteristic) to the middle bridge structure 40 as well as the port and starboard floor support structures 50, 52. Thereafter, the reinforcing insert can be removed from its mold and inserted into the hull 35, which was previously allowed to cure.
Prior to inserting the reinforcing insert into the hull 35, a bonding compound is preferably applied to the bottom sides of the bottom walls 70 of the longitudinal supports 36L, 36R as well as to the outer surfaces of the edge/perimeter flanges 51, 53. When the reinforcing insert is inserted into the hull 35, the insert nests within the hull 35 with the edge flanges 51, 53 being positioned above the chines 120, and the bottom walls 70 of the longitudinal supports 36L, 36R being positioned below the chines 120. In lower profile embodiments, the flanges 51, 53 and the bottom walls 70 can be positioned below the chines.
The bottom walls 70 are preferably angled to match the V-shaped angle of the hull 35. Thus, because of the angled configuration of the bottom walls 70, the longitudinal supports 36L, 36R provide a self-aligning feature, which assists in centering the reinforcing insert within the hull 35. During insertion of the reinforcing insert, the front nose 56 fits snuggly within the bow of the boat 20 to further enhance the self-aligning feature of the reinforcing insert.
After the reinforcing insert is mounted within the hull 35, holes can be drilled through the floor structure to allow a buoyant material 85 (see
Once the reinforcing insert is secured within the hull 35, the top deck unit 79 can be bonded to the hull 35 and the floor structure 43. Thereafter, other components such as steering console 34, integrated rear bucket seat unit 33 and other structures can be structurally coupled to the top deck unit 79.
With regard to the forgoing description, it is to be understood that changes may be made in detail, especially with respect to the shape, size and arrangement of the parts. It is intended that the specification and depicted aspects be considered illustrative only and not limiting with respect to the broad underlying concepts of the present disclosure.
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57-80980 | May 1982 | JP |
Number | Date | Country | |
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20040226500 A1 | Nov 2004 | US |