Pontoon boats have gained tremendous popularity based on their smooth rides and capabilities of handle a high number of passenger comfortably. A great advantage of pontoon boats compared to conventional single hulled boats, is that they provide a wide range of options to be offered by the manufacturers in the passenger area such as varying seating arrangements.
Often pontoon boats are ordered with specific layouts, deck furniture, accessories, and finishes selected by customers and the pontoon manufacturer builds the pontoon as ordered. The options available typically include different seating arrangements, different configurations of the main passenger area which may be defined as the region encompassed by the pontoon boat fencing, and skin coloring and designs. The fencing typically extends along the side peripheral edges of the deck and may be spaced from the bow and stern peripheral edges. The fencing typically comprises a plurality of fencing sections joined to one another. Each fencing section comprising aluminum framework defined by welded tubular framework with sheet metal paneling, often termed the “skin,” attached to and spanning the framework. The framework of each fencing section generally has a tubular base framework rail member extending along the pontoon boat deck, another upper tubular framework rail member defining an upper rail of the fencing, and vertical, angled, and/or horizontal members extending therebetween. The skin is typically painted sheet aluminum with a thickness between 0.032 and 0.050 inches and is conventionally attached to the framework by crimping down an elongate aluminum tab extending along the lengths of aluminum tubing at the edges of the aluminum panels, clamping the paneling edges between the tab and the aluminum tubing body. Removal and replacement of damaged aluminum panels from the framework is difficult, requiring opening up the clamped tabs and re-crimping the tabs when new panels are installed. Such effort is tedious and often results in damage to the crimping tabs requiring supplemental attachment means such as rivets for example.
Such repair, by replacing only the panels, whether it occurs during the buildout of the pontoon during manufacture, or if occurs in use by the end user, often or typically results in a non-satisfactory result. Therefore, typically when a section of fencing has a damaged panel, the entire section of fencing, including the framework and paneling is replaced. Such replacement of entire fencing sections is expensive due to high labor costs associated with, for example, welding of the tubular aluminum. Moreover, the old fencing section must be disposed of with the associated costs. Where the end user or a boat dealer needs a fencing section replaced remote from the place of fabrication, shipping costs are high since the entire fabricated fencing section must be shipped as the whole unit, and the unit, of course, must be carefully packed to prevent damage during such shipping. Additionally, such replacement typically requires the section be fabricated after the order, adding further delays.
A system and method for assembly of pontoon fencing that reduces labor costs to manufacture the fencing, that facilitates repair of damaged paneling of the fencing without replacing the entire fencing section, and that allows an end user to readily replace paneling, even for simple aesthetic purposes, would be well received by the pontoon manufacturing industry and the pontoon boating public.
A pontoon boat with fencing defining the passenger region on a deck of the pontoon boat. The fencing comprising a plurality of fencing sections, each fencing section comprising a fencing framework and paneling secured to the fencing framework. The fencing framework of each fencing section comprises modular components including a plurality of aluminum tubular extrusion segments with opposing open ends, a plurality of segment connectors interconnecting the tubular extrusion segments, each segment connector having a main body portion and a plurality of insert portions extending into the open ends of the tubular extrusion segments. In embodiments, the plurality of tubular extrusion segments including a plurality of panel holding tubular extrusion segments, each with a skin retainer configured as a resilient retainer strip attached thereto that captures and secures an edge portion of the paneling to the respective tubular extrusion segment. In embodiments, the framework has no welded connections.
A pontoon boat, in embodiments, has fencing utilizing modular components for the fencing framework and further utilizes retainer strips, attachable and detachable from the framework, for securing the paneling, aka the skin, onto the fencing framework. A feature and advantage is that damaged component in a fencing section may be readily replaced, without discarding the entirety of the fencing section. For example, pontoon boat with a damaged skin, the assembled fencing section, including the framework of the section, may be partially disassembled allowing the damaged panel to be removed, a new replacement panel installed in its place, with the framework reassembled. In embodiments the resilient retainer strips may be replaced when a new section of paneling is installed.
In embodiments, a limited number of configurations of tubular extrusions, cut into extrusion segments, may be combined with a limited number of connector components, to assemble the fencing framework, the connector components conforming to open ends of the extrusion segments. Separate retainer strips capture the edges of the paneling and secure the edges to the framework segments. In embodiments, the retainer strips have a tapered insertion portion, such as a prong, that is received into lengthwise grooves formed in the framework segments with the paneling edges sandwiched and secured between the retainer strip and an exterior surface of the framework segment to which the retainer strip is attached. The tapered end allows insertion of the insertion portion and an expanded portion with deflectable tabs locks the insertion portion into the framework segment groove.
In embodiments, a modular system for erecting fencing for pontoon boat decks comprises a plurality of aluminum extruded framework segments, a plurality of segment connectors for connecting the framework segments at their end portions to form the fencing framework with fencing framework windows, sheet metal paneling configured as a plurality of panels, the panels sized to the fencing framework windows, and a plurality of resilient paneling retainer strips securable to the framework segments to secure edge portions of the plurality of panels to the fencing framework thereby securing the panels in the fencing framework windows.
In embodiments, each framework segment may be cut from an aluminum extrusion, each framework segment having end portions with end openings and an elongate groove extending the length of the segment. In embodiments, the plurality of segment connectors for connecting framework segments at their end portions each have an exposed portion and a plurality of insert portions for insertion into the end opening of the framework segments. The insert portions conformingly shaped to be snugly received in the end portion end openings of the framework segments.
A feature and advantage of embodiments is that a robust, structurally strong fencing framework may be assembled utilizing modular components. This allows manufacture and fabrication of the principal components of the fencing remote from the place of assembly of the fencing on the pontoon boat. In embodiments, all of the fabrication of the components of a pontoon boat fencing, except the fabrication of particular sheet aluminum panels may be done remotely from the place of fabrication of the fencing and/or pontoon boat. A feature and advantage of embodiments, is that segment connectors can be advantageously outsourced providing optimized pricing, and may be readily warehoused, using relatively little space, at, for example, the pontoon boat manufacturing facility. A feature and advantage of embodiments, is that a boat owner may be able to replace panels of the fencing of their pontoon boat easily and without specialized tools and without specialized training, providing a like-new quality and appearance.
A feature and advantage of embodiments is that principal components of the fencing for pontoon decks is formed from conventional materials readily available to manufacturers, for example, aluminum extrusions for the framework segments, sheet aluminum of 0.032 or 0.050 inch thickness for the paneling, and conventional metal connectors such as screws and rivets. Additionally, the pontoon deck fencing comprises fencing segment connectors formed of conventional materials such as polymers, for example as polyvinyl chloride (PVC) formulations, or aluminum or other metal castings or machined parts. The segment connectors may be configured, for example as, in-line connectors to coaxially connect two segments, or configured as an L-connector to connect two segments defining an L shape which may be perpendicular or obliquely arranged with respect to each other, or configured as T-connectors to connect two segments coaxially and a third segment perpendicular or obliquely to the two coaxial segments, or configured as a Y-connector for connecting three segments, none of which are coaxial. Additional connector arrangements are contemplated in addition to these specific configurations.
A feature and advantage of embodiments is a method of assembly of a pontoon boat fencing framework that does not require welding, or as much welding, as in conventional fencing for pontoon boats. A further feature and advantage of embodiments, is a method of assembly of a pontoon boat fencing framework that can utilize lengths of extrusions and simply cut the lengths of extrusions to a needed length thereby providing the tubing segment with open ends. A repair facility (or the manufacturing facility) can maintain in stock inventory of different tubing extrusions, different segment connectors, rolls of aluminum sheet metal stock. To repair a fencing section, or to manufacture a new fencing section, the facility cuts to size the needed tubing segments, selects the particular needed segment connectors, cuts the needed paneling from the aluminum sheet metal stock, and assembles or repairs the fencing section. In embodiments, the facility may paint the aluminum or the rolls of sheet metal stock may be prepainted.
A feature and advantage of embodiments, is repairing fencing with a damaged panel does not require replacing the framework supporting the damaged panel, rather the panel itself may be replaced by partially disassembling the fencing framework, removing the damaged panel from the partially disassembled framework, replacing the damaged panel with a panel cut to the size of the replaced panel, installing, and reassembling the fencing framework. In embodiments, the partial disassembly of the framework may involve removal of one, two, or all of the particular retainer strips securing the damaged panel from the fencing framework. The resilient polymer retainer strips may be reused or may be replaced as a consumable item when a panel is replaced.
A feature and advantage of embodiments is that there is no uncrimping and recrimping of metal hold-down tabs on fencing framework when fencing panels are replaced.
In embodiments of the invention, a fencing section framework may comprise aluminum tubing segments that utilize the unitary elongate tabs that are crimped onto the edge portion of the paneling rather than utilizing the resilient retainer strip inserted into the tubing slot. Such segments with the unitary elongate tabs may be combined with the tubing segments with the slots that receive the retainer strips, or the framework may be entirely formed of the tubing segments with the crimpable unitary tabs. The segments removably connected by the segment connectors such that upon repair of a fencing skin, to the extent a crimpable tab is damaged on a particular tubing segment, the segment may be replaced rather than the entire welded framework. In embodiments, the framework may be formed of extruded aluminum tubing members welded together in a conventional fashion but the tubing having the slots for receiving the resilient retainer strips. Replacement or repair of a damaged paneling section may be accomplished with removal of the resilient retainer strips, removal of the damaged paneling section, installation of a new paneling section, and securing the new panel section with new or existing resilient retainer strips. In embodiments, other configurations of replaceable retainer strips may be utilized that attach to the respective tubing segments in other ways, for example attachment by conventional metal fasteners, or fasteners that maintain the insertion portion of the retainer strip expanded in the tubing segment until the fastener is removed.
Referring to
Continuing to refer to
The exploded fencing section 50, as depicted in
In embodiments, the retainer strip 80 is best shown in
The segment connectors 72, 76 are depicted first as an L-connector illustrated at the four corners 82, 83, 84, and 85 of the framework are depicted in
The T-shaped segment connector 76 is depicted in
The corner caps 88, shown best in
For an initial assembly of a fencing section 50, the aluminum tubular segments 62, 63 may be cut to a desired selected size, the segment connectors 72, 76 may be selected, the tubing segments connected to one another by insertion of the insert portions 116, 118, 133, 135 of the segment connectors into open ends 67, 68 of the tubing segments 62, 63. The connections between the segment connectors and tubing segments may be further secured with threaded fasteners, such as screws 78, extending through the wall of the end portions of the tubing segments into the respective insert portions 116, 118, 133, 135 of the segment connectors. Additionally, adhesives may be utilized to further secure the connections. The tubing segments and connectors are joined to define the fencing section framework 60. Once the framework has been assembled, paneling 96 sized to the framework is positioned in place and secured in place by the retainer strips 80. In embodiments, the retainer strips 80 are press fit onto slots 104 defined in the framework such that edge portions 110 of the paneling 96 is secured between the retainer strips 80 and the surface 97 of the framework. In embodiments double sided tape or adhesives may be utilized for further securement of the paneling. In embodiments, other configurations of retainer strips may be utilized such as retainer strips secured with metal fasteners extending into the framework. Corner caps may be attached to the segment connectors to provide a finished look and to further secure and conceal the ends of the retainer strips.
When a paneling 96 is to be replaced, the retainer strips 80 and corner caps 88 that secure the damaged paneling in place may be removed, a new replacement paneling positioned on the framework and new or existing retainer strips 80 and corner caps 88 are reattached to secure the replacement paneling in place. In this manner, the paneling replacement may be made without requiring replacement of the fencing framework or removal from the pontoon of the fencing framework.
Similarly, modular framework components, if damaged, or if otherwise desired to be changed out, may be replaced by partial disassembly of the needed connections to remove the particular component or components to be replaced. That is, removal of retainer strips on to be replaced components or adjacent to the to be replaced components, removal of screws 78 from the connections, removal of the insert portions of the segment connectors from the ends of the connected tubing segments thereby disconnecting the respective segment connectors. Then the segment connectors and/or segments may be replaced and the framework reassembled.
Referring to
The invention is not restricted to the details of the foregoing embodiment (s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. U.S. Pat. Nos. 11,312,450; 11,192,610; and 7,950,340 are incorporated by reference herein. The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.
The following clauses illustrate example subject matter described herein.
Clause 1. A pontoon boat having a bow, a stern, a port side, a starboard side, the pontoon boat having: a deck, the deck having a periphery; a starboard pontoon and a port pontoon secured to a bottom side of the deck; pontoon boat furniture mounted on the top of the deck; fencing mounted to the deck, the fencing defining a passenger area on the deck which includes the pontoon boat furniture, the fencing extending along the deck periphery at the starboard side and the port side of the deck, the fencing spaced from or positioned at the deck periphery at the bow, and the fencing spaced from or positioned at the deck periphery at the stern; where the fencing includes a plurality of fencing sections, each fencing section including a fencing framework and paneling secured to the fencing framework; where fencing framework of each fencing section has a plurality of aluminum tubular extrusion segments with opposing open ends, a plurality of segment connectors interconnecting the tubular extrusion segments, each segment connector having a main body portion and a plurality of insert portions extending from and unitary with the respective main body portion, the insert portions sized for and received in the open ends of the tubular extrusion segments connecting thereto; the body portion of each segment connector outwardly exposed and having an outer peripheral contour that is substantially flush with outer peripheral contours of the tubular extrusion segments connected thereto, the plurality of tubular extrusion segments including a plurality of panel holding tubular extrusion segments, each with edge panel retainer strips attached thereto that secure an edge portion of the paneling to the respective tubular extrusion segment.
Clause 2. The pontoon boat of clause 1, where the edge panel retainer strip of each fencing framework is formed of a resilient polymer and have, when viewed from an end, a T-shape with the lower leg of the T being an insertion portion that is inserted into a slot in the respective panel holding tubular extrusion segment and one of the upper legs of the T sandwiches the edge portion of the paneling between said one of the upper legs and an outer surface of the respective panel holding tubular extrusion segment.
Clause 3. The pontoon boat of clause 1 or 2, where the plurality of segment connectors of each fencing framework includes an inline segment connector, the inline segment connector having two insert portions that are coaxial.
Clause 4. The pontoon boat of clause 1, 2, or 3, where the plurality of segment connectors of each fencing framework includes an T-segment connector, the T-segment connector having three insert portions, two of which are coaxial.
Clause 5. The pontoon boat of clause 1, 2, 3, or 4, where the plurality of segment connectors of each fencing framework includes an L-segment connector, the L-segment connector having two non-coaxial insert portions.
Clause 6. The pontoon boat of any of the above clauses, where the plurality of tubular extrusion segments of each fencing framework has a lowermost segment defining a lower margin of the respective fencing framework, and an upper most segment defining an uppermost margin of the respective fencing framework.
Clause 7. The pontoon boat of any of the above clauses where the segment connectors of each fencing framework has polyvinylchloride.
Clause 8. The pontoon boat of any of the above clauses where each connector insert of each segment connector of each fencing framework is secured to the respective tubular extrusion segment to which it is connected by at least one screw or rivet extending through a wall of the tubular extrusion segment into the respective connector insert.
Clause 9. The pontoon boat of any of the above clauses where each of the fencing frameworks do not have any welded joints.
Clause 10. A fencing section system for pontoon boat decks, the fencing section system having: a plurality of aluminum extrusion segments, each extrusion segment having a pair of open ends; a plurality of sets of segment connectors, each segment connector has a main body portion and a plurality of insert portions extending therefrom and integral with the main body portion, each of the plurality of insert portions sized for insertion into the open ends of the plurality of aluminum extrusion segments; a plurality of panel edge portion retainer strips; where a plurality of the plurality of aluminum extrusion segments having a connection portion extending lengthwise on the respective aluminum extrusion segments for receiving one of the panel edge portion retainer strips; and a plurality of panels with an edge portion extending therearound.
Clause 11. The fencing system of clause 10, where the body portion of each segment connector has an outer contour that matches outer contours of a plurality of the aluminum extrusion segments.
Clause 12. The fencing system of clause 10 or 11, where the plurality of segment connectors include inline connectors where two insert portions are in coaxial alignment, and a plurality of L connectors where two insert portions are not coaxially aligned.
Clause 13. The fencing system of clause 10, where the connection portion extending lengthwise on the plurality of aluminum extrusion segments is configured as a slot defined by two confronting wall edge portions of the each respective aluminum extrusion segment.
Clause 14. The fencing system of clause 13, where the plurality of panel edge retainer strips have a exposed flat portion that seats on an exterior surface of one of the plurality of aluminum extrusion segments with an edge portion sandwiched between the exposed flat portion and the respective aluminum extrusion to which it is attached.
Clause 15. The fencing system of any of clauses 10-14, where the plurality of segment connectors of each fencing framework has polyvinylchloride.
Clause 16. A method of replacing the skin of a pontoon boat fencing mounted on a deck of the pontoon boat, the method including: partially disassembling a framework section of the fencing on the pontoon boat by removing one or more polymer retainer strips on the framework that secure an existing panel of the skin while leaving the framework attached to the deck of the pontoon boat; removing the existing panel and replacing the existing panel with a replacement panel of the same size as the existing panel; replacing the one or more polymer retainer strips with the same one or more polymer retainer strips or with new one or more polymer retainer strips.
Clause 17. The method of clause 16, where the one or more polymer retainer strips are secured to the framework at slots on the framework with insert leg of the retainer strip inserted into the slot.
While the aforementioned particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, that changes and modifications may be made without departing from this invention and its broader aspects. Therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention. It will be understood by those with skill in the art that if a specific number of an introduced claim element is intended, such intent will be explicitly recited in the claim, and in the absence of such recitation no such limitation is present. For non-limiting example, as an aid to understanding, the following appended claims contain usage of the introductory phrases “at least one” and “one or more” to introduce claim elements. However, the use of such phrases should not be construed to imply that the introduction of a claim element by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an”; the same holds true for the use in the claims of definite articles.
This application claims priority to U.S. Provisional Application No. 63/452,283 filed on Mar. 15, 2023, entitled Pontoon Boat with Modular Fencing, the contents of which is expressly incorporated by reference herein.
Number | Date | Country | |
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63452283 | Mar 2023 | US |