Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B7/00—Collapsible, foldable, inflatable or like vessels
  • B63B7/06—Collapsible, foldable, inflatable or like vessels having parts of non-rigid material
  • B63B7/08—Inflatable
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B32/00—Water sports boards; Accessories therefor
  • B63B32/50—Boards characterised by their constructional features
  • B63B32/51—Inflatable boards, e.g. drop-stitch inflatable boards
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B34/00—Vessels specially adapted for water sports or leisure; Body-supporting devices specially adapted for water sports or leisure
  • B63B34/20—Canoes, kayaks or the like
  • B63B34/21—Canoes, kayaks or the like characterised by constructional features
  • B63B34/22—Inflatable; having inflatable parts

Definitions

• the present invention relates to an inflatable boat and a method of making the boat. More particularly, the inflatable boat has or may have an overall configuration which is the same as or similar to a kayak, along with a method of making the same.
• the boat has an overall configuration which may be the same as, or has similarities to, a type of boat which is commonly termed a "kayak".
• the basic configuration of this boat comprises a main structure which is an inflatable flotation structure having connected front, rear and side portions interconnected pneumatically with one another to form a single flotation chamber so that the pressurized air is present throughout the entire flotation structure.
• This drop stitch structure comprises upper and lower fabric layers which are connected to one another by means of a core section.
• the cord section comprises a large number of threads or cords having upper and lower end portions which connect to the upper and lower fabric layers.
• Fig. 1 is a side eievational view of the main structure of a kayak type boat made in accordance with the present invention
• Fig. 2 is a top plan view of Fig. 1 ;
• Fig. 3 is an isometric drawing illustrating a drop stitch structure that is used in the present invention
• Fig. 4 is an isometric drawing showing an upper or lower fabric sheet of the drop stitch structure of Fig. 3;
• Fig. 5 is a view quite similar to Fig. 2, but indicating the locations of sectional views of Fig. 6;
• Fig. 8 is a view of a sheet of fabric showing cutout lines of a plurality of sidewall portions in accordance with the method of the invention
• Fig. 9 shows a pair of right and left sidewall portions that have been cut out and removed from the cutout location
• Fig. 10 is another view relating to the method, showing the two sidewall portions in a location to be joined to a drop stitch structure
• Fig. 11 is a sectional view showing one method in which components are joined in the kayak
• Fig. 12 shows two drawings similar to Figs. 5 and 6, but which are presented without the floor to illustrate a step in the method;
• Fig. 13 is a plan view of a fabric similar to that shown in Fig. 8 S showing other cutout lines for components of the invention
• Fig. 14 is a plan view showing two components cutout as in Fig. 13 to be added to the kayak;
• Fig. 15 is a top plan view illustrating the positioning of the two components of Fig. 14 in the kayak;
• Fig. 16 is a side elevational view of the kayak as shown in Fig. 15, emphasizing the location of the two members shown in Fig. 14;
• Fig. 17 is a top plan view similar to Fig. 5;
• Fig. 23 illustrates the same structure as shown in Fig. 21 with the two side members being bonded to opposite side portions of the drop stitch structure.
• the basic configuration of the kayak 10 will now be discussed with reference to Figs. 1 and 2 which show the main structure of the kayak.
• the kayak 10 has a mid-section 12, front and rear sections 14 and 16, and right and left side sections 18 and 20. Also, there are top and bottom surface regions 22 and 24, and a the kayak 10 seating region 27 and which there is a seating compartment 26 defined by a floor 28 and an inner seating compartment sidewall 30.
• the main part of the kayak comprises an inflatable flotation structure 31 which functions as substantially the entire support structure within which the seating compartment 26 is situated.
• This flotation structure 31 comprises the front and rear sections 14 and 16 and also the side sections 18 and 20.
• the "drop stitch fabric” 32 comprises upper and lower fabric layers 34 and 36, with a core section 38 positioned between (and connected to) the upper and lower fabric layers 34 and 36.
• This core section 38 comprises a plurality of individual threads or cords 40 which have upper and lower end portions which connect to, respectively, the upper and lower fabric layers 34 and 36.
• drop stitch to mean the entire assembly of the upper and lower layers with the threads or cords already connected or to mean only the threads or cords. Therefore, since this drop stitch fabric performs a structural function in its inflated condition, in the following text instead of using the commonly used phrase "drop stitch fabric” to define the entire structure shown in Fig. 3, for clarity, this will be referred to as the "drop stitch structure”. Also, as indicated above, this term covers the entire structure which comprises the upper and lower fabric layers 34 and 36, and also the core section 38 which comprises the threads 40.
• Fig. 4 a portion of the drop stitch fabric layer 34 or 36 is split apart for purposes of illustration.
• the upper and lower fabric layers each may consist of bi- or tri-axial polymer threads 42 (see Fig. 12) which are laminated between two very thin polymer layers 44 (in this particular example the polymer is PVC layers) to form the polymer fabric layers 34 and 36.
• the final fabric layer 34 or 36 may be approximately 0.5 to 1 mm thick.
• Each layer 34 and 36 is both water and air impervious and is quite flexible in its non-inflated condition.
• the drop stitch structure is able to withstand rather heavy loads.
• the drop stitch fabric has a closed interior which is pressurized, it can withstand pressures up in the range of eight to ten PSI (pounds per square inch) and quite possibly much larger loads.
• Fig. 5 (with one exception) is the same as Fig. 2.
• Fig. 6 and Fig. 5 are shown side-by-side with horizontal broken lines indicating the same front-to-rear locations.
• Fig. 6 there are shown eight cross-sectional sections along the length of the kayak 10 and these are identified by the numerals 6-1 through 6-8, and broken lines extend from each of these sections 6-1 to 6-8 to show the corresponding location as seen on a top plan view of the kayak 10.
• These two sidewalls 18 and 20 function as a sidewall section and completely enclose the outside perimeter of the drop stitch structure 32.
• the core section 38 which is made from the drop stitch structure is present in all eight cross-sectional Figs. 6-1 through 6-8 and also extends through the entire length of the kayak 10.
• the right and left sidewall portions 18 and 20 are present in all eight cross-sectional drawings of Figs. 6-1 through 6-8, and these two, along with its adjacent upper and lower fabric layers 34 and 36 extend the entire length of the kayak and overiap each other at the front and rear end locations of the kayak 10.
• This seating compartment 26 has an entire interior border wall 30 which extends around the entire perimeter of the seating compartment 26.
• the floor 28 shows up only in cross-sectional views of 6-3, 6-4, 6-5, 6-6 and 6-8, and the floor 28 covers the entire floor area defined by the inside wall 30.
• the two sidewalls 18 and 20 and the inner border wall 30 completely enclose the region of the core structure to make it totally closed and air tight so that the total interior of the core structure 38 can be inflated.
• a block or section 56 of the drop stitch structure material from which two intermediate drop stitch structure members are to be cutout there is shown two cutout lines 58, each having an elongate configuration which matches closely the drop stitch structure 32.
• the block 56 of the drop stitch structure material is cut along these lines 58 to form a pair of intermediate drop stitch structure members 60, but with only one of these being used in making this one kayak.
• Fig. 8 there is shown in plan view a flexible, waterproof, air tight layer 62 and there is shown a plurality of cutout lines 64 and 66 which match the contours of the right and left sidewall members 18 and 20.
• the layer 62 is cut along these lines to form two sets of the right and left sidewall members 68 and 70. A single one of each of these is shown in Fig. 9, and these two members 68 and 70 are used in step 4 to form the right and left side sections 18 and 20, with six members 68 and 70 left over.
• Fig. 10 To describe a third step, reference is first made to Fig. 10. There is shown in Fig. 10 one of the drop stitch structure contour cutouts 60 shown in Fig. 7. There are also shown in Fig. 10 on opposite sides of this cutout structure 60 a pair of the right and left side members 68 and 70.
• This third step is to cut a central portion of the drop stitch structure 60 along a cutout line 72 which matches the contour of the seating compartment 26. In Fig. 10, there is shown that this cutout portion has been removed, leaving an open space 74 which is to become the seating region 27.
• the fourth step is to bond edge portions of the two sidewall members 68 and 70 to upper and lower edge portions of the drop stitch structure member 72 formed with its open region 74.
• Fig, 11 This is accomplished in a first way as shown in Fig, 11 , where there are shown the upper and lower fabric layer portions 78 and 80 of the drop stitch structure 76. It can be seen that there are four areas of overlap of the edge portions 82 of the sidewall cutouts 68 and 70 that overlap the outer edges 83 of the upper and lower sheets 78. However, there is a possibility that this overlap could be reversed so that the two edges 83 of the fabric layers 78 and 80 would overlap the edges 82 of the side members 68 and 70. As another alternative, there could simply be an extra member overlapping both edges 82 and 83 and making the connection.
• the next step is to properly position and bond to the drop stitch structure the inside border wall 30 that surrounds and defines the seating compartment 26. This is done in substantially the same way as described above with regard to the outer sidewalls 18 and 20.
• the procedure is to make a cutout of an elongate fabric strip having the proper width dimension to connect in overlapping relationships with the upper and lower fabric layers 78 and 80 of the drop stitch structure 74.
• an inner fabric layer strip 84 which has a contour that matches the mid-cutout region 72 of the drop stitch structure 60.
• This inner wall 84 can be made by a single fabric layer 85 which is placed around the entire cavity and overlaps at a juncture location with the drop stitch structure.
• a fabric sheet 89 which is the same as, or similar to, the fabric sheets shown in Fig. 8.
• There is one set of three cutout lines 86 which match the configuration of the previously mentioned reinforcing member 50 which is shown in Fig. 5, and which functions to cooperate with the other components at the front of the kayak to cause the lifting of what we call the "nose 52" of the kayak.
• the other three cutout lines 90 follow the contour of the floor member 28 and each member which results by being cutout along the line 90 becomes a floor member 28.
• These two separate cutout members which are shown in Fig. 14 are designated 50 and 28, respectively and are shown installed in the immediately adjacent Fig. 15 and also in Fig. 16. These are shown having been put into place by being bonded to the kayak's structure.
• the forward reinforcing member 50 which, as indicated earlier, helps to provide the upturn configuration of the nose portion 50.
• the member cutout along line 90 has now become bonded to the perimeter of a lower surface of the lower part of the inside wall member 30 and the adjacent lower inner surface portion of the drop stitch fabric structure to become (and function as) the floor 28.
• Fig. 15 the floor member 28 is shown in plan view and the side elevation view of Fig. 16, and its perimeter is indicated at 28 by a heavy broken line in Fig. 15.
• Fig. 18 shows the very same kayak as shown in Fig. 6, with the exception that there is now included a removable cushion seat 100, and Fig. 17 also slows in plain view. Since this cushion seat is made with substantially the same components with the same method as described above with regard to the kayak itself, this will not be discussed any further in this text. All of the components of this kayak are totally flexible in the un-inflated condition. Further, all of the components, including the upper and lower layers of the drop stitch structure, are water impervious and also air impervious so that the inflated air can be maintained, and there was no leakage of water.
• the kayak In the collapsed position, the kayak can be folded to occupy a very small space.
• an air-valve Through which it can be inflated and deflated, and this is indicated schematically at 102 in Fig. 17.
• the surface of the inflated portions of the boat are quite firm and the entire structure of the boat maintains its configuration of the kayak.
• Figs. 19 and 20 there are shown several dimensions which would be acceptable in this embodiment of the kayak.
• the length dimension "a” could be approximately eleven feet in length, but could be made smaller or larger.
• the rise dimension indicated at "b” could be, for example, in the vicinity of a foot, or possibly ten inches.
• the dimension "c" which is the maximum width dimension of the seating compartment could be approximately one half of the total width "e” of the kayak which could be about three feet.
• the dimension "d" which is shown to be the narrowest location of the flotation structure would be, for example, about one quarter of the total width "e”.
• In terms of inch dimensions, in an actual kayak that is constructed with the drop stitch structure of eight inches could have a width dimension "d" of possibly as much as a foot or possibly down to a eight or nine inches.
• the flotation structure could have a maximum width dimension, as indicated at "e” in Fig. 20, and the right and left flotation structure side portions could each have a width dimension as indicated at "d” in Fig. 20 of about a quarter of the dimension "e”.
• the sum of the two width dimensions at "d” would be no less than one quarter of the maximum width dimension of the flotation structure at "e” and no greater than three quarters of the width dimension "e”.
• the limitations would be no greater than about three fifths of the maximum dimension at "e” and no less than about two fifths.
• the sum of dimension "d" could be about one half of the maximum dimension of the width of the flotation structure.
• these dimensions are not to be strictly limited, and could be increased by percentages of twenty-five percent, fifty percent, seventy-five percent, and upwardly by further by twenty-five percent increments up until there was possibly two hundred percent higher.
• some of these dimensions could be increased by substantial amounts, while other components would not have a corresponding increase, but a lesser or greater increase or no increase at all.
• these dimensions could likely be decreased in increments down to ninety percent, eighty percent, seventy percent, sixty percent, fifty percent, or even as low as forty-five percent, forty percent or possibly lower.
• some of these dimensions could be increased while others are decreased by increments of five percent or ten, fifteen, twenty, thirty, forty or higher, while other dimensions could be decreased by the same percentage values.
• FIG. 21 A second embodiment of the present invention is shown in Figs. 21 , 22 and 23.
• Components of this second embodiment which are the same as, or similar to, components of the first embodiment shown herein, will be given like numerical designations with an "a" suffix distinguishing those of second embodiment.
• the overall configuration of the kayak like boat of the first embodiment described in Figs. 1-3 is the same as this second embodiment.
• This second embodiment differs in some respects only in the manner that the drop stitch structure 32a is enclosed to make the structure air tight and water tight.
• a rectangular portion of the drop stitch fabric 32a which functions as the drop stitch structure 31a.
• This comprises the upper and lower fabric layers 34a and 36a which are connected to the core section 38a which in turn comprises a plurality of threads or cords 40a.
• each of these have upper and lower connecting edge portions 106a and 108a.
• Each of these edge portions 106a and 108a has an adhesive surface with a width dimension of, for example, one inch and possibly more or less.
• Such closure members are currently commercially available as EAM tape.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• Ocean & Marine Engineering (AREA)
• Textile Engineering (AREA)
• Air Bags (AREA)

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• 2008
  • 2008-09-22 CA CA2700381A patent/CA2700381A1/en not_active Abandoned
  • 2008-09-22 EP EP08832274A patent/EP2200895A1/de not_active Withdrawn
  • 2008-09-22 AU AU2008302049A patent/AU2008302049A1/en not_active Abandoned
  • 2008-09-22 WO PCT/US2008/077265 patent/WO2009039516A1/en active Application Filing

Non-Patent Citations (1)

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