GB2299549A - Boat Building System and Method - Google Patents

Abstract

A boat building system and method in which boat parts, such as frames, a keel, deck, and hull components, formed from one or more parts, can be joined to one or more adjacent parts using lugs 27 and apertures 31 which inter-connect and which can be locked together in position initially by a locking member (eg a peg 38, Fig 2b) prior to forming a strong, permanent joint using conventional boat building techniques and in which undesirable projecting lugs and locking members are subsequently removed prior to any subsequent finishing operation.

Description

BOAT BUILDING SYSTEM AND METHOD This invention relates to a boat building system and method, and to the component parts for building a boat.

Traditionally, boats are built by manufacturing a plurality of frames and a keel, and these then have to be set up or assembled in a boatyard, in order to receive the deck and hull, and all the other components parts. This is a time-consuming business, since each frame has to be correctly located relative to its adjacent frames and the keel, and then held firmly in position until it has been permanently connected to its adjacent parts. This setting up often involves marking out the position of each frame etc. on a floor of the boatyard, and then propping each frame in position, e.g. with battens, scaffolds, blocks, beams, and the like.Then the traditional jointing of the parts has to occur, e.g. using resin impregnated straps or other jointing means across each joint, and each frame, the keel and perhaps also hull plates, deck plates and the like, must all be held firmly in place until satisfactory joints have been achieved. This method of manufacture is usually a skilled job due to the fact that there are no straight edges in most boat designs.

The present invention seeks to overcome the problems associated with the above-mentioned method of boat manufacture, and to provide a method of manufacture, and a manufacturing system, both of which are particularly suited to CAD systems, and hence to the mass production of boats.

For example, the invention would be very useful for manufacturing a large number of boats having a common, or similar design, at least so far as the basic hull and deck are concerned.

According to one aspect of the present invention, I provide a method of building a boat comprising forming a plurality of boat parts, such as frames, a keel, deck and hull components, formed from one or more parts, and joining each part to one or more adjacent parts by passing one or more lugs formed on a particular part through a respective aperture formed in the one or more adjacent parts, and placing in position a locking member such that the parts bearing the lug and respective aperture are interlocked, prior to forming a permanent joint between the adjacent parts, and subsequently removing any undesirable projecting lugs and locking members, prior to any subsequent finishing operation.

According to another aspect of the present invention, I provide a boat building system comprising a plurality of boat parts, such as frames, a keel, deck and hull, each formed from one or more parts, each part having one or more projecting lugs thereon and/or one or more apertures therein to receive a projecting lug of an adjacent part, and a plurality of locking members for use with the projecting lugs, to lock the same in position in an aperture of an adjacent part when the two parts are assembled with the lug projecting through the aperture. The boat parts can be made from any material normally used in boat construction, such as wood or metal, e.g. steel or aluminium.

The invention also extends to a kit of parts for carrying out the above described method and/or for manufacture of a boat using the above described system.

In one embodiment of the invention, each lug is in the form of a projecting ear with an aperture therein, and an adjacent part has an aperture therein sized sufficiently large so that it just accepts the lug of its adjacent part when the two parts are joined to each other at a right angle, and the locking member comprises a peg which forms a tight fit in said aperture. Several adjacent, but spaced, lugs may be provided on any one part for engagement within correspondingly spaced and sized apertures in the adjacent part, each of which lugs has an aperture therein to receive a peg.

Normally, the present invention is used to connect two parts together at right angles to each other, but it is envisaged that the two parts could extend at different angles, e.g. by forming the lug or aperture at a particular angle on/in its respective part.

Sometimes it is necessary to join more than two boat parts together at a particular location. For example, when joining a main frame part to a hull, the hull would have one or more apertures formed therein, through which a respective lug or lugs would be passed, and held in position with a respective peg, with the frame part extending normal, or almost normal, to the hull part. However, when joining a transverse frame or transverse bulkhead to a longitudinal frame or bulkhead, there might be two transverse frame parts being joined to a single longitudinal bulkhead, with one of the frame parts being located on each side of the longitudinal bulkhead.In this event, it would be advisable to form each transverse bulkhead or frame part with one or more projecting lugs and with one or more cutouts in the edge from which the lugs project to receive the or each projecting lug on the other transverse bulkhead or frame part, so that the said two parts may be connected to the longitudinal bulkhead or frame part in the same transverse plane. Equally, a similar construction could be used to connect two longitudinal frame or bulkhead parts, in the same longitudinal plane, to a single transverse frame or bulkhead part (or perhaps even to two interconnected transverse frame or bulkhead parts).

In a modification, instead of forming two apertures in one part to receive the two lugs of two separate parts to be connected thereto, one to each side thereof, there may be only one aperture formed in the one part, which receives a hook-like lug provided on one of the separate parts, and an interlocking lug of the other separate part, with part of the two lugs being received in respective mating recesses or cutouts in the other separate part, the arrangement being such that the hook shape is formed by a slot in the lug which received a portion of the one part, and is held in position by the presence of the other lug in the aperture, which itself is locked in position with a peg. Such an arrangement is particularly suited to constructions in which the part having the aperture therein is narrow, and would thus be weakened by two or more separate apertures.

In an alternative embodiment of the invention, the locking member could be a locking ring which engages around the lug with a clamping action. For example, the lug may have an enlarged head over which the ring is forced, i.e.

the lug may act as a cam to expand the ring, before it is locked in position behind the cam. Such an arrangement might be particularly suitable, e.g. when two frame or bulkhead parts are to be connected to a hull or deck part, both frame or bulkhead parts being located adjacent to each other on one side of the hull or deck part, with their respective lugs being adjacent each other on a corner of the frame or bulkhead part, and engaging together in a single aperture in the deck or hull part, and locked in position with a single locking ring.

Once the frame of a boat, and perhaps also the hull and deck, has been assembled or constructed from the parts described above, using the methods and systems described, permanent strong joints have to be formed at each junction of parts. These are usually achieved using adhesive or adhesive-based systems. Traditionally, such joints are formed using jointing material formed from fibre reinforcement soaked in resin or adhesive, which is applied over each junction and allowed to set hard. The resin or adhesive acts as a traditional glued joint, which is reinforced with a fibrous "strap" or "bracket" which can conform to the surface contours at this junction. When the boat parts are constructed out of metal, such as steel or aluminium, preferably the permanent strong joints are formed by welding the boat parts together. Once the joint has been formed satisfactorily and hardened, any unwanted material projecting from the junction can be sawn off, the resultant area filled as necessary and sanded or filed down, prior to finishing. This would apply particularly to lugs projecting through hull parts or deck parts.

The invention is now described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is a side elevation of a longitudinal bulkhead part of a boat; FIGURE 2 is a perspective view of a transverse bulkhead formed of three parts, in an "exploded" situation, and of two spaced longitudinal bulkheads, showing how the bulkheads are joined together; FIGURE 2a is a section on the line A-A of Figure 2 but with the parts assembled; FIGURE 2b is a part sectional scrap view on the line B-B of Figure 2a, showing to an enlarged scale a detail of a joint at one of the junctions in Figure 2; FIGURES 3a - 3c are part sectional, scrap views showing three stages in the assembly of a junction between a longitudinal bulkhead or frame part, and two transverse bulkhead or frame parts, but using a modified form of the invention;; FIGURE 4 is a view similar to figure 2a but of an alternative embodiment showing a different joint, and with the parts in a position ready for assembly; and FIGURE 4a is a detail of the part of the joint identified as 4a in Figure 4.

Referring to Figures 1 and 2 of the drawings, which show some component parts of a boat, e.g. a 26ft. yacht, a longitudinal bulkhead part 1 which extends from a rear end 3 to a forward end 5 at the front of a cabin area 7, the rear end of which is indicated at 9, the top edge 11 of the bulkhead 1 is shaped to receive the deck of the boat, whereas the under edge 13 is shaped to receive the hull of the boat. A possible position of the stern of the boat is shown in outline at 15. In Figure 2, two longitudinal bulkhead parts are illustrated together with a transverse bulkhead shown generally at 17. The bulkhead part 17 is made up of an inboard bulkhead part 21, and port and starboard outboard bulkhead parts 23 and 25.In accordance with the invention, the bulkhead parts are joined together at right angles to each other by forming a plurality of lugs such as the lugs 27 on the outboard transverse bulkhead parts 25 and lugs 29 on the inboard bulkhead part 21, respectively, and locating these in apertures 31 formed at selected locations to correspond with those of the transverse bulkhead in the longitudinal bulkhead 1.

Recesses 33 and 35 are also provided in the edges of the respective transverse bulkhead parts 25 and 21 to receive the lugs 29 and 27 respectively when the various bulkhead parts are assembled together as shown in Figure 2a. In order to hold the assembled parts in their assembled position as shown in Figure 2b, holes 37 are formed in each of the lugs 27 through which locking pegs 38 are placed.

These locking pegs 38 locate behind the bulkhead parts through which the respective lugs project and the holes 37 are so located that when correctly positioned the pegs will be tight up against the surface of the bulkhead part, this firmly locking the component parts together at the joint or junction.

As can be seen from Figure 2, further lugs 39 and 41 are provided on each of the outboard frame parts 23 and 25 which are used to connect hull parts of the boat to the transverse bulkheads or frame parts using a similar principle. In other words the lugs 39, 41 are located in apertures similar to apertures 31 formed in the appropriate hull parts and locked in position with pegs passing through the holes illustrated in the respective lugs.

The above described system of jointing can be used at every junction between transverse frames and longitudinal frames (or bulkheads) in the boat and every junction between deck parts and hull parts, and if the junction is not a right angle junction, then the lugs and/or apertures are inclined at the appropriate angle to achieve the correct angle of join.

Sometimes it is undesirable to provide more than one aperture, such as the apertures 31, in a frame or bulkhead part to enable other frame or bulkhead parts to be joined thereto at right angles from either side, for example, when the material of the appropriate bulkhead part is not very wide as, for example, in the portion 43 on the longitudinal bulkhead part 1 in Figure 1, which is used to separate a ceiling of the cabin area 7 from the deck above the cabin area. In that event, only a single aperture 45 is formed in the bulkhead part and a joint such as shown in Figures 3a to 3c is used instead of that shown in Figures 2 and 2a. In the joint of Figures 3a to 3c the transverse bulkhead parts identified at 47 and 49 are formed with modified lugs 51 and 53 respectively, the lug 51 being hook-like due to the provision of a slot 55.The lug 51 is not provided with a hole therein but a hole 57 is provided in the lug 53. As can be seen from Figures 3a to 3c, the joint between the bulkhead parts 2, 47 and 49 is formed by first passing the hook-like lug 51 through the aperture 45 and engaging an edge portion of the bulkhead 1 defining the aperture 45 in the slot 55, thereby locking the bulkhead part 47 in place in the bulkhead part 1. The lug 53 in the bulkhead part 49 is then passed through the aperture 45 in the bulkhead part 1 so as to engage in a recess 59 provided in the bulkhead part 47 with the hook-like lug 51 engaging in a corresponding recess 61 in the bulkhead part 49. A peg 58 is then passed through the aperture 57 to lock the joint together with the lug 53 acting as the locking member for the lug 51. The completed joint is shown in Figure 3c.

An alternative type of joint is shown in figures 4 and 4a which is particularly useful for joining bulkhead parts to deck parts and hull parts. Referring to these Figures, the modified transverse bulkhead or frame parts are illustrated at 21b, 23b and 25b and are each shown having a projecting lug 63 at their respective bottom corners adjacent the position where they are joined to a longitudinal bulkhead 1, the two lugs 63 being designed to pass through an aperture 65 formed in a hull part 67 when the adjacent parts 21b, 25b are 1 have been joined together.

The two lugs 63 are locked in position in the aperture 65 in the hull part 67 by a locking ring 69 which is forced over projecting means 71 on the lug 63 and fits in position in recessed portions 73 on the lug 63.

Once all the above described joints have been assembled, permanent joints between the respective transverse frame and longitudinal frame or bulkhead parts and between the frame or bulkhead parts and the respective deck and hull parts are formed in a traditional manner. For example, it is normal to use an adhesive or other jointing materials and in one arrangement glass or other fibrous straps impregnated in a resin are used to make the joints at each of the junctions between the various parts. These joints really form no part of the present invention and may take any form, including known forms.Once the traditional permanent joints have been effected, then any unwanted projecting lugs and locking means such as the pegs or locking ring 69 can be removed by sawing off the projecting lugs and pegs, whereupon the areas or surfaces concerned can be smoothed down by grinding or in other known manner as is traditional in the boat building trade, the areas filled as necessary, and then finished with appropriate waterproof coatings.

The present invention allows a boat manufacturer to form the frame of a boat including deck parts and hull parts extremely easily and quickly without having to mark out the locations of the various component parts of the boat and then position and prop the various frame parts and hold them in position while all the permanent joints between the parts are formed prior to joining the deck parts and hull parts to the interconnecting frame or bulkhead parts. The whole of the boat frame including hull and deck parts are easily assembled and temporarily locked in position using the projecting lugs which locate in the apertures in the frame parts to which they are to be connected and the locking pegs or, in the case of the deck and hull parts, the locking ring 69, and this method and system of assembly can be undertaken using relatively unskilled labour. The time required as compared with traditional boat building methods for building a boat frame is very substantially reduced and thus considerably reduces the end cost of the boat. Furthermore, because of the nature of the temporary joints, some of which may be permanently left in place, enhanced strength at each joint or junction is provided. The present invention lends itself to mass production techniques and computer aided design techniques since once a boat has been designed, the whole process of forming the longitudinal and transverse frame parts can be achieved using computerised manufacturing methods, e.g. a computer controlled laser cutting machine.

Furthermore, the various four-way junctions totally control the shape of the boat over its length and width at each frame position and eliminates the need for measurement and setting up for shape. The concept also permits the structure to be test built and, if unsatisfactory, dismantled before final assembly, thus allowing test building for people new to boat building.

It is envisaged that the present invention could be used both by professional boat builders and by DIY boat builders who could purchase a kit of parts and assemble the kit themselves.

It will of course be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.

Claims (11)

CLAIMS:

1. A method of building a boat comprising forming a plurality of boat parts, and joining each part to one or more adjacent parts by passing one or more lugs formed on a particular part through a respective aperture formed in the one or more adjacent parts, and placing in position a locking member such that the parts bearing the lug and respective aperture are interlocked, prior to forming a permanent joint between the adjacent parts, and subsequently removing any undesirable projecting lugs and locking members, prior to any subsequent finishing operation.

2. A boat building system comprising a plurality of boat parts having one or more projecting lugs thereon and/or one or more apertures therein to receive a projecting lug of an adjacent part, and a plurality of locking members for use with the projecting lugs, to lock the same in position in an aperture of an adjacent part when the two parts are assembled with the lug projecting through the aperture.

3. A boat building system according to Claim 2 wherein at least one lug is in the form of a projecting ear with an aperture therein, and an adjacent part has an aperture therein sized sufficiently large so that it just accepts the lug of its adjacent part when the two parts are joined to each other at a required angle, and the locking member comprises a peg which forms a tight fit in said aperture.

4. A boat building system according to Claim 2 or 3, wherein several adjacent, but spaced, lugs are provided on any one part for engagement within correspondingly spaced and sized apertures in the adjacent part, each of which lugs has an aperture therein to receive a peg.

5. A boat building system according to any one of Claims 2, 3 or 4 wherein more than two boat parts are joined together at a junction.

6. A boat building system according to any one of Claims 25 wherein there is at least one aperture formed in one part, which receives a hook-like lug provided on one separate part, and an interlocking lug on another separate part, with part of the two lugs being received in respective mating recesses or cutouts in the other separate part, the arrangement being such that the hook shape is formed by a slot in the lug which received a portion of the one part, and is held in position by the presence of the other lug in the aperture, which itself is locked in position with a peg.

7. A boat building system according to any one of Claims 26 wherein each locking member is a locking ring which engages around a lug with a clamping action.

8. A boat building system according to Claim 7 wherein the lug has an enlarged head over which the ring is forced, the forcing causing the lug to act as a cam temporarily to expand the ring, prior to the ring locking in position behind the cam.

9. A boat building system according to any one of Claims 28 wherein once the frame of a boat has been assembled, permanent strong joints are formed at each junction of parts.

10. A method of building a boat as claimed in Claim 1 substantially as hereinbefore described with reference to the accompanying drawings.

11. A boat building system substantially as hereinbefore described with reference to the accompanying drawings.