Watercraft Port Canopy Assembly with Flexible Joints

This application is a non-provisional of U.S. Patent Application Ser. No. 63/654,591, filed May 31, 2024, which is incorporated herein by reference.

Floating watercraft ports provide easy drive-on docking and out-of-water storage of watercraft having various hull types, including pontoon boats. Pontoon boats are manufactured in a number of lengths and widths and employ pontoons of various shapes and hull configurations (e.g., two- and three-pontoon configurations (commonly referred to as tri-toons)). Accordingly, it is advantageous for a floating drive-on pontoon port to be adjustable to accommodate and simplify the loading and unloading (to/from the port) of pontoon boats of different sizes and configurations.

One example provides a flexible canopy assembly including a canopy frame to support a flexible cover to form a canopy, the canopy frame including at least a first beam and a second beam and a plurality of trusses to extend between the first beam and the second beam. A plurality of columns is to support the canopy frame, each column including a leg having a lower end to couple to a floating watercraft port, a gusset to connect to an upper end of the leg, the gusset to engage the corresponding one of the first beam and the second beam, and at least one binding device to hold the corresponding one of the first beam and the second beam to the gusset to form a flexible joint there between to enable the canopy frame and the column to move relative to one another at the flexible joint.

In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise.

When docking a watercraft, it is beneficial to remove the watercraft from the water. Removing a watercraft from the water minimizes growth of barnacles and aquatic plant life on the watercraft, reduces the chances for the watercraft to acquire and transport invasive species, reduces damage from contact with a dock (e.g., “dock rash” caused by repeated rubbing of the watercraft against a dock and denting, particularly the pontoons of pontoon boats), reduces the occurrence of oxidation and discoloration of portions of the watercraft that would otherwise be submerged, and reduces the chance for damages that might result from adverse weather and water conditions (e.g., high winds, high waves, high currents, etc.).

The traditional docking system for removing watercraft from the water has long been a winch-style boat lift which is constructed of aluminum and has adjustable legs which sit on the bottom of body of water. In addition to reducing potential water damage, such lifts also typically include a canopy assembly that mounts to the lift to protect a docked watercraft from environmental elements (e.g., sun, rain, hail). Traditional canopy assemblies typically comprise an aluminum frame which mounts to the lift and supports a canvas or nylon cover to form a roof or canopy over the lift (and a watercraft stored thereon).

In recent years, as an alternative to winch-style lifts, floating watercraft ports have been developed which provide easy drive-on docking and out-of-water storage for any number of watercraft types (e.g., personal watercraft, pontoon boats). Floating watercraft ports typically include a number of floating sections comprising foam-filled plastic shells which are coupled together to form an upper surface onto which a watercraft is driven and lifted out of the water via the buoyancy of the floating watercraft port. The floating sections are typically pivotally coupled to one another to provide articulating movement therebetween to enable the watercraft port to move with the motion of the water and to assist with on/off loading of a watercraft.

Due to their rigid construction, conventional aluminum canopy assemblies are not well suited for mounting to floating watercraft ports, as the motion and flexing of the watercraft ports causes fatigue and cracking of the aluminum, particularly at joints between frame components (e.g., welded and bolted joints).

The present application provides a canopy assembly employing non-rigid, flexible joints to enable canopy system elements to flex and move relative to one another. While the canopy assembly may be adapted to mount to any number of structures, including stationary/fixed structures (e.g., stationary docks), the canopy assembly is described primarily herein in terms of being adapted to mount to a floating watercraft port, where the canopy system can flex in response to motion of the floating watercraft port and thereby eliminate material fatigue and failures associated with traditional, rigid aluminum canopy assemblies. In examples, binding mechanisms (e.g., straps, clamps, and lashings) are used to hold together components of the canopy assembly (without the use of interconnecting fasteners that directly and rigidly fasten elements to one another) to form flexible joints that enable canopy assembly components to flex and move relative to one another. In some examples, the canopy assembly joints include at least one molded plastic element interface element (e.g., a molded plastic gusset) to reduce and/or eliminate metal-to-metal contact between canopy assembly components, and to enable flexibility while reducing component wear.

is a perspective view of a canopy assembly, according to one example of the present disclosure, which is illustrated as being mounted to a floating watercraft port. In other examples, canopy assemblymay be adapted to mount to any number of structures other than a floating watercraft port, both fixed and non-fixed structures, such as a stationary dock, for instance. According to the illustrated example, canopy assemblyincludes a canopy frameover which a flexible coveris to be installed (e.g., an elastic, water-resistant fabric to be stretched over canopy frame) to form a canopy, and a plurality of columnsto support and elevate canopy frame/flexible cover. In, flexible coveris shown in dashed lines for ease of illustrating canopy frame, withbelow illustrating flexible coverin greater detail.

In examples, as described in greater detail herein, each columnforms a flexible joint with canopy frameto enable columnsand canopy frameto move relative to one another at the flexible joints. In the example of, columnsare adapted to mount to watercraft portto support canopy frameand flexible coverto form a canopy to protect watercraft portand watercraft disposed thereon (e.g., from sun and rain), wherein the flexible joints enable canopy frameand columnsto flex relative to one another in response to movement of floating watercraft port(e.g., in response to waves or the loading/off-loading of a watercraft), as well as to other applied forces, such as wind forces, for instance.

In the illustrated example, floating watercraft portincludes a base sectionand an entrance sectionwhich are pivotally coupled to one another to form an upper surfaceonto which a watercraft may be driven on/off for docking and storage. Base and entrance sectionsandextend along a longitudinal axisbetween an entrance endand bow endand define a port sideand a starboard side. In one example, a hull depressionshaped to receive a hull of a watercraft is molded into upper surfaceand extends longitudinally from entrance endtoward bow end. In some examples, as illustrated, an opposing set of port and starboard rows,and, of adjustable rollers and/or wheels extend longitudinally along hull depressionto form a transport track to transport a hull of watercraft there along during loading and off-loading of the watercraft to/from watercraft port.

In examples, base and entrance sectionsandare pivotally coupled to one another to enable articulating movement therebetween to enable watercraft portto readily move with the motion of the water and to assist with on/off loading of a watercraft to/from upper surface. While not illustrated, watercraft portmay be coupled to a stationary structure, such as to a dock or posts, for example, such as via base sectionand/or entrance section. It is noted that the implementation of floating watercraft portofrepresents one potential implementation, and that watercraft portmay be implemented in any number of other configurations, including implementation having more or fewer than 2 sections, with canopy assemblybeing adaptable for use with any such implementation. Examples of other implementations of floating watercraft ports with which canopy assemblymay be employed are illustrated bybelow. It is further noted that, in examples, base section and entrance sectionsandcomprise rotationally molded shells of high-density polystyrene filled with a marine-grade expanded polystyrene (EPS) foam.

In the example of, canopy frameincludes at least a first beam and a second beam, illustrated at first beamand second beam. In one example, as illustrated, first and second beamsandextend longitudinally in parallel with one another in an opposed and spaced apart manner. In one example, first and second beamsandlongitudinally extend in parallel with longitudinal centerlineof watercraft port, with first beamextending along port sideand second beamextending along starboard side. In examples, the beams, such as beamsandare constructed of metal, such as aluminum. In other examples, beamsandmay be constructed of any suitable material having sufficient strength and weight characteristics (e.g., lightweight for ease of shipping and assembly while providing structural integrity without warping or bowing over time), such as a polymeric material, for instance.

Canopy framefurther includes a plurality of trussesextending transversely between and supported by first and second beamsand. In examples, trussesinclude a plurality of center trusses, illustrated as center trusses-, and a pair of end trusses, illustrated as end trussesand. As will be described in greater detail below (e.g., see), end trussesandinclude end capsat opposing ends which include beam inserts (see) configured to be inserted into open ends of first and second beamsand. In examples, end capsfurther include beam slots (e.g., see) to receive a cross-beam at opposing end of canopy frame, illustrated as cross-beamsand. Positioning beam inserts of end capswithin the ends of first and second beamsand, as well as employing cross-bracesand, assists in maintaining a desired/selected spacing between first and second beamsand, and in providing rigidity to canopy frameas well as to canopy assemblyoverall.

In examples, trussesare made of a polymeric material. In examples, trussesare rotationally molded using a polymetric material. In other examples, trussesmay comprise a metal material, including a lightweight metal, such as aluminum, for instance.

In examples, as will be described in greater detail below, first and second beamsand, as well as cross-bracesand, include one or more clip retainer slots (e.g., see) extending along their longitudinal lengths which are adapted to receive a plurality of mounting clips which are disposed along perimeter edges of flexible coverto facilitate mounting and securing of flexible coverto canopy frame. In examples, installation of such mounting clips within the clip retainer slots may be done without the use of tools.

According to examples, canopy framefurther includes a plurality of ridge connectors, wherein a ridge connectoris connected between each pair of adjacent trusses. In one example, as described in greater detail below, opposing ends of each ridge connectormount to corresponding mounting studs (e.g., seein) extending from opposing sides of each truss(e.g., see), wherein the ridge connectorsand peaks of each trusstogether form a ridge beamto secure together and stabilize the plurality of trussesand to support and form a peak (for directing rain water) for flexible coverwhen disposed on canopy frame. In examples, flexible covermay be secured to ridge connectors, such as via a hook and loop type attachment strap.

According to the example of, each columnhas a leghaving a lower endand an opposing upper end. In one example, each columnincludes a base supportto which lower endof legis connected, with based support, in-turn, being adapted to couple to watercraft port. In other cases, columnsmay be adapted to connect to other structures, such as fixed docks or other supports, for example. In examples, each columnfurther includes a gussetconnected to upper, where gussetis configured to engage and support a corresponding one of the first and second beamsand. In one example, a first pair of spaced apart columnssupports first beam, and a second pair of spaced apart columnssupports second beam. In examples, each legcomprises a telescoping leg to enable a height adjustment of columns.

In examples, as will be described in greater detail below, each columnincludes a binding device(e.g., see) to hold the corresponding one of the first and second beamsandto gussetto form a flexible jointtherebetween to enable canopy frameand columnto move relative to one another at flexible joint, where flexible jointis characterized by an absence of a fasteners that directly interconnect and rigidly fasten the corresponding one of the first and second beamsandto gusset. In other words, binding deviceholds or binds the corresponding one of the first and second beamsandto gussetwithout making a direct, rigid, interconnection therebetween.

is a perspective view of canopy assemblyof, further illustrating flexible coverdisposed over canopy frame, according to one example. It is noted that flexible coveris opaquely illustrated to show portions of canopy framedisposed thereunder. A number of mounting clipsdisposed on the inside surface of flexible cover, are illustrated as being retained within clip retainer slotsextending longitudinally along second beamand cross-beam(as well as first beamand cross-beam, not illustrated) to secure flexible coverto canopy frame(seebelow).

respectively illustrate a perspective, a side view, and an end view of gusset, according to one example. In the illustrated example, gussetincludes a base memberhaving a hollow shaftwhich is configured to fit over and receive upper endof leg(illustrated by dashed lines). In one example, base memberincludes a plurality attachment holesto receive fasteners, such as set screws, to rigidly connect gussetto leg. A cross-memberextends transversely to base memberand includes, at opposing ends thereof, a pair of flange armsandeach including opposing side wallsandextending generally vertically from a bottom wall. In examples, opposing side walls,and bottom wallof flange armsandtogether from a beam channelto receive and support a corresponding one of the first and second beamsand.

In one example, a cross-channelextends across cross-membertransversely to beam channel, wherein a bottom surfaceof cross-channelis at a lower level (vertically) than bottom wallof beam channeland segments beam channelsuch that flange armsandprovide spaced apart segments of beam channel. In one example, each flange armandincludes a binder openingextending therethrough below beam channel. In one example, a pair of stiffening wingsandrespectively extend between undersides of flange armsandand base member.

is a schematic diagram generally illustrating the engagement of a column, via gusset, with the corresponding one of the first and second beams/of canopy frame. Gussetis mounted to legwith upper endpositioned within hollow shaft, and the corresponding one of the first and second beamsandis positioned within beam channel. In one example, a gapis formed between bottom surfaceof cross-channeland the corresponding one of the first and second beamsand, where gapenables a binding deviceemployed to hold a trussto first or second beam/to pass through if a position of a trussoverlaps with a position of a gusset(e.g., see). In one example, beam channelhas a depth, D, which leaves a remaining height, H, of first or second beam/exposed from beam channel. In examples, the remaining height, H, is greater than a depth, D, of a mounting flange of an end bracket of a truss(see) so that a trusscan be positioned at a same location as a columnwithout interfering with gusset. A clip retainer slotis illustrated extending longitudinally along first and second beams/which, as described above, is configured to receive and retain mounting clips disposed on flexible cover.

In the example of, a pair of binding devicesbind/hold beam/to gussetwithin beam channelwithout establishing a rigid/fixed interconnection therebetween (i.e., no direct interconnection between first or second beam/and gusset) to thereby form flexible jointbetween beam/and columnwhich enables enable canopy frameand columns(see) to move relative to one another at flexible joint. In other examples, it is noted that a single binding device, or more than two binding devicesmay be employed. In examples, gussetis formed of a polymeric material (e.g., rotationally molded), while beams/and legsare formed of a metal, such as aluminum. According to such examples, in addition to the polymeric material of gussetproviding additional flexibility to flexible joint, the polymeric material of gusseteliminates metal-to-metal contact between first and second beams/and legs, thereby reducing wear therebetween.

In one example, as illustrated, binding devicecomprises a strap-like binding device which is configured to extend through a corresponding binder openingand about a corresponding on of the first and second beams/, wherein binding devicecan be tightened to hold first and second beams/within beam channelwithout forming rigid/fixed interconnection therebetween (i.e., surface contact only). In one example, binding devicemay comprise a worm-drive clamp. In one example, binding devicemay comprise a ratchet-strap binder. In one example, binding devicemay comprise a strapping tensioner. In one example, binding devicemay be a hook-and-loop type strap. In one example, binding devicemay comprise a jaw-type clamp. In one example, binding devicemay comprise a lashing type binder. Any number of suitable binding devices in addition to those mentioned above may be employed to hold first and second beams/within a corresponding beam channelwithout forming a direct interconnection therebetween.

respectively illustrate perspective, side, and end views of a center truss, according to one example. Center trussextends longitudinally between opposing end bracketsandwhich are configured to engage a corresponding one of the first and second beams/(e.g., see). In one example, each end bracket defines a horizontal backet plateand a vertical bracket platewhich are arranged at a substantially right angle relative to one another and are configured to respectively engage a top surface and an inner side surface (i.e., facing the opposing beam) of a corresponding one of the first and second beams/. In other examples, it is noted that end bracketsandmay employ different configurations, such as for engaging first and second beams/having a perimeter surface that is other than rectangular in shape (e.g., round, oval, hexagon, etc.). In other examples, end bracketsandmay be configured to engage more than two sides of corresponding first and second beamsand. In one example, at least end bracketsandare formed of a polymeric material, wherein remaining portions of center trussesmay be a metal material. In other examples, trussesthe entirety of each truss is made of a polymeric material.

In one example, each end bracketandfurther includes a binder openingextending therethrough to enable a binding device, such as binding device, to pass through hold trussto the corresponding one of the first and second beams/(see). Each center trussalso includes a pair of mounting studsdisposed on opposing lateral sides at an apexof center truss, where mounting studsare for mounting of corresponding ridge connectors(e.g., see).

is a schematic diagram generally illustrating the engagement of an end bracket, such as end bracket, of a center trusswith a corresponding one of the first and second beams/of canopy frame. In one example, horizontal bracket plateand vertical bracket platerespectively engage a top surfaceand a side surfaceof first or second beam/. In one example, as illustrated, binding devicecomprises a strap-like binding device (similar to that illustrated byto hold gusset) which is configured to extend through binder openingand about a corresponding on of the first and second beams/, wherein binding devicecan be tightened to hold first and trussto first or second beam/without forming rigid/fixed interconnection therebetween (i.e., surface contact only). Similar to that described above with regard to gusset, end bracketsand, together with binding device, form a flexible jointbetween beam/and center trusseswhich enables trussesand first and second beams/to move relative to one another at flexible joint. In examples, a depth, D, of vertical bracket plateextending from top surfaceof first or second beam/is less than the height, H, of first or second beam/exposed from gusset(see), so that end brackets/of trussescan be positioned at a location coincident with columnswithout interfering with gussets(e.g., see).

is a perspective view illustrating an end truss, according to one example. End trussextends longitudinally between opposing end caps, with each end capincluding a beam slot, and a beam insertextending therefrom in a direction transverse to the longitudinal dimension of end truss. With reference tobelow, (as well as), beam insertsare inserted into open ends of first and second beamsand, and cross-beamis inserted into beam slotsof opposing end caps. In one example, fasteners (not illustrated) extending through side walls of first and second beams/and into beam insertsare employed to secure end trussto first and second beams/. In examples, at least end campsof end trussesare made of a polymeric material with a remaining portion being made of metal. In other examples, the entirety of each end trussis a polymeric material.

In examples, end capsfurther include beam slots (e.g., see) to receive and retain a cross-beamat opposing end of canopy frame, illustrated as cross-beamsandin. Positioning beam insertsof end capswithin the ends of first and second beamsand, as well as employing cross-beamsand, helps to maintain a desired/selected spacing between first and second beamsand, and in provides rigidity to canopy frameand to canopy assemblyas a whole.

are an enlarged perspective views illustrating portions of canopy frameand columnsof canopy assemblyand illustrate the mounting of center trussesand end trussesto first and second beams/, and the mounting of first and second beams/to a column, according to one example.illustrates an end truss, in this case, end truss, mounted to first and second beams/with beam inserts of end capsinserted therein, and cross-beaminstalled between end caps. Center trussesandare also shown disposed on first and second beamsand.illustrates an example of a center trussbeing installed at a location coincident with a column, where the depth, D, of beam channelof gusset(see) and the depth, D, of vertical bracket plateof end bracketof center truss(see) ensure that the vertical bracketand gussetdo not interfere with one another.

is a cross-sectional view illustrating a first and second beam/, according to one example. First and second beams/(as well as cross-beams, see) include at least one clip retainer slotextending along there longitudinal lengths which is configured to receive and retain therein a plurality of mounting clip disposed along a perimeter of flexible cover, such as illustrated by example mounting clip. Mounting clipis insertable and retained within clip retainer slotwithout the use of tools, wherein mounting clipcan slide laterally within clip retainer slot. In examples, the tension of flexible (e.g., elastic) coverwhen stretched over canopy frameproduces an upward force on and retains mounting clipwithin clip retainer slot. In examples, clip retainer slotsare disposed on each side of first and second beams/so that first and second beams/can be installed at any orientation.

respectively illustrating different configurations of canopy assemblyemployed with different types of floating watercraft portsand, where different implementations of canopy assemblymay employ different numbers and lengths of trusses, and different lengths of first and second beams/. In some examples, first and second beamsandmay come in segments of varying lengths which can be joined together to form first and second beamsandhaving different lengths for different implementations. In, floating watercraft portrepresents a watercraft port configured for a pontoon port where, relative to watercraft portof, watercraft porthas a greater number of trussesand first and second beams/of greater length. In, floating watercraft portrepresents a watercraft port configured for a pair of personal watercraft, where relative to watercraft portof, watercraft porthas fewer trussesand first and second beams/of shorter length.

In summary, by employing binding devices to form flexible joints to hold together components of the canopy assembly (without the use of interconnecting fasteners that directly and rigidly fasten components directly to one another), components of a canopy assembly, in accordance with the present disclosure, are able to flex and move relative to one another at the flexible joints and thereby reduce and/or eliminate wear and stress fatigue present in conventional, rigid metal canopy assemblies. Wear and fatigue are also reduced by employing polymeric material for at least portions of components forming the flexible joints (e.g., polymeric gussets and end brackets) to eliminate metal-to-metal contact between canopy assembly components. Further, using a flexible, elastic canopy cover that is coupled to the canopy frame via clips that can slide within clip retainer slots in the canopy frame enables the canopy cover to adjust to flexing and movement of the canopy frame and columns. While a canopy assembly as described herein may be used with/mounted to any type of structure, the ability to flex makes the canopy assembly ideally suited for mounting to non-stationary bases, such as floating watercraft ports, and enables the canopy assembly to flex in response to wind and other forces.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described herein without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.