Clamshell Float Bouy for Lines

This application claims benefit under Title 35, United States Code § 119 (e) of U.S. Provisional Application No. 63/657,383 filed on Jun. 7, 2024.

The following invention relates to floats, such as buoy floats which have a line passing therethrough or connected thereto. More particularly, this invention relates to floats which are formed by joining two halves together and which engage the line associated with the float.

Lines and associated rigging are used for a variety of different purposes in the marine environment. Lines (also called ropes) can be used onboard a boat and also can be used off of the boat, such as for securing a boat to a dock or connecting a boat to an anchorage point. Lines can also be used in waterways, such as to designate areas which are excluded from boat traffic, such as swimming areas.

Often lines that are intended to be used in or near the water benefit from having a float (or buoy) attached to the line to keep the line from sinking beneath the surface. When a line sinks it can be difficult to find when needed. Also, when a line sinks it can often cease to perform its intended function (or be less effective), such as to be visible and notify boat operators as to the presence of the line (and information communicated by the position of the line). Furthermore, a boat can strike a line and damage it (or damage the boat) if the line cannot be easily seen.

It is known in the prior art to attach a float to a line by designing a float of material which is less dense than water by an appreciable amount. The float includes a through bore passing therethrough, along which through bore the line is routed. The float provides sufficient buoyancy to keep the line which is attached to the float from sinking too far below the surface (or keeps the line above the surface, at least at the float). The line can thus be easily found and is more readily visible. Depending on the length of the line, more than one float can be attached to the line as needed.

Often a line benefits from having a specialty configuration at ends thereof, or along the line. These specialty configurations, such as eyes, loops, hooks and the like, typically cannot fit through the through bore in the float. Thus, it is necessary to pass the line through the bore hole before the specialty configuration is associated with the line, such as by tying knots in the line, attaching structures to the line, etc. Such a specialty configuration can thus take a large amount of specialty expertise and specialty time for a line with floats thereon, to be configured/constructed as desired.

Another problem with line floats in the prior art is that the rope can typically pass longitudinally through the through bore hole in the line, moving the float out of a most desired position along the line. To prevent such longitudinal motion of the floats along the line, knots can be provided on the line adjacent to each end of the float. However, making such knots requires further time and expertise and cannot fit through the through bore in the float. Furthermore, knots in lines provide points of weakness, such that the line can have less strength than desired and/or required for a particular use.

Accordingly, a need exists for a float for a line which can be easily installed upon a line, even if the line already has a specialty configuration associated therewith. Such a float would beneficially also be configured to resist longitudinal translation along the line, but rather hold its position without requiring knots to be formed in the line. Such a float would also beneficially avoid becoming waterlogged, be compatible with the marine environment (including saltwater environments), be durable and be of simple and low cost manufacture.

With this invention, a float for a line is provided which is attachable to a line without requiring the line to be passed axially/longitudinally through a through bore of the float. Rather, the float is provided in two halves which can be attached together to complete manufacture of the float installed upon the line. The buoy/float thus has a somewhat clamshell configuration with the line passing therethrough.

In an example embodiment, the two separate halves are identical to each other, thus simplifying and reducing cost of manufacture. In one embodiment, the two separate halves are formed of injection molded plastic, and can thus be manufactured in a common mold. The two separate halves are later brought together to complete the float. Beneficially, plastics of different material colors are molded to have a similar shape and then pairs of separate halves having different colors are brought together, resulting in a float which is half one color and half a second color. As an alternative, both halves could have a common color.

Each of the halves, in addition to having an injection molded half shell, also includes a foam core which fits within an interior central compartment of the half shell to complete each half of the float. In one embodiment, this foam core fills a majority of an interior of the half shell. Inner walls can be provided within the half shell and parallel to each other (and parallel to the end walls of the half shell), to isolate two end compartments from a main central compartment. The foam core fits within the main compartment, while in one embodiment foam tips fit within the two end compartments and to maximize buoyancy for the float.

Both the foam core and the foam tips preferably are formed of a closed cell solid polymeric hydrocarbon material. One example would be styrofoam. Other example materials could be various different urethane foams. It is desirable for the foam to impart some degree of resiliency and rigidity to the float and to, for instance, allow the float to function somewhat as a bumper between a boat and other objects such as a dock. The foam core is thus preferably formed of a material which has a relatively high crush strength, and yet still can deform somewhat when exceptionally high compression loads are encountered. When such high compression loads are relieved, the foam can return to an original shape, restoring the float toward an original size and shape. The half shell typically has a thin side wall and does not provide significant strength itself, but rather acts as a containment for the foam core.

Considering each half shell in more detail, each half shell includes a hemi-spheroid outer side wall surrounding the main central compartment. A shape of this outer side wall, in one embodiment is somewhat similar to a shape of a football or rugby ball which has been cut in half along a plane in which the line lies. However, the ends are flat (or nearly flat) and preferably parallel with each other and define an overall length of the float, truncating the float from having an entire form like that of a football. The two halves could be asymmetrical in one embodiment, such as with one half larger than the other and each half still being a semi-spheroid.

The end walls at either end of the half shell include semi-circular portals herein. These portals are sized to allow the line to extend into and out of the interior surrounded by the half shell. The interior includes a line pathway and a through bore passing through the float. The end walls are preferably similar to each other, such that the half shells can generally be oriented with either end closer to one end of the line, and either end closer to the other end of the line, and making the float generally reversible as to its orientation on the line.

Inner walls are provided parallel with each other and inboard of the end walls. These inner walls are preferably each a similar distance away from the adjacent end wall, with the inner walls dividing the two end compartments from the main central compartment. A central portion of each inner wall is cut away at a mid-notch, which allows the line to pass through the inner wall. Teeth (at least one) extend radially into this mid-notch as part of the inner wall. These teeth are pointed at tips thereof, extending most deeply into the mid-notch of the inner wall, with the teeth configured to engage within fibers of the line and keep the line from moving relative to the inner wall. In this way, and when two halves are brought together upon the line, these teeth act to keep the float from moving longitudinally upon the line. Teeth could alternatively be coupled to the end walls, the foam or some other structure.

The foam core has a trough extending into a flat side thereof. The trough has a diameter similar to that of the line and is generally semi-cylindrical to allow the line to rest within the trough. A semi-spheroid side of the foam opposite the flat side generally has a shape matching that of the outer wall of the half shell. The foam core includes truncated flat ends adjacent to each of the inner walls when the foam core is located within the main central compartment. The foam core thus essentially fills the main central compartment in one embodiment.

The two end compartments can be fitted with foam tips. Each of these foam tips also preferably includes troughs in a flat side thereof, with an arcuate side opposite the flat side generally configured to be adjacent to portions of the outer wall of the half shell, and between the inner wall and the end wall of each and compartment. In this way, each end compartment is substantially filled with one of the foam tips.

The outer wall of each half shell terminates at an edge. In one embodiment, this edge has a groove in a face on one side of the half shell, and a tab extending from the face on the other side of the half shell. The tab can fit within the groove, so that when two outer walls of two shells are brought together with a tab of one outer wall of one shell within a groove of the other outer wall of the other shell, such interlocking tabs and grooves help to cause the two half shells to form a whole spheroid shape with enhanced rigidity.

Furthermore, and when such tabs and grooves are interlocking together, preferably slots are provided in the half shell just below the groove and clips extend beyond each of the tabs, each of the clips and slots acting as a fastener pair. The clips are sized to fit within the slots. The clips include a tooth near a beveled tip thereof, so that the beveled tip can easily fit into the slots and the tooth can catch within an edge of the slot, to allow the clips to hold the two outer walls of the two half shells together.

A further fastener can also be provided to secure the two halves together. In one embodiment, a single threaded standoff or post extends upwardly parallel with one of the edges of the outer shell at a midpoint between the inner walls of the half shell and adjacent to one of the edges. A bore post standoff is provided at a similar location, but adjacent to the edge with the groove. The threaded standoff and the bore post standoff of the two separate halves are aligned together on a common fastener centerline. A fastener, such as a screw, can then pass through the bore post and into the threaded standoff. Threads on the screw can enmesh with threads on the threaded standoff, so that when the screw is tightened the bore post and the threaded standoff are held tightly together. Optionally, two such fasteners are attached to either side of the float, for the securing of the two halves together, to complete the float and its installation upon the line.

Accordingly, a primary object of the present invention is to provide a float which can be attached to a line without needing to feed an end of the line through the float.

Another object of the present invention is to provide a float which is in the form of two clamshell halves that can be snapped together on a line.

Another object of the present invention is to provide a float which is attachable to a line in a manner keeping the line from translating through the float.

Another object of the present invention is to provide a float formed of two halves which are identical, or nearly identical, and attachable together to simplify manufacture.

Another object of the present invention is to provide a combined float and line which includes the float located at a desired position along the line and interposed between features on the line which do not fit through a pathway passing through the float.

Another object of the present invention is to provide a method for attaching a float to a line without needing to feed an end of the line through a hole in the float.

Another object of the present invention is to provide a float which remains less dense than water even when water incursion through an outer wall of the float occurs.

Other further objects of the present invention will become apparent from a careful reading of the included drawing figures, the claims and detailed description of the invention.

Referring to the drawings, wherein like reference numerals represent like parts throughout the various drawing figures, reference numeralis directed to a float (), which is configured to have two clamshell-like half shellswhich join together over a line L, to place the floatupon the line L. The floatcan be easily installed upon a line L, without needing to feed the line L through a hole in the floatat an end of the line L, and the floatis configured to hold itself to the line L in a manner resisting longitudinal motion of the line relative to the float.

In essence, and with particular reference to, basic details of the floatare described, according to one example embodiment. The floatis a hollow structure with a spheroid exterior. Two half shellsof similar form are joined together to complete construction of the float. Inner wallsinside each of the half shellsprovide added structural support to the floatand also are configured to engage a line L routed through the float, when the two half shellsare joined together, with such engagement of the line L keeping the line L from translating through the float. Endsof the exteriorof the floatare flattened and each include a portalfor routing of the line L therethrough. Foam corescan reside within the interiorof the floatto enhance buoyancy thereof. A troughin the foam corespreserves a pathway for the line L to be routed through the float. Foam tipsare also provided to fill space between the inner wallsand ends.

More specifically, and with particular reference to, basic details of the floatstructure are described when the floathas been fully constructed by joining the two half shellstogether. The exteriorof the floatis preferably substantially radially symmetrical about a centerline C along which a line L can pass through the float to. The exteriorhas a largely spheroid shape. When viewed in section perpendicular to the centerline C, the exterioris substantially a circle, regardless of where the section is taken. At a midpoint of the central line C, such a circular cross-section would have its greatest diameter. The exteriorcan be somewhat effectively described as having the shape of a rugby ball or a football that has had each of its pointed ends truncated and flattened, at least somewhat.

In one embodiment, the two half shellswhich come together and give the exteriorits appearance can be formed of separate colors. In such an embodiment, the exteriorwill be half in a first color and half in a second color different from the first color. For instance, the exteriorof the floatcould be blue on one side and yellow on a second side. Other colors (or the same single color) could be used for the exterior. In one embodiment, such color is provided by coloring injection moldable plastic before forming the two half shellsby injection molding, so that the color is embedded within the material and not merely on the surface thereof. A seamdefines a line between the two half shells, where the first color transitions to the second color, in embodiments where such a two color construction is provided. This seamalso defines lateral edges of each half shell, which are joined together when the floatis constructed by joining the two half shells.

In one embodiment, the seam edgesengage each other somewhat when the two half shellscome together. For instance, in one embodiment the seam edgesinclude either a tabextending from a face of the seam edgeor a grooveextending down from the face into the grooveof the other seam edge. Such tabsand groovesare similar in size so that the groovescan receive the tabs. To make the two half shellsidentical, the placement of either tabsor grooveswould follow a pattern where half of the seam edgeswould be fitted with tabsand half of the seam edgeswould be fitted with grooves.

The placement of the tabsand grooveswould be such that when two identical half shellsare brought together to complete the float, tabsof one half shellare always adjacent to groovesand the other half shell, for interlocking of the same edgestogether during construction of the float. In one example, the seam/edgeon a left side of each half shellhas a tabthereon and a right side of each half shellhas a groovethereon. One half shell can then be rotated 180° so that when the half shellsare joined together, tabsand groovesof one half shellare aligned with groovesand tabsof the other half shell.

As another alternative, one half shellcould be somewhat less than entirely identical in form. For instance, some half shellscould have seam edgeswhich only include tabsextending therefrom and other half shellscould have seam edgeswhich only include groovesextending therefrom.

With particular reference to, particular details of the half shellsare described by reference to figures which show only one half shell, but recognizing that two half shellsare brought together to complete the float. It is also conceivable that shells could be provided in a size other than half size, such as with three shells each being one-third size coming together or four quarter shells coming together to complete the float, or some other number of identical or unique shells, which together form the completed float.

An interiorof the float(also called the central compartment) is preferably similar in shape to the exteriorand only differing based on a thickness of the side walls of the half shells. Typically, such thickness is merely between about 1 and 3 mm or approximately 1/16 inch. The interiorcould be left open, but most preferably is filled with foam coreand foam tips, so that the interioris largely filled with solid material when the floatis constructed. At a minimum, a majority of the central compartment is filled with foam.

Each half shellis typically a rigid monolithic unitary mass of material, typically formed by injection molding. As mentioned above, the half shellscould each be identical to each other, or could be similar in many ways but slightly different from each other, while still configured to attach to each other to complete the finished floatand to define the exteriorand interiorof the float.

The half shellspreferably include at least one form of fastener for holding the two half shellstogether, in addition to the tabsand groovesidentified above. In one example embodiment, two different forms of additional fasteners are provided for holding the half shellstogether. One fastener is in the form of slotsand clips, which engage each other near the seam edgesto hold the half shellstogether.

Each slotpreferably includes both a hole in the exteriorand also a box housingwhich surrounds the slot. The box housingassists in allowing the clipsto be secured to the slots. Each clippreferably extends generally away from the seam edgesat various locations and along arrow A (), defining a direction that the half shellsare moved towards each other when connecting together. These clipsinclude an elongate trunk portion and a toothed tip. The toothed tip can engage with an edge of a box housingwhen the clipsare inserted into the box housingand through (or at least into) the slots. The clipscan flex somewhat perpendicular to the direction that they extend (along arrow D of), allowing the toothed tipsto move laterally somewhat when passing through the box housing, and then snap into the slotsto engage and hold the clipsto the slots. This configuration of slots, box housingand clipscould be altered in various ways and still allow for a snapping connection of complimentary formed fastener portions to allow for the two half shellsto be joined together. Some forms of fasteners could be more permanent in nature, while other forms of fasteners could be reversibly detached, should it be desired at some point to open up the floatinto two separate half shellsagain, such as to replace a line L passing therethrough.

In one example embodiment, clips(such as four clips) are provided on a left side of the half shellwhile box housingsand slotsare provided (such as four slotsand box housings) on a right side of the half shell. Then, one of the half shellscan be rotated 180° so that slotsand box housingsof one half shellcan be brought together with clipsof the other half shell. In this way, half shellswhich are identical to each other can be brought together and attached to complete the float.

In one embodiment a second fastener is also provided in the form of holesand associated standoffsand a mechanical fastener, such as a screw, bolt, rivet, pin, or other mechanical fastener. In the embodiment shown, one of the holesis a blind bore in a standoffwhile another holewithin another standoffpasses through the exterior, so that the holeis in the form of a through bore. Generally, a mechanical fastenercan pass along the through bore and be threaded into the blind bore.

The blind bore holecan be sized so that threads on the screw type mechanical fastenercan engage material from which the standoffis formed. Alternatively, the blind bore could be tapped with female threads in advance to match threads of the screw type mechanical fastener. If the mechanical fasteneris in the form of a rivet, the blind bore holewould instead be in the form of a through bore extending out of the exteriorto allow opposing heads of the rivet to each pass through to the exteriorof the float. Similarly, if a bolt and nut are utilized, the holeswould each be configured as through bores. Similarly, if the two holesare similar in type (such as similar through bores), the holesof two half shellscan be brought together and held together by a fastener.

By placing one type of holeon one side of the half shelland the other type of holeon the opposite side of the half shell, one of the half shells can merely be rotated 180° so that the two different types of holescan be aligned together for receipt of a mechanical fastener.

By providing two different types of fasteners, should environmental conditions such as thermal expansion or contraction (or corrosion) cause one of the fastener types to be compromised, the other fastener would be more likely to provide independent full redundancy to keep the two half shellssecurely attached together. In this way, the floatcan remain functional in a reliable fashion for a long expected service life, such as at least as long as an expected service life for the line L.

With particular reference to, details of the inner wallsare described, according to one example embodiment. The interior wallscan provide for additional structural strength to the half shellsand also are configured to provide engagement with the line L, to resist translational movement of the line L (along arrow B of) and to keep the floatfrom moving along the line L when the floathas been constructed and attached to the line L.

Each inner wallis preferably a planar structure which is oriented within a plane perpendicular to the centerline C. Two inner wallsare provided in one embodiment, with each of the inner wallscloser to one of the endsof the float. Each inner wallis a semi-circle with a curved terminusadjacent to the side wall exteriorof the floatand a mid-terminuswhich is close to a plane in which the seam edgesare oriented, and near where the two half shellscome together.

In one embodiment, each inner wallincludes a notchtherein. The notchis near the centerline C and keeps open a pathway for the line L to pass along the centerline C through the float. Each notchincludes a tooththerein (at least one). Each toothextends from a rootwhere the toothjoints to the inner walland a tipopposite the root. In one embodiment, the teethhave a length which causes the tipsto extend approximately halfway from the rootsto a top of each notch. As an example, if the line L is one inch in diameter, a notchcould have a ½ inch of depth and perhaps slightly less than a ½ inch in width (e.g. ⅜ inch). The teethwould have a height of about ¼ inch extending from the rootat the bottom of each notchto the tips, which would be located near a geometric center of each notch.

When two half shellsare brought together, the notchesof the two inner wallswould be adjacent to each other and result in an open space having a height of about one inch and a width of about ¾ of an inch. Two opposing teethwould extend toward each other, each extending about ¼ inch, so that tipsof the two teethwould be about ½ inch away from each other. These dimensions provide one typical example, with other dimensions being optional and adjustable to provide suitable engagement with the line L. For instance, the teethcould be ⅛ inch long to place tips¾ inch from each other, or could be other sizes. One toothcould also optionally be provided in each notch.

The line L is typically formed of multiple separate fibers and potentially strands/bundles of separate fibers, which can be displaced somewhat by the teethand side walls of the notches. Because the notchesare generally square/rectangular and the line L is generally circular in cross-section, some available area within the notchesis available for line L distortion from a circular cross-section to a somewhat square cross-section where the lines L pass through the notches. Furthermore, the teethcan further displace portions of the line L within the mid notches. In addition, material forming the line L can to some extent be compressed. As a result, the line L can still fit through the mid notchesin the inner wallswhen the half shellsare brought together, but it is a tight fit which distorts the line L somewhat and with the teethembedded somewhat into the line L. In one embodiment, side walls of the notchescan also be embedded somewhat into the line L. In this way, the line L resists motion along arrow B in a longitudinal direction that the line L extends, when the line L has been captured between the two half shellsduring construction of the float.