Rail and panel system for a pontoon boat

Abstract

The invention relates to boundaries used on a watercraft. Specially, the invention relates to boundaries used on pontoon boats. The boundaries generally include a rail and panel system positioned around an outer periphery of the pontoon boat. The invention also relates to a method of forming and installing the boundaries on a watercraft.

1 . A watercraft including: 
 a frame;    a rail supported by the frame; and    a non-metallic panel supported by the rail.    
   
   
       2 . The watercraft of  claim 1 , wherein the non-metallic panel is constructed of a polymer-based material.  
   
   
       3 . The watercraft of  claim 1 , wherein the non-metallic panel is constructed of polycarbonate.  
   
   
       4 . The watercraft of  claim 1 , wherein the watercraft is a pontoon boat.  
   
   
       5 . The watercraft of  claim 1 , wherein the rail and the non-metallic panel cooperate to define a boundary of the watercraft.  
   
   
       6 . The watercraft of  claim 1 , wherein the rail is formed from a substantially square-shaped tube.  
   
   
       7 . The watercraft of  claim 1 , wherein the non-metallic panel has interlocking portions adjacent to a top and bottom edge, that are profiled to interlock with the rail.  
   
   
       8 . The watercraft of  claim 7 , wherein the tube includes four sides and an extension coupled to one of the sides.  
   
   
       9 . The watercraft of  claim 8 , wherein the tube includes a recess adjacent to the extension.  
   
   
       10 . The watercraft of  claim 9 , wherein the extension includes a first tab cooperable with said interlocking portions.  
   
   
       11 . The watercraft of  claim 10 , wherein the interlocking portion on the non-metallic panel includes a second tab configured to cooperate with the recess and the first tab to couple the panel to the tube.  
   
   
       12 . The watercraft of  claim 9 , wherein the recess is defined as a notch and the interlocking portion of the non-metallic panel includes a second tab configured to be positioned in the notch.  
   
   
       13 . The watercraft of  claim 7 , wherein the non-metallic panel is configured to directly contact both the extension and one side of the tube including the extension.  
   
   
       14 . The watercraft of  claim 1 , wherein the non-metallic panel includes a panel member that defines a first plane and a tab extending from the panel member substantially perpendicularly relative to the first plane.  
   
   
       15 . The watercraft of  claim 1 , wherein the non-metallic panel includes a panel member that defines a first plane and a tab extending from the panel member angles backward to form an acute angle to the first plane.  
   
   
       16 . The watercraft of  claim 1 , wherein the non-metallic panel is configured to couple directly to the rail.  
   
   
       17 . A watercraft including: 
 a frame;    a rail member supported by the frame;    a panel member coupled to the rail; and    means for coupling the panel member to the rail member.    
   
   
       18 . The watercraft of  claim 17 , wherein the panel member is constructed of a polymer-based material.  
   
   
       19 . The watercraft of  claim 17 , wherein the means for coupling the panel member to the rail member includes a tab positioned on the panel member.  
   
   
       20 . The watercraft of  claim 17 , wherein the means for coupling the panel member to the rail member includes a recessed portion in the rail member.  
   
   
       21 . The watercraft of  claim 17 , wherein the means for coupling the panel member to the rail member includes an extension coupled to the rail member.  
   
   
       22 . A boundary for a watercraft, the boundary comprising: 
 a rail including a recessed portion and an extension; and    a panel including first and second ends, the first end including an interlocking portion.    
   
   
       23 . The boundary of  claim 22 , wherein the interlocking portion of the panel is configured to be positioned in the recessed portion of the rail to couple the panel to the rail.  
   
   
       24 . The boundary of  claim 23 , wherein the extension is configured to bend to contact the interlocking portion of the panel to couple the panel to the rail.  
   
   
       25 . The boundary of  claim 22 , wherein the extension includes a tab configured to correspond to the interlocking portion of the panel to couple the panel to the rail.  
   
   
       26 . The boundary of  claim 22 , wherein the panel is constructed of a polycarbonate material.  
   
   
       27 . The boundary of  claim 22 , wherein the rail includes four sides and one of the sides includes both the recessed portion and the extension.  
   
   
       28 . The boundary of  claim 22 , wherein the first and second ends of the panel define a first plane, and the interlocking portion is substantially perpendicular to the first plane.  
   
   
       29 . The boundary of  claim 22 , wherein the first and second ends of the panel define a first plane, and the interlocking portion angles backward to form an acute angle to the first plane.  
   
   
       30 . A method of manufacturing a watercraft, comprising the steps of: 
 providing a flotation platform;    extruding a plurality of rails;    defining a rail structure by attaching the plurality of rails to the flotation platform;    providing a polymer-based panel; and    interlocking the polymer-based panel to the rails to define a boundary wall.    
   
   
       31 . The method of  claim 30 , wherein the flotation platform is defined as a pontoon boat platform.  
   
   
       32 . The method of  claim 30 , wherein the flotation platform defines a periphery and the rail structure is supported by the flotation platform around the periphery.  
   
   
       33 . The method of  claim 30 , wherein the rails are extruded to define a generally Q-shape.  
   
   
       34 . The method of  claim 33 , wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.  
   
   
       35 . The method of  claim 33 , wherein the polymer-based panel and the rails are interlocked to each other by providing an interlocking tab on the panel adjacent to an edge of the polymer-based panel.  
   
   
       36 . The method of  claim 35 , wherein the interlocking tab on the polymer-based panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to form the interlocking engagement.  
   
   
       37 . The method of  claim 35 , wherein two Q-shaped rails are provided in parallel with the receiving areas positioned in a facing relationship, and the polymer-based panel is positioned between the parallel rails in the receiving areas.  
   
   
       38 . The method of  claim 36 , wherein the extending portion of the Q-shaped rails has a complementary overlapping tab and the overlapping tabs on the panel and the Q-shaped rails interlock the panel and rails together.  
   
   
       39 . The method of  claim 36 , wherein the Q-shaped rails are extruded to define a notch in the square portion and opposed to the extending portion, whereby the interlocking tab of the polymer-based panel is received in the notch, and the extending portion is subsequently crimped to entrap the panel.  
   
   
       40 . A boundary for a watercraft, the boundary comprising: 
 a rail including a recessed portion and an extension;    a panel configured to be attached to the rail; and    cooperative interlocking members associated with the panel and the rail, the members configured to attach the panel to the rail.    
   
   
       41 . The boundary of  claim 40 , wherein the cooperative interlocking members include a first tab positioned on the extension and a second corresponding tab positioned on the panel.  
   
   
       42 . The boundary of  claim 41 , wherein the first tab is configured to interlock with the second tab to couple the panel to the rail.  
   
   
       43 . The boundary of  claim 40 , wherein the panel is constructed of a polycarbonate material.  
   
   
       44 . A method of making a rail for a watercraft, and for use with a panel having tabs along an edge thereof, the method including the steps of: 
 providing a metallic material; and    extruding the metallic material to produce a tube having a substantially square cross section including an extension and a recess, the recess adjacent to the extension.    
   
   
       45 . The method of  claim 44 , wherein the extension is provided with a tab for interlocking with the panel tab.  
   
   
       46 . The method of  claim 44 , wherein the recess is provided as a notch for receiving the panel tab.  
   
   
       47 . A pontoon boat including: 
 a flotation platform defining a perimeter;    a motor supported by the flotation platform;    a plurality of rails supported by the flotation platform, the rails positioned around the perimeter, the rails including a substantially square tube having a recess and an extension positioned adjacent the recess, the extension including a first tab; and    a plurality of polymer-based panels having first and second ends and sides extending therebetween, each of the panels including a second tab on each side, the second tab configured to interlock with the first tab of the extension to secure the panels to the rail.    
   
   
       48 . A method of manufacturing a watercraft, comprising the steps of: 
 providing a flotation platform;    extruding a plurality of rails;    defining a rail structure by attaching the plurality of rails to the flotation platform;    providing a non-metallic panel; and    coupling the non-metallic-based panel directly to the rails to define a boundary wall.    
   
   
       49 . The method of  claim 48 , wherein the rails are extruded to define a generally Q-shape.  
   
   
       50 . The method of  claim 49 , wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.  
   
   
       51 . The method of  claim 50 , wherein the non-metallic panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to contact the non-metallic panel.  
   
   
       52 . The method of  claim 51 , wherein the non-metallic panel includes a tab that angles backward to form an acute angle between the tab and the non-metallic panel.