Modular mast for hydrofoil

Abstract

A modular mast for use with a hydrofoil, the modular mast includes a mast base having an upper end for coupling to a board and a lower end, a mast extension having an extension upper end for coupling to the lower end of the mast base and an extension lower end for coupling to a fuselage, and an attachment mechanism for securing the mast base to the mast extension. The upper end of the mast base may include an integral base plate or detachable base plate in a plane perpendicular to the mast base for attaching the hydrofoil to a board, and the mast extension may include one or more tenons for insertion into respective one or more mortises in the lower end of the mast base. Several different attachment mechanisms are disclosed.

Description

MODULAR MAST FOR HYDROFOILCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The application claims priority to provisional application U.S. Serial No. 63 / 606,446 filed July 9, 2024, hereby incorporated by reference in its entirety.BACKGROUND

[0002] Hydrofoils can be added to many different platforms for wind propelled water sports, such as kite foiling, wing foiling, wakesurf foiling, prone foiling, and windsurfing. In these sports the user stands on a board with a hydrofoil mounted on the bottom. The hydrofoil lifts the board off the water to minimize drag, allowing the user to use less power to move around.

[0003] An example of a known hydrofoil 10 is shown in Fig. 1. Hydrofoil 10 includes a mast 12 which would be attached to a riding board (not shown) at one end using base plate 14. The other end of mast 12 is attached to a fuselage 14, which includes a fore wing 16 and an aft wing 18, or stabilizer attached to either end of fuselage 14. Users may invest significant funds into their hydrofoil and may prefer to transport the hydrofoil to many locations around the world.Although the board and the front and rear wings are typically detachable from the mast to provide for a more compact transport, mast 12 as shown in Fig. 1 can approach or exceed 1 meter in length. This length makes transporting the hydrofoil cumbersome and expensive, particularly as carry-on luggage for air travel.SUMMARY

[0004] A modular mast can be disassembled for transport and reassembled before use such that the assembled mast has structural integrity similar to that of a unitary mast. The split foil design allows for smaller packing (including carry-on). It has other advantages as well. If one portion of the split foil is damaged, there is no need to replace both portions. Also, if one rides in water with varying depths, a user can carry less equipment overall by having one base piece and one or more extension pieces having varying heights.

[0005] A modular mast for use with a hydrofoil with a modular mast includes a mast base having an upper end for coupling to a board and a lower end, a mast extension having an extension upper end for coupling to the lower end of the mast base and an extension lower end for couplingto a fuselage, and an attachment mechanism for securing the mast base to the mast extension. The upper end of the mast base may include an integral base plate or detachable base plate in a plane perpendicular to the mast base for attaching the hydrofoil to a board, and the mast extension may include one or more tenons for insertion into respective one or more mortises in the lower end of the mast base. Several different attachment mechanisms are disclosed.BRIEF DESCRIPTION OF THE FIGURES

[0006] FIG. 1 shows a perspective view of a prior art hydrofoil for use in wind propelled water sports.

[0007] FIGS. 2A and 2B show exploded perspective views of a modular hydrofoil mast, in embodiments.

[0008] FIG. 2C shows a side view of the modular mast of FIGS. 2A.

[0009] FIGS. 3 A and 3B show perspective views of a mast extension and mast base of the modular mast of FIG. 2A, in embodiments.

[0010] FIGS. 3C and 3D show a base plate of the modular mast of FIGS. 2A, in embodiments.

[0011] FIGS. 4 A, 4B, and 4C show another modular mast for use in a hydrofoil with another attachment mechanism, in embodiments.

[0012] FIGS. 5 A, 5B, 5C, and 5D show partial views of the modular mast of FIGS. 4A - 4C.

[0013] FIGS. 6A and 6B shows a three-part modular hydrofoil mast, in embodiments.

[0014] FIGS. 7A, 7B, 7C, and 7D show an aluminum modular mast for use with a hydrofoil, in embodiments.

[0015] FIG. 8A shows an aluminum modular hydrofoil mast, in embodiments.

[0016] FIG. 8B shows a perspective view of the mast base of FIG. 8A.

[0017] FIG. 8C shows a perspective view of the mast extension of FIG. 8 A.

[0018] FIG. 8D shows a perspective view of the modular hydrofoil mast of FIG. 8 A.

[0019] FIGS. 9A, 9B and 9C show a modular hydrofoil mast with tenons utilizing a carbon fiber leaf spring detent as an attachment mechanism, in embodiments.

[0020] FIGS. 10A, 10B, and 10C show a modular hydrofoil mast having an attach mechanism of a spring detent, in embodiments.

[0021] FIGS. 11 A - 1 IB show a side and perspective view of a modular hydrofoil mast with tenons and tensioning cables for retention, in embodiments.

[0022] FIGS. 12A, 12B, and 12C show perspective views of an aluminum embodiment utilizing alignment pins, in embodiments.

[0023] FIG. 12D shows a side view of the modular hydrofoil mast of FIG. 12A

[0024] FIGS. 13A, 13B, and 13C show perspective views of modular mast with a cam mechanism on tenon, in embodiments.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] Exemplary embodiments will be described in detail herein, with examples thereof represented in the drawings. When the following descriptions involve the drawings, like numerals in different drawings represent like or similar elements unless otherwise indicated. Implementations described in the following exemplary embodiments do not represent all implementations consistent with the present disclosure. Instead, they are merely examples of apparatuses and methods consistent with some aspects of the present disclosure as detailed in the appended claims.

[0026] Further, directional terms such as “upper” and “lower” are used to indicate relationships between parts as disclosed herein and generally refer to the orientation of a hydrofoil when in use while attached to a board.

[0027] FIGS. 2A - 2C shows a modular mast 100 for use in a hydrofoil. FIGS. 3 A - 3D show partial views of modular mast 100. FIGS. 2A - 2C and 3A - 3D are best viewed together in the following discussion.

[0028] For clarity of illustration, modular mast 100 is depicted in FIGS. 2A - 2C in an orientation opposite to how it would be used when attached to a board. Modular mast 100 includes mast base 102 and mast extension 104 that may be secured to each other to form a complete mast for use with a hydrofoil such as that shown in FIG. 1. Mast base 102 includes an integral base plate 106 at its upper end that may be secured to a board using screw holes 108. The lower end of mast base 102 includes two mortises 110 separated by a stringer 112 spanning the thickness of mast base 102 and extending throughout all or a part of the length to increase strength.

[0029] Mast extension 104 includes an upper end having two tenons 114, which are sized and shaped for insertion into mortises 110 of mast base 102. In embodiments, tenons 114 fit snugly into mortises 110 and have a length sufficient to provide overall strength to modular mast 100.Each tenon 1 14 includes a threaded socket 116. The lower end of mast extension 104 may be coupled to a fuselage 126 (FIG. 3C) having a fore wing 128 and an aft wing (not shown) similar to those shown in FIG. 1. In embodiments, fuselage 126 may be integrally formed with mast extension 104 or may be detachable.

[0030] To secure mast extension 104 to mast base 102, various attachment mechanisms may be used. As shown in FIGS. 2A - 2C, tensioning rods 118 are inserted through apertures 120 in base plate 106. Mast base 102 may include channels aligned with threaded sockets 116 to guide a threaded end of tensioning rods 118 therein. Tensioning rods 118 include a T-bar head 122 for tightening the tensioning rods 118 into threaded sockets 116 to securely attach mast base 102 to mast extension 104.

[0031] Although FIGS. 2A - 2C show two tenons and corresponding mortises, this is for purposes of illustration. More or fewer mortise and tenon attachment mechanisms may be used without departing from the scope of this disclosure. In addition, the relative sizes of components, such as the length, width and thickness of the mast base and mast extension, as well as the length of tenons, may vary from what is depicted.

[0032] FIGS. 3A - 3B show perspective views of mast extension 104 and mast base 102 of modular mast 100. FIGS. 3C - 3D show a top view of base plate 106 of modular mast 100. Mast extension 104 is shown in FIG. 3A with a portion of fuselage 126 and fore wing 128. Tenons 114 extend upward from mast extension 104, with threaded sockets 116 secured in the upper part of tenons 114. In embodiments, modular mast 100 has a thickness profile such that the mast is thicker in a middle part of its width at stringer 112 and tapers to a point at the leading and trailing edges. Similarly, tenons 114 may have a varying thickness along their width. Threaded sockets 116 may be placed at a horizontal position along the width of each tenon at its thickest point.

[0033] FIG. 3B shows tenons 114 partially inserted into mortises 110 of mast base 102. FIG. 3C shows one tensioning rod fully inserted into aperture 120 and the other partially inserted.Aperture 120 is countersunk to provide room for washer 124 and T-bar head 122 so that base plate 106 may be mounted to a board using screw holds 108 in base plate 106

[0034] FIGS. 4A - 4C show a modular mast 130 for use in a hydrofoil with another attachment mechanism. FIGS. 5A - 5D show partial views of modular mast 130. FIGS. 4A - 4C and 5A - 5D are best viewed together in the following discussion.

[0035] Mast 130 includes a mast base 132 that may be attached to a board, such as a wing foiling board, using base plate 136. Mast 130 includes a mast extension 134 which is attached to mast base 132 by inserting tenons 138 into respective mortises 140 in mast base 102. Mortises 140 are shown in more detail in FIG. 5C and are separated by a stringer 142 extending through the length of mast base 132 to increase strength. In embodiments, tenons 138 are sized to fit snugly into mortises 140. A fuselage may be attached to the lower end of mast extension 134.

[0036] A tensioning attachment mechanism secures mast extension 134 to mast base 132 and provides structural integrity. Tensioning pins 144 have a T-shaped head and a threaded bottom, and a length comparable to the length of mast base 132 minus the length of the tenon 138. The T- shaped head 146 of each tension pin 144 is received in a slot 148 in tenon 138 as shown in FIG. 5A. After T-shaped heads 146 of tension pins 144 are received into slots 148, mast extension 134 is inserted into mast base 132, and flange nuts 150 are inserted through apertures in base plate 136 and bolted onto the threaded bottoms of tension pins 144.

[0037] Slots 148 may include a through-hole for receiving the head of tension pin 144 and a channel 152 for receiving a length of tension pin 144. As shown in FIGS. 5A and 5B, channels 152 may be on opposite sides of tenons 138 to better resist torque on the mast 130 during use. Although channel 152 is depicted with a certain length, the channel may be longer or shorter as necessary to provide sufficient retention strength. Channel 152 may also form a slot through the entire thickness of the tenon.

[0038] Embodiments are shown in the figures to illustrate principles discussed herein. The dimensions shown are for purposes of illustration but other dimensions may be used. In any of the embodiments discussed herein, a mast base may be used with mast extensions having a variety of lengths. For example, depending on the water conditions (calm, turbulent), masts of different lengths are desired. Combining a mast base with one of a plurality of mast extensions of different lengths allows the completed mast height to be varied for different water conditions.

[0039] In embodiments, any of the mast bases discussed herein may be used with more than one mast base. FIGS. 6A and 6B show a three-part modular hydrofoil mast 154. Mast base 156 is an example of mast bases 102 and 132 and may be connected to a board using a base plate as described above. Mast base 156 may be used with an intermediate mast extension 158 as well as mast extension 160. Mast extension 158 is an example of mast extensions 104 and 134 and would be attached to a fuselage as discussed above. Slots 162 receive T-shaped heads of tensionrods 164. Intermediate mast extension 158 is positioned between mast base 156 and mast extension 160. Channels 166 extend through mast extension 158 so that tension rods 164 pass from mast extension 160 through intermediate mast extension 158 and into mast base 156. In embodiments, intermediate mast extension 158 may also include slots 168 to receive a T-shaped head of tension rod 164 so that it can be used without mast extension 160. Different lengths of tension rods 164 may be provided for use with different combinations of mast bases, mast extensions and intermediate mast extensions.

[0040] FIGS. 7A - 7D show an aluminum modular mast 170 for use with a hydrofoil. Similarly to the embodiments discussed above, aluminum modular mast 170 includes mast base 172 which is an example of mast bases 102, 132 and 156, and mast extension 174 which is an example of mast extensions 104, 134 and 160. An upper end of mast extension 174 includes tenons 178. Tenons 178 are inserted into corresponding mortises in mast base 172. As described above, an attachment mechanism features tensioning rods 180 which are inserted through apertures in base plate 176 so that a threaded end can engage with a threaded hole in tenons 178. Although a specific attachment mechanism is shown in FIGS. 7A - 7D, any of the attachment mechanism discussed herein may be used.

[0041] FIG. 8A shows a disassembled aluminum modular mast 182. FIG. 8B shows a perspective view of the mast base 184, which is an example of mast base 172. FIG. 8C shows a perspective view of the upper end of assembled mast 182 before base plate 190 is attached. FIG. 8D shows a perspective view of assembled modular hydrofoil mast 182 of FIG. 8 A. Mast extension includes tenons 188 which are sized to fit inside corresponding mortises in mast base 184. Mast 182 is shown with a separate base plate 190, but base plate 190 may also be integrally formed with mast base 184. Mast 182 uses short threaded pins 192 inserted through channels in mast base 184 and tightened using an extended wrench 194 which may be inserted through the same channels to tighten pins 192 in threaded holes in tenons 188.

[0042] FIGS. 9A - 9C shows a modular mast 196 with a different attachment mechanism. Mast extension 198 includes two leaf springs 200 which are inserted into openings 202 in mast base 204 during assembly of modular mast 196. Leaf springs 200 may have the same width or different widths, as shown. Each leaf spring 200 includes two sides 206 and 208 separated by a gap 210. A retention notch 212 is located on the bottom of each side 206, 208 of a leaf spring 200. When mast extension 198 is fully inserted into mast base 204, retention notches 212 arereceived in receiving slots 214. Sides 206 and 208 and gap 210 are dimensioned to be slightly wider than opening 202 so that retention notches 212 are pressed into receiving slots 214. Embodiments with retention notch geometry providing a tensioning force along the length of the mast have also been considered.

[0043] FIGS. 10A - 10C show a modular hydrofoil mast 216 similar to modular hydrofoil mast 196. Instead of retention notches and receptacles, mast 216 uses an attachment mechanism to secure mast extension 220 to mast base 218 that includes a spring detent 222 in mast extension 220 that engages with corresponding holes 224 in mast base 218. Outward pressure on the spring detents 222 causes them to be retained in holes 224.

[0044] FIGS. 11 A and 1 IB show a side and perspective view of a modular mast 226. As described for the other embodiments discussed herein, modular mast 226 includes a mast base 228 and a mast extension 230. Tenons 232 on mast extension 230 are inserted into corresponding mortises in mast base 228. Tensioning cable 234 is threaded through mast base 228 and used to pull mast extension 230 into mast base 228. In this embodiment, tensioning cable 234 is attached to a flanged rod 236 which is rotated to tension the cable, and friction with the baseplate prevents the flanged rod from rotating back. Alternate embodiments may utilize a cam mechanism to tighten tensioning cable 234.

[0045] FIGS. 12A, 12B, and 12C show perspective views of modular mast 240 utilizing alignment pins 242 and an engagement mechanism. FIG. 12D shows a side view of the modular mast 240 of FIG. 12 A. Modular mast 240 may be made of extruded aluminum and include first half 244 and second half 246. First half 244 may be an example of a mast base or a mast extension. Alignment pins 242 on second half 246 are inserted alongside tabs 245 on first half 244 to align the first and second halves during assembly. Bolts may be installed through apertures 248, extend through channels in first half 244 and tabs 245 to engage with threaded holes 250 in second half 246.

[0046] FIGS. 13A, 13B, and 13C show perspective views of modular mast 252 with an attachment mechanism that uses a cam mechanism to secure mast extension 254 to mast base 256. Hooked slot 258 in tenon 260 slides over pin 262 and cam 264 as tenon 260 is inserted into mast base 256. After tenon 260 is fully inserted, cam 1408 may be turned using pin 1406 into the hook portion of hooked slot 258. A stringer 266 may be provided across the thickness of modular mast 252 to increase its strength and structural integrity.

[0047] A variety of attachment mechanisms that include a vertical component along the length of the mast, such as tensioning rod 118, have been described. In addition, cross-sectional attachment mechanisms that secure a mast extension to a mast base through the thickness of the mast may also be used. This may include one or more bolts inserted through the side of the mast and the tenon that are secured with a nut to hold the two mast pieces together. Further, a spring pin may be used instead of a nut and bolt.

[0048] Another example of a cross-sectional method will be described with reference to FIG. 12C. While threaded holes 250 in FIG. 12C are shown as a structure wholly contained within second half 246, these threaded holes may alternatively be provided by inserting a bar through a hole in the side of second half 246 in a direction perpendicular to the length of the mast. The bar would include a threaded hole for receiving the threaded end of a bolt inserted through aperture 248. One or more bars having a threaded hole may be inserted across the thickness of any of the modular masts disclosed herein.

[0049] In embodiments, any of the modular masts disclosed herein may be made of carbon fiber, steel, aluminum or titanium, for example.

[0050] In a representative example for some embodiments, tenon length of 100mm has proven sufficient for restoring stiffness and riding characteristics for a carbon mast of width 14mm and chord length of 120mm and wall thickness of 1.5mm.

[0051] Changes may be made in the above methods and systems without departing from the scope hereof. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall therebetween.

Claims

CLAIMSWhat is claimed is:

1. A hydrofoil with a modular mast, comprising: a mast base having an upper end for coupling to a board, and a lower end; a mast extension having an extension upper end for coupling to the lower end of the mast base, and an extension lower end for coupling to a fuselage; and an attachment mechanism for securing the mast base to the mast extension.

2. The hydrofoil of claim 1, wherein: the upper end of the mast base further comprises an integral base plate in a plane perpendicular to the mast base for attaching the hydrofoil to a board; and the mast extension further comprises one or more tenons for insertion into respective one or more mortises in the lower end of the mast base.

3. The hydrofoil of claim 2, wherein the tenons include threaded sockets.

4. The hydrofoil of claim 3, wherein the mast base further comprises one or more channels, aligned with the respective threaded sockets, extending from an aperture in an upper side of the base plate through the mast base for receiving one or more tensioning rods.

5. The hydrofoil of claim 4, wherein the tensioning rods have a threaded end for engaging with the threaded socket, and a T-Bar head for tightening the tensioning rods.

6. The hydrofoil of claim 2, wherein the one or more tenons further comprise a T-shaped slot for receiving a head of a tension pin.

7. The hydrofoil of claim 6, wherein the tension pin has a threaded end opposite the head, the threaded end extending through a corresponding channel in the mast base through an aperture in the base plate.

8. The hydrofoil of claim 7, further comprising a flange nut for engaging with the threaded end of the tension pin.

9. The hydrofoil of claim 1, wherein:the mast extension further comprises one or more tenons for insertion into respective one or more mortises in the lower end of the mast base, the tenons each having a threaded receiver; and the mast base further comprises channels aligned with threaded receivers.

10. The hydrofoil of claim 9, further comprising one or more bolts inserted through the channels in the mast base to engage with the threaded receivers in the one or more tenons.

11. The hydrofoil of claim 1, further comprising an intermediate mast extension having an intermediate extension upper end with one or more tenons for coupling to respective mortises in the lower end of the mast base and an intermediate extension lower end having one or more mortises for receiving one or more tenons on the extension upper end of the mast extension.

12. The hydrofoil of claim 11, wherein the one or more tenons of the mast extension further comprise a threaded socket.

13. The hydrofoil of claim 12, wherein the intermediate mast extension further comprises channels aligned with the threaded sockets in the mast extension and with corresponding channels in the mast base.

14. The hydrofoil of claim 1, wherein the attachment mechanism is a tensioning cable.

15. The hydrofoil of claim 1, further comprising a fuselage coupled to the lower end of the mast extension, the fuselage having a fore wing and an aft wing.

16. A method of assembling a hydrofoil with a modular mast comprising a mast base having an upper end for coupling to a board and a mast extension having a lower end for coupling to a fuselage, the method comprising: inserting tenons on an upper end of the mast extension into corresponding mortises in a lower end of the mast base, the tenons having a threaded socket; inserting tensioning rods having a threaded end for engaging with the threaded socket and a T-Bar head through channels in the mast base; and tightening the tensioning rods in the threaded sockets using the T-Bar head.

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