MODULAR RIGGING SYSTEM FOR SUPPORTING A SAILBOAT MAST

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/738572, filed Dec. 24, 2024, the contents of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present disclosure generally relates to a system for supporting a mast of a sailboat, and in particular to a modular rigging system for supporting the mast.

BACKGROUND

In sailboat design, sails are mounted to a stable structure called a mast. The mast of a sailboat is typically a tall, thin rod which is mounted to a sailboat in a vertical position when viewed relative to the horizon in flat water. When a sail is attached to the mast, forces and moments generated by wind passing over the sail are either absorbed by or passed through the mast to the rest of the boat. A partial result of the forces experienced by a sailboat is a state of heel, during which a sailboat leans over due to the moment generated by the force of the wind on the sail. When in such a state, the mast is no longer vertically positioned relative to the horizon and instead creates an angle with the horizon, often between 5 or 35 degrees. This state results in even more pronounced loading of the mast.

When under sail, waves complicate the situation further. A sailboat may experience significant acceleration and deceleration in several directions simultaneously as it travels through waves. These accelerations result in momentary shock loading of the mast.

The overall result of this dynamic scenario is that the mast experiences significant loading throughout use. To accommodate this loading, a system for supporting the mast is provided that supports against significant deformation or failure of the mast in all six degrees of freedom. This support is maintained while also allowing minor elastic deformation of the mast itself. Furthermore, this system provides desired support equivalently to both the left and right side of the mast, as loading conditions for the mast can be mirrored depending on the boat's position relative to the wind direction.

The widely accepted solution to supporting the mast is through the use of metal or carbon fiber wires or cables, which are anchored to the deck of the sailboat and are attached to points along the mast. Typically, the mast is supported by a series of these cables, with an equal number supporting the mast on either side, at least one supporting the mast from the front—or bow—of the boat, and in some cases at least one supporting the mast from the rear. In aggregate, these cables make up the standing rigging system of the sailboat. Cables which are supporting the left and right side of the mast are referred to as shrouds. Cables which are supporting the fore and aft of the mast are referred to as forestay and backstay respectively. The cables are under a significant amount of tension, so that when the mast experiences a load in a direction, the cable(s) opposite the load hold the mast largely in place save for minor elastic deformation. Tension is added to the system using turnbuckles, which are screw-like apparatuses which are positioned between a mounting point on the surface of the boat, sometimes referred to as a chainplate, and the cable.

However, standard standing rigging systems are heavy due to the number of metal components and recommended spare parts. The excess weight of the system results in reduced performance of the sailboat. Additionally, each cable uses an individual turnbuckle, which is expensive and adds more additional weight to the boat. The threads on turnbuckles act as stress concentrators to the material, along with being exposed to corrosive environments. These factors, especially when combined, lead to cracking and premature failure of turnbuckles which are installed in existing standing rigging systems. Furthermore, the system typically is installed by a specialist installer, who in many cases designs a custom solution for the individual boat and also custom fabricates each length of cable. As a result, installing the standing rigging system is expensive and time consuming. Furthermore, it makes repairs difficult to achieve, especially when offshore.

Accordingly, while existing current standing rigging systems for sailboats are suitable for their intended purposes the need for improvement remains. Particularly in providing a standing rigging system having the features described herein.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure described or claimed below. This description is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light and not as admissions of prior art.

BRIEF DESCRIPTION

A modular rigging system for supporting a mast of a sailboat is disclosed. The modular rigging system comprises a first toggle configured to connect to a chainplate of the sailboat. A first thimble is configured with at least two first attachment points which are configured to receive a first adjustable connector. The modular rigging system further comprises a second thimble, wherein the second thimble is configured with at least two second attachment points configured to receive a second woven fiber. A lower tensioning section is provided which includes the first adjustable connector, wherein the first adjustable connector is coupled between the first toggle and the first thimble. Additionally, a synthetic shroud segment is made of a length of woven fiber and is configured to connect to and span the distance between the first thimble and the second thimble. The modular rigging system further comprises a mast attachment portion which is configured to couple between the shroud apparatus and the mast; and an optional upper tensioning section which includes a second adjustable connector, wherein the second adjustable connector is coupled between the mast attachment portion and the second thimble.

Various refinements exist of the features noted in relation to the above-mentioned aspects. Further features may also be incorporated in the above-mentioned aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated examples may be incorporated into any of the above-described aspects, alone or in any combination.

BRIEF DESCRIPTION OF DRAWINGS

The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present disclosure. The disclosure may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

FIG. 1A is a side view of a sailboat while underway;

FIG. 1B is a front view of a sailboat while underway;

FIG. 2A-2B are a front view and a side view of a configuration of a rigging system of a mast for a sailboat;

FIG. 3 is a view of a prior art turnbuckle arrangement in the rigging system of a mast;

FIG. 4 is a perspective view of a modular rigging system for a mast according to an embodiment;

FIG. 5 is a perspective view of a toggle of the modular rigging system of FIG. 4 according to an embodiment;

FIG. 6A is a perspective view of a thimble of a modular rigging system of FIG. 4 according to an embodiment;

FIG. 6B is a perspective view of the thimble of FIG. 6A contained within the modular rigging system of FIG. 4 according to an embodiment;

FIG. 7 is a perspective view of a lashing of the modular rigging system of FIG. 4 according to an embodiment;

FIG. 8A is a perspective view of a dog-bone device of the modular rigging system of FIG. 4 according to an embodiment;

FIG. 8B is a perspective view of the dog-bone device contained within a segment of the modular rigging system of FIG. 4 according to an embodiment;

FIGS. 9A-9F are perspective views of toggles according to one or more additional embodiments;

FIGS. 10A-10D are perspective views of modular rigging system utilizing different arrangements of components according to one or more additional embodiments;

FIGS. 11A-11C are perspective views of roller pins for use with the toggles of FIG. 5 or FIGS. 9A-9F according to one or more embodiments;

FIG. 12 is a perspective view of a tensioning arrangement for the modular rigging system according to one or more embodiments;

FIG. 13A is a perspective view of a tensioning plate for the tensioning arrangement of FIG. 12 according to an embodiment;

FIG. 13B is a perspective view of the tensioning plate of FIG. 13A within a segment of the tensioning arrangement of FIG. 12 according to an embodiment;

FIG. 14A-14C are perspective views of additional embodiments of tensioning arrangements according to one or more embodiments.

FIG. 15 shows an additional embodiment of a thimble that allows the end user to forego needing lashings at the top of the mast.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. Although specific features of various examples may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced or claimed in combination with any feature of any other drawing.

DETAILED DESCRIPTION

The following detailed description and examples set forth preferred materials, components, and procedures used in accordance with the present disclosure. This description and these examples, however, are provided by way of illustration only, and nothing therein shall be deemed to be a limitation upon the overall scope of the present disclosure. The following terms are used in the present disclosure as defined below.

Embodiments of the present disclosure provide for a standing rigging system for a sailboat that reduces the weight of the system by reducing the number of redundant components and limiting the number of metal components. Further embodiments of the present disclosure provide for a standing rigging system that can easily be repaired while offshore. Still further embodiments of the present disclosure provide for a standing rigging system that reduces the cost and time required to install a new standing rigging system onboard the sailboat. Further embodiments of the present disclosure provide for a standing rigging system which can be easily retrofitted onto a sailboat to replace an existing standing rigging system. Further embodiments of the present disclosure provide for a standing rigging system comprised of standardized modular parts of various sizes, allowing for production of an off-the-shelf type kit to be purveyed by retail stores and foregoing the need for an expert professional to design and or install a customized system for each sailboat.

Turning now to FIGS. 1A-3, a sailboat 10 is shown having a prior art metal cable standing rigging system. As shown in FIG. 1A, the sailboat 10 has a mast 12, which extends vertically from the sailboat 10. The mast 12 connects to the sailboat 10 at a mast base 13. The mast 12 supports a plurality of sails 14, which in some embodiments extend from the front and rear of the mast. A forestay 16 couples the mast 12 to a point proximate the forwardmost point of the sailboat 10. In some embodiments, the forestay 16 has a connection point on a front surface of the mast proximate a mast tip 18. In some embodiments, the forestay 16 connects to a point on the front surface of the mast which is separated by a distance D1 from the mast tip 18 (see FIG. 1A). In some embodiments, the sailboat 10 may have multiple forestays which each of which extends from a forward section of the sailboat to a point on the front surface of the mast 12. As shown in FIG. 1A, the forestay 16 can be configured to provide support to at least one of the plurality of sails 14.

A backstay 20 couples the mast 12 to a point proximate the rearmost point of the sailboat 10. In some embodiments, the backstay 20 connects directly to a point on a rear surface of the mast 12 proximate the mast tip 18. In some embodiments, a strut 22 extends from a point on the rear surface of the mast 12 proximate the mast tip 18, and the backstay couples a point on the strut to the point proximate the rearmost point of the sailboat (as shown in FIG. 1A). A single backstay 20 may be replaced by two or more backstays which couple various points on the rear of the mast to the rear of the sailboat 10. It should be appreciated that while embodiments herein may refer to a particular backstay or forestay configuration, this arrangement is provided for exemplary purposes and the claims should not be so limited. Any backstay or forestay configuration now in existence or developed in the future may be used with the rigging system described herein without deviating from the teachings provided.

In FIG. 1A-3 the mast 12 is supported on the left and right sides by metal shrouds 30. Several arrangements of metal shrouds 30 are known in the art. As shown in FIG. 1A, a base end 34 of a cap shroud 32 is connected to the sailboat 10 at a point adjacent to either the left or right of the mast base 13. The other end of the cap shroud 32 is connected to a mast connection point 36, which is positioned on a side surface of the mast on the same side as the base end 34. The mast connection point 36 is at the same height as the connection point for forestay 16. At least one spreader 38 supports the cap shroud 32 at an at least one respective cap shroud midpoint 40. In some embodiments, the cap shroud 32 is continuous and configured as one metal cable that extends from the base end 34 to the mast connection point 36. In some embodiments, the cap shroud 32 is configured as a series of discontinuous metal cables which are connected together at respective cap shroud midpoints 40 using junctions (not shown) on the spreader 38. In the metal cable standing rigging system, the cap shroud 32 provides support to the mast 12 such that it does not topple when experiencing forces caused by either the plurality of sails 14 or gravity (best shown in FIG. 1B).

For some sailboats, additional support is desired to ensure the mast 12 does not deform or buckle between the mast base 13 and the mast connection point 36. In such embodiments of the metal cable standing rigging system, at least one diagonal shroud 42 is provided on either side of the mast which is coupled to a spreader base 44. As shown in FIG. 1A, the other end of the diagonal shroud 42 is connected to the sailboat 10 at a diagonal base end 46 proximate the base end 34, as will be described with respect to FIG. 3. For sailboats with taller masts, multiple diagonals per side may be desirable, as shown in FIGS. 1B-2B. Diagonal shrouds which extend between respective spreaders (for example, the upper diagonal shroud 42 in FIG. 1B) may either be continuous from the diagonal base end 46 such that each metal cable extends from the diagonal base end, or may be discontinuous such that the diagonal shroud has an upper diagonal base end at the junction (not shown) and does not connect to the diagonal base end 46 on the sailboat.

As shown in FIG. 2A, in an embodiment the metal shroud arrangement 30 is substantially symmetrical on the left and right side of the sailboat 10 relative to a vertical center axis CA of the mast 12. In particular, each cap shroud 32 and any diagonals 42 are mirrored such that the mast has equivalent support on both the left and right side. Minor defects in the prior art manufacturing process of metal cable standing rigging system may result in minor discrepancies between sides. As shown in FIG. 2B, the symmetrical components of the metal shroud arrangement 30, the forestay 16, and the backstay 20 provide support to the mast 12 from the left, right, front and rear of the sailboat 10 respectively.

FIG. 3 shows a detailed view of the base end 34 and diagonal base end 46 of the metal cable standing rigging system. In some embodiments, the sailboat 10 has chainplates 48 which comprises the base end 34 and the diagonal base end 46. The chainplate is secured to the deck of the sailboat and provides a reinforced point for anchoring the base ends of the prior art metal cable standing rigging system. Typically, the sailboat 10 has at least two chainplates 48, with each positioned in a mirrored position on either side of the mast.

Prior art metal cable standing rigging systems utilize turnbuckles 50 as the anchors between the chainplate 48 and each respective cap shroud 32 and each respective diagonal shroud 42 at the base end 34 and diagonal base end 46 respectively. Other devices are known which can replace the turnbuckle on smaller sailboats, such as shroud adjuster plates or downsized turnbuckles known by the trade name “Sta-Master.” The turnbuckle is adjustable to provide more or less tension to the respective shroud it is connected to using a crescent wrench, pliers, or other similar tools known in the art. More tension is often desirable, for example, when sailing in extreme winds where the forces experienced by the mast 12 are amplified.

The chainplate 48 comprises a metal body with a number of anchor holes corresponding to the number of desired base ends and diagonal base ends for the given sailboat 10. Each turnbuckle 50 has a turnbuckle toggle 52 which connects to a respective anchor hole via clevis pins 54.

The below description is directed to one “segment” of a modular rigging system. A segment of the modular rigging system can replace any similar segment of the metal cable standing rigging system. For example, a segment of the modular rigging system may replace a cap shroud in totality, or the cap shroud may be replaced by several discontinuous segments which would mimic the arrangement of the discontinuous cap shroud described above. The same applies to continuous and discontinuous diagonal shrouds.

Referring now to FIG. 4, the modular rigging system 100 is shown for the sailboat 10 according to some embodiments of the present disclosure. The modular rigging system 100 attaches to the chainplate 48 using a modular toggle 102 and clevis pin 54. This attachment configuration allows the modular rigging system 100 to be retrofitted onto an existing sailboat as a replacement for a metal cable rigging system, and/or allows the modular rigging system to be fitted on a new sailboat.

The modular toggle 102, which is described in further detail in relation to FIG. 5, comprises a roller pin 104. The roller pin 104 is used as a purchase for an end of a first length of woven fiber 106. The first length of woven fiber 106 is wrapped around the roller pin 104 and through a receiver of a first thimble 108 a number of times to form a band-like arrangement, sometimes referred to as lashings (see FIG. 7). One end of the first length of woven fiber 106 is secured to either a first thimble 108 or the modular toggle 102, and the other free end is used to add tension to the first length of woven fiber 106, as will be described later in relation to FIGS. 12-14. The free end of the first length of woven fiber 106 is tied around the band-like arrangement formed by the remainder of the first length of woven fiber, and cinched tight to prevent or reduce the risk of the knot slipping while the modular rigging system is under load. Other methods of tying the free end of the first length of woven fiber 106 may be desirable, such as tying the free end to either the modular toggle 102 or the first thimble 108. Alternatively, different knots may be used to achieve the same result.

A second length of woven fiber 110 couples the first thimble 108 to a second thimble 112. The second length of woven fiber 110 is pre-cut to a pre-determined length so that the an overall length of the modular rigging system 100 matches the desired segment length closely. Each end of the second length of woven fiber 110 is spliced or otherwise attached to itself around each of the first thimble 108 and second thimble 112 to form a loop. In some embodiments, the second length of woven fiber 110 is made of ultrahigh molecular weight polyethylene or high modulus polyethylene fiber, often known by the trade name Dyneema manufactured by Avient Corporation of Avon Lake, OH. On a weight for weight basis, Dyneema or an equivalent fiber has a tensile strength that is several times stronger than steel, while also being several times lighter. Thus, replacing the metal standing rigging system with the modular rigging system provides advantages in significant weight savings by replacing the metal cables with lighter synthetic fibers. Those skilled in the art will appreciate that other similar woven and/or synthetic fibers could be used instead of Dyneema.

A third length of woven fiber 114 couples the second thimble 112 to a mast attachment portion 116 (i.e. replacing the mast connection point 36). In some embodiments, such as the embodiment shown in FIG. 4, the mast attachment portion 116 is achieved with an assembly of several components, such as a second modular toggle 118 with a second roller pin 120, a dog bone 122, and a tang 124. These and other embodiments will be described in relation to FIGS. 8, 9, and 10. The third length of woven fiber 114 is connected between the second thimble 112 and the second modular toggle 118, and is therefore adjustable in the same manner. In some embodiments the second modular toggle 118, second roller pin 120, and the third length of woven fiber 114 can be foregone entirely using the circular shaped thimble embodiment, shown in FIG. 16, to directly connect the second length of woven fiber 110 to a variety of mast connection hardware solutions 116.

The first length of woven fiber 106 and the third length of woven fiber 114, may be made of the same material as the second length of woven fiber 110, or may alternatively be made of other known rope materials such as nylon or polyester, for example. Other adjustable lengths of woven fiber, such as ratchet straps, may also be used as a substitute. Additionally, the first length of woven fiber 106 and the third length of woven fiber 114 may be replaced by other means of achieving an adjustable connector of variable length.

The modular toggle 102 is shown according to some embodiments in FIG. 5. In some embodiments, the second modular toggle 118 shares the design of modular toggle 102. The modular toggle 102 has a largely U-shaped profile, with two legs 126a, 126b terminating in a pair of arcuate sections 128. The arcuate sections 128 each have a radius matching the profile of the roller pin 104, and each arcuate section is shaped as a rounded shoulder extending between legs 126a, 126b. The shoulders respectively engage or hold each end of the roller pin captive while leaving a gap 127 therebetween sized to receive the first length of woven fiber 106. Each leg 126a, 126b is shaped as a rounded arrowhead with a thickness 130. A plurality of holes 132 and 134 supporting numerous tensioning and attachment arrangements are formed or stamped through the thickness 130. In an embodiment, the plurality of holes 132 are arranged in a triangular pattern. The plurality of holes 134 are arranged such as one hole is formed through a distal portion of each leg 126a, 126b, and another is formed through a midsection of each leg 126a, 126b. Each respective hole 132 or hole 134 of leg 126a, b is co-axial with the equivalent hole on the other leg such that a pin can slide through. The plurality of holes 134 (holes shown on leg 126b not shown) have a larger diameter than the plurality of holes 132, such that the plurality of holes 134 can receive larger diameter pins, namely clevis pin 54, when compared to the plurality of holes 132. Modular toggle 102 is removably connected to chainplate 48 via clevis pin 54, which is guided through the hole 134 proximate the distal ends of legs 126a, b. A cotter pin 136 is then fitted through clevis pin 54 to prevent or reduce the risk of the pin 54 slipping out. A cotter ring or similar device may be used in place of cotter pin 136.

In some embodiments, the modular toggles 102, 118 are manufactured by stamping a flattened work piece out of a sheet of metal with the desired holes, then bending the work piece about a middle axis to create the radius of the arcuate section 128. Alternatively, the modular toggles 102, 118 may be manufactured using casting or forging metal working processes. In some alternative embodiments, some or all of the manufacturing process is achieving using a CNC machine. In still further embodiments, the toggle 102 may be fabricated using an additive manufacturing process.

The first thimble 108 is shown according to some embodiments in FIGS. 6A-B. The first thimble is also equivalent to the second thimble 112, with all description below applying second thimble 112. The first thimble 108 has a generally planar rounded teardrop shaped body with an edge or thickness 138. In other embodiments the first and or second thimble may also have a generally planar rounded circular shaped body. A groove 140 is formed in the thickness 138 and extends from a point 139 adjacent to or on a first radius 141 of the teardrop to a second position 143 on an opposite side of the first radius 141, with the diameter of the slot approximately matching the cross-section of the second length of woven fiber 110. Thus, when the second length of woven fiber 110 is spliced to itself about the first thimble 108 at splice point 142, the groove 140 secures it in place (as shown in FIG. 6B) such that shock loading does not result in the second length of woven fiber escaping the groove 140. The bottom of the teardrop shaped body is formed as a receiver 144 for the first length of woven fiber 106. The receiver 144 may utilize a plurality of ridges 145, which hold the wraps of the first length of woven fiber 106 in place as shown in FIG. 6B and serve to separate the adjacent wraps within the receiver 144 to reduce friction between adjacent wraps which facilitates tensioning. Bounding walls 146 may also be included to either side of the receiver 144 to ensure the first length of woven fiber 106 does not shift while under load. The receiver 144 is symmetrical about a center cutting plane of the first thimble 108 (i.e. a cutting plane through the groove 140 which splits the thickness 138 evenly down the middle). The thimble 108 is configured with a tensioning hole 148 which is formed through a central section of the thimble. In an embodiment, the thimble 108 is additionally configured with a plurality of tensioning holes 150, which are arranged in a triangular pattern about the tensioning hole 148. The size of the thimble 108 may be scaled up or down during manufacturing according to a desired diameter of the second length of woven fiber 110. In particular, the thimble is sized to ensure that the receiver 144 and groove 140 are sized to reduce or minimize undesirable stress concentrations and/or awkward positioning of the first and second lengths of woven fiber.

In some embodiments, either first thimble 108 and/or second thimble 112 may have a generally planar body with a circular cross-section in lieu of the teardrop shaped planar body. In some embodiments, the circular cross-section may enable the respective thimble 108, 112 to be used without the respective length of woven fiber 106, 114. A person of ordinary skill in the art will readily appreciate that the first thimble 108 and/or second thimble 112 may have a cross section with a different shape without departing from the scope of the present disclosure.

The thimbles 108, 112 may be manufactured via a CNC machining, casting, or forging. Additive manufacturing, such as 3D printing, could also be used. The thimbles 108, 112 are manufactured using titanium, aluminum, or stainless steel alloys, ceramic, ceramic-metallic or “cermet”, carbon fiber, or any other fiber reinforced polymer or composite materials.

Referring now to FIG. 7, an exemplary arrangement is shown of the modular toggle 102, the first length of woven fiber 106, and the thimble 108. The first length of woven fiber 106 is coupled to the modular toggle 102 and the thimble 108, and is wound between the toggle and thimble in a non-overlapping manner until a desired number of windings (five shown as an example in FIG. 7) is achieved. Each winding passes between the ridges 145 (FIG. 6A) of the thimble 108. The collection of windings are held in place by the bounding walls 146. The rolling pin 104 (FIG. 5) of the toggle 102, may also comprise a plurality of ridges for holding the windings of the first length of woven fiber 106 in place. The desired length of the first length of woven fiber is adjustable by tightening or loosening the free end prior to securing it, as described above. It should be appreciated that in other embodiments the ridges 145 of the thimble and the ridges of the rolling pin may be omitted.

Referring now to FIGS. 8A-B an example is shown of a mast attachment portion 116, according to some embodiments. The embodiment of the mast attachment point 116 used in the modular rigging system 100 may vary based on the design of sailboat 10, as described in relation to FIGS. 9 and 10. FIG. 8A shows an embodiment of a dog bone 122 which has a widened lemniscate-like shape with an edge or thickness 152. The thickness 152 may be uniform, or the dog bone 122 may be fashioned such that the nodes of the lemniscate vary in thickness, as shown in FIG. 8A. In the illustrated embodiment, node 151 has an increased thickness relative to node 153. In the case of varying thickness along the dog bone 122, the surface is smooth to achieve an uninterrupted transition surface between nodes 151, 153. Each node of the lemniscate has a respective of hole 154a, 154b bored therethrough. Hole 154a extends through node 151 and hole 154b extends through node 153. FIG. 8B shows a mast attachment portion 116 incorporating the dog bone 122. The third length of woven fiber 114 is coupled to the second modular toggle 118 which comprises roller pin 120. The second modular toggle 118 shares the features described in regard to modular toggle 102 above. The distal holes 134 of the second modular toggle 118 are aligned with hole 154a, and a clevis pin 54 is inserted. A cotter pin 136 is inserted into the clevis pin 54 to to couple the clevis pin to the dog bone 122 and second modular toggle 118.

FIG. 8B further shows a tang 156. In some embodiments, tang 156 comprises two legs 158a, 158b formed of separate pieces of sheet metal. Each leg 158a, b has a rounded base section 159a, 159b with a hole 160 provided therethrough. In some embodiments, the hole 160 is threaded. The rounded base sections 159a, 159b are a half-circle, and the hole 160 is provided through the center of both rounded base sections. Each leg 158a, 158b has an angled portion 162a, 162b, which is a largely rectangular section of sheet metal extending from the respective rounded base section 159a, 159b. Angled portion 162a is bent away from the rounded base section 159a at an angle that is more shallow than the angle between angled portion 162b and rounded base section 159b. Each angled portion 162a, b terminates in a rounded distal sections 164a, b, which is a half circle which mirrors the rounded base sections 159a, 159b. In some embodiments, the tang 156 is manufactured as a single piece. A threaded connector (not shown), such as a screw, bolt, or other fastener known in the art, is coupled to the mast 12 through hole 160 to connect the tang 156 to the mast. Concentric rigging holes (not shown), are provided through the rounded distal sections 164a, b. The rounded distal sections 164a, 164b are in plane with the rounded base section 159a, 159b. A clevis pin 54 is inserted through concentric rigging holes and rigging hole 154b of dog bone 122. A cotter pin or ring (not shown), is inserted through the clevis pin to couple the clevis pin to the dog bone 122 and the tang 156.

The dog bone 122 may be manufactured via CNC machining, die casting, forging, or additive manufacturing (such as 3D printing). The dog bone 122 is made of titanium, aluminum, or stainless steel alloys, ceramic, ceramic-metallic or “cermet”, carbon fiber, other fiber reinforced polymer materials, or other materials which can be shaped using the aforementioned method while achieving similar material properties.

Referring now to FIG. 9A-F a series of additional embodiments are shown for the modular toggle 102. As described below in relation to FIGS. 10A-D, either modular toggle 102 or second modular toggle 118 could be any toggle embodiment described herein. Modular toggle 102 and second modular toggle 118 do not need to be the same toggle embodiment. FIG. 9A shows a toggle 102 according to the embodiments described in relation to FIG. 5. FIG. 9B shows a toggle 202, which eschews the sheet metal design of toggle 102 in favor of a unitary planar body 204 which could be machined or die cast more easily. Unitary body 204 comprises a bar 206 that extends between two arms 205, 207 and functionally replaces the roller pin 120. The arrangement of the plurality of holes 134 and the plurality of holes 132 are equivalent to the arrangement described in relation to toggle 102.

FIGS. 9C and 9D show similar additional embodiments of the modular toggle. FIG. 9C shows a modular toggle 302 with a unitary planar body which has a semi-circular distal end 304. Modular toggle 302 has an angled section 306 which is trapezoidal in shape and angled slightly relative to distal end 304. Angled section 306 terminates in a base section 308, which is planar relative to distal end 304. Base section 308 has a bar 310, and has a half-oval shaped opening 312 between the bar 310 and the angled section 306, through which a woven fiber can be wound as described above. Angled section 306 additionally has a trapezoidal opening 314 provided therethrough. A rigging hole 316 is provided through the center of the circular segment of distal end 304. FIG. 9D shows a modular toggle 402 with a largely equivalent design, with the only difference being that bar 310 is replaced with a roller pin 404, which is captive to the modular toggle 402 but free to rotate. In some embodiments, modular toggle 302 and modular toggle 402 may be attached directly to mast 12 using a threaded fastener or pin positioned through rigging hole 316. In some other embodiments, modular toggle 302 and modular toggle 402 are attached to mast tang 156.

FIGS. 9E and 9F show embodiments of the modular toggle which are configured to attach to the mast 12 without the use of the tang 156. FIG. 9E shows a modular toggle 502 according to some embodiments, which has a unitary body 504 with a wedge-like shape. The unitary body 504 is shaped with a straight section 506, which is fashioned to snugly fit against the mast 12. The unitary body 504 has a hole 508 extending laterally through a side of the unitary body 504 such that the hole 508 proceeds through the body and straight section 506. The hole 508 receives a threaded fastener or pin known in the art to secure the modular toggle 502 directly to the mast 12. The unitary body 504 further comprises a bar 510. A half-oval shaped opening 507 is provided adjacent the bar 510 for reviewing a woven fiber. FIG. 9F shows a t-ball toggle 602. A t-ball is a type of connector shape that is known in the art that slots directly into a receiver (not shown) in the side of the mast 12 such that the t-ball toggle 602 is securely attached to the mast 12. A metal cylinder 603 is bent in the shape of a pentagon with two parallel legs 605a, b, with a strut 604 at the point of the pentagon. A t-ball 606 is mounted to the end of the strut. The two parallel legs 605a, b are connected by a base leg 608, which also acts as a bar around which a woven fiber can be wound.

FIGS. 10A-10D show various exemplary embodiments of modular rigging system 100 with different mast attachment portion 116 arrangements. In FIG. 10A, the third length of woven fiber 114 is wrapped about clevis pin 54, which is inserted through tang 156 to create the mast attachment portion 116. In FIG. 10B, modular toggle 202 is utilized as second modular toggle 118, with second modular toggle 118 secured directly to the tang 156 with clevis pin 54 without the use of dog bone 122. In FIG. 10C, modular toggle 302 is utilized as second modular toggle 118, and a threaded fastener or pin is threaded directly through the distal rigging hole 134 to connect the modular rigging system 100 to mast 12. In FIG. 10D, the third length of woven fiber couples second thimble 112 with t-ball toggle 602, which is inserted directly into the receiver in the side of mast 12. In FIG. 10E, the third length of woven fiber 114 couples second thimble 112 with modular toggle 502, which is connected to mast 12 as described above. The mast attachment portion 116 arrangement is chosen based on the mast design, amount of load, and existing rigging system (if any). Modular toggle 102 could also be substituted with any described toggle design depending on the configuration of chainplate 48.

It should be appreciated that the embodiments of FIG. 10A-10D are provided as examples to show the flexibility of the modular rigging system 100 and are not intended to be limiting. In other embodiments, other combinations of the components of modular rigging system 100 may be used without deviating from the teachings provided herein.

FIGS. 11A-C show various embodiments of a roller pin (i.e. roller pin 120 or 404). In FIG. 11A, a roller pin 220 is shown, which has a round, elongate body 222 with flattened caps 224 on either end. FIG. 11B, shows a roller pin 320, which has a round, elongate body 322 which has two round protrusions 324 with reduced thickness for insertion into a modular toggle (i.e. modular toggle 402). FIG. 11C shows a roller pin 420 with largely the same design as roller pin 320 with increased thickness and a hole 422 provided therethrough. According to some embodiments, a roller pin may have ridges (not shown), for securing the windings of a woven fiber in place. As shown, the roller pin embodiments do not include bearings. However, in some embodiments, the roller pins have bearings, in particular needle, sliding contact, or roller bearings, integrated therein. Those skilled in the art will readily appreciate that other devices which ensure smooth rotational motion may be used.

In some embodiments, the modular rigging system 100 is assembled by first coupling the first modular toggle 102 to the chainplate 48. Then, the first thimble 108 is coupled to the first modular toggle 102 via a first length of woven fiber 106. The second thimble 112 is coupled to the first thimble 108 by the second length of woven fiber 110. The second thimble 112 is coupled to the mast attachment portion 116 via the third length of fiber 114 or attached directly using the circular thimble embodiment as the second thimble 112, foregoing the need for the third length of fiber 114. The mast attachment portion 116 is coupled to the mast 12.

FIG. 12 shows a tensioning assembly for adding tension to the second length of woven fiber 110 by adjusting the length of first length of woven fiber 106. In the illustrated embodiment, four tension plates 800 are provided. Each tension plate 800 is secured to either first toggle 102 or first thimble 108 using quick pins 802, with one tension plate 800 on either side of each of the first toggle 102 and first thimble 108. Two turnbuckles 804 (shown as turnbuckle 50 of the prior art) are fitted with receivers 805 to engage or couple with the elongate quick pins 806, which are inserted through both of a set of tension plates 800 and receivers 805. To add tension, turnbuckles 804 are tightened to reduce a separation distance between the first modular toggle 102 and the first thimble 108. Reducing the separation distance also reduces the effective length of the first length of woven fiber 106. A tension of the first length of woven fiber 106 is increased by pulling the first free end. Pulling the first free end also removes slack from the portion of the first length of woven fiber 106 that extends between the modular toggle 102 and the first thimble 108. By reducing the length of first length of woven fiber 106, the second length of woven fiber 110 is stretched and subject to increased tension. Once a desired tension of the second length of woven fiber 110 is achieved, the free end of the first length of woven fiber 106 is tied as described above or otherwise affixed to reduce the risk of slipping. After securing the free end of the first length of woven fiber, the tension plates 800, turnbuckles 804, and tensioning quick pins 802, 806 are removed.

In some embodiments, usage of the tensioning assembly may be described as follows. First, a tension plate 800 is coupled to each of the first modular toggle 102 and the first thimble 108 via a plurality of quick pins 802. Respective receiver ends 805 of the turnbuckle 804 are coupled to each respective tension plate 800 via elongate quick pins 806. The turnbuckle 804 is then tightened to reduce a length of the turnbuckle 804, in turn reducing the effective length of the first length of woven fiber 106. Slack is removed from the first length of woven fiber 106. The first length of woven fiber 106 is secured by tying off the free end as described above in reference to FIG. 4.

FIG. 13A. shows a detailed view of tension plate 800. Tension plate 800 is a generally v-shaped piece of sheet metal/plate with a plurality of tensioning holes 820 provided therethrough. The plurality of tensioning holes 820 are arranged in a triangular pattern which matches the triangular pattern of one of the toggle embodiments, such that a quick pin can be pushed through each of the plurality of tensioning holes 820 and the plurality of holes 132. A pair of symmetric elongate tensioning holes 822 are also provided, with each positioned symmetrically about center axis CAT near distal ends of the tension plate 800. An additional central elongate tensioning hole 824 is provided with a center on the center axis CAT for alternative arrangements for adding tension (see FIG. 14B).

FIG. 13B. shows two tension plates 800 connected to first thimble 108. Each tension plate is aligned with first thimble 108 so that each respective tensioning hole 150 and 820 align. Quick pins 802 are then inserted to hold the tension plates in place. Two elongate tensioning 806 are pushed through symmetric elongate tensioning holes 822 to secure the turnbuckles (see FIG. 12). The central elongate tensioning hole 824 aligns with hole 148.

FIGS. 14A-C show additional exemplary arrangements for adding tension to the second length of woven fiber 110 by adjusting the length of the first length of woven fiber 106, according to some embodiments. In FIG. 14A, the arrangement of FIG. 12 is provided, but two additional turnbuckles 804 are included which are connected to the tension plates via the respective central elongate tensioning holes 824, which align with hole 148 of thimble 108, and hole 134 of modular toggle 102. Additional elongate quick pins enable the attachment of the two additional turnbuckles 804. In FIG. 14B, a tensioning arrangement is shown which includes only the additional elements described in relation to FIG. 14A with the four tension plates 800. In particular, the symmetric elongate tensioning holes 822 are not utilized to attach turnbuckles. Alternatively, FIG. 14C shows that turnbuckles 804 can be connected directly to modular toggle 102 and first thimble 108 by pushing elongate quick pins 806 directly through holes 134 and 148 respectively while connecting them to receivers 805 of the turnbuckles.

FIG. 15 shows an exemplary embodiment of a modular thimble 900. In some embodiments, modular thimble 900 is coupled directly to the mast 12 via mast attachment hardware (not shown) with a clevis pin through the central hole 902 of the modular thimble 900. The mast attachment hardware may be, for example, a shroud fitting or tang known in the art.

Embodiments of the present disclosure provide for a modular rigging system for sailboats that have a number of advantages over the prior art. Embodiments of the modular rigging system have reduced weight over prior art metal cable rigging systems and have increased flexibility in the connection between the mast and the deck/hull of the sailboat. Embodiments provide for allowing the sailboat operator to repair or change the configuration of the rigging while not moored or in port. Still further embodiments allow an operator to carry a small number of spare components to facilitate repairs or changes under operation. Still further embodiments allow for the packaging and sale of a standardized kit of components off-the-shelf at retail locations allowing end users the ability to easily procure and implement the modular rigging system on their own vessels with limited expertise or special tooling. It should be appreciated that while embodiments herein illustrate a particular sailboat, this is for exemplary purposes and the rigging system described herein may be scaled for use on any size boat having a mast without deviating from the teachings herein.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the disclosure or an “exemplary” or “example” embodiment are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Likewise, limitations associated with “one embodiment” or “an embodiment” should not be interpreted as limiting to all embodiments unless explicitly recited.

Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is generally intended, within the context presented, to disclose that an item, term, etc. may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Likewise, conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is generally intended, within the context presented, to disclose at least one of X, at least one of Y, and at least one of Z.

The disclosed systems and methods are not limited to the specific embodiments described herein. Rather, components of the systems or steps of the methods may be utilized independently and separately from other described components or steps.

This written description uses examples to disclose various embodiments, which include the best mode, to enable any person skilled in the art to practice those embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.