CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 63/324,251, filed Mar. 28, 2022, which is incorporated herein by reference in its entirety.

FIELD

The present disclosure relates to marine drives, and in particular to stern drives having a powerhead for propulsion, for example an electric motor.

BACKGROUND

The following U.S. patents are incorporated herein by reference in entirety.

U.S. Pat. No. 6,287,159 discloses a support apparatus for a marine propulsion system in a marine vessel wherein a compliant member is attachable to the transom of a marine vessel. In certain applications, the compliant member is directly attached to an intermediate plate and to an external frame member that is, in turn, attached directly to the transom of the marine vessel. The intermediate plate is attached directly to components of the marine propulsion system to provide support for the marine propulsion system relative to the transom, but while maintaining non-contact association between the marine propulsion system and the transom.

U.S. Pat. No. 9,446,828 discloses an apparatus for mounting a marine drive to a hull of a marine vessel. An outer clamping plate faces an outside surface of the hull and an inner clamping plate faces an opposing inside surface of the hull. A marine drive housing extends through the hull. The marine drive housing is held in place with respect to the hull by at least one vibration dampening sealing member which is disposed between the inner and outer clamping plates. A first connector clamps the outer clamping plate to the outside surface of the hull and a second connector clamps the inner clamping plate to the outer clamping plate. The inner and outer clamping plates are held at a fixed distance from each other so that a consistent compression force is applied to the vibration dampening sealing member.

SUMMARY

This Summary is provided to introduce a selection of concepts which are further described herein below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

In non-limiting examples, a stern drive is for propelling a marine vessel having a transom. The stern drive has a drive assembly configured to generate a thrust force in water, a powerhead configured to power the drive assembly, and a mounting assembly configured to couple the drive assembly to the transom outside of the marine vessel and further configured to suspend the powerhead on the transom inside of the marine vessel. The mounting assembly comprises a vibration dampening member which isolates vibrations of the drive assembly and the powerhead relative to the transom.

Optionally, the powerhead may comprise an electric motor. Optionally, the stern drive may have a center of gravity which is aligned with the transom. Optionally, the vibration dampening member may comprise a monolithic annular ring which may extend around the stern drive. The mounting assembly may comprise a rigid mounting ring which is fastened to the transom wherein the vibration dampening member couples the rigid mounting ring to the drive assembly and the powerhead. Optionally, a rigid mounting plate may support the drive assembly and the powerhead, wherein the vibration dampening member couples the rigid mounting plate to the rigid mounting ring. Optionally, at least one of the rigid mounting ring and the rigid mounting plate is adhesively bonded to the vibration dampening member. Optionally both the rigid mounting ring and the rigid mounting plate are fixed to the vibration dampening member by adhesive bonding and/or without mechanical fasteners. Optionally, the vibration dampening member may comprise a monolithic annular ring and further the rigid mounting ring and the rigid mounting plate together may encase the monolithic annular ring. The rigid mounting ring and the rigid mounting plate could, for example, be made of aluminum.

In non-limiting examples, the stern drive may comprise a drive assembly configured to generate a thrust force in water, a powerhead configured to power the drive assembly, and a mounting assembly configured to couple the drive assembly to the transom outside of the marine vessel and to suspend the powerhead on the transom inside of the marine vessel. Optionally the stern drive is further configured so that the drive assembly, the powerhead, and the mounting assembly may be installed on the marine vessel as a single component from outside the transom.

Optionally, the powerhead comprises an electric motor. Optionally, the stern drive has a center of gravity which is aligned with the transom. Optionally, the mounting assembly may comprise a vibration dampening member which isolates vibrations of the drive assembly and the powerhead relative to the transom. Optionally, the vibration dampening member comprises a monolithic annular ring which extends around the stern drive. Optionally, the mounting assembly comprises a rigid mounting ring which is fastened to the transom and the vibration dampening member may couple the rigid mounting ring to the drive assembly and the powerhead. Optionally, a rigid mounting plate supports the drive assembly and the powerhead, which vibration dampening member may couple the rigid mounting plate to the rigid mounting ring. Optionally, at least one of the rigid mounting ring and the rigid mounting plate is adhesively bonded to the vibration dampening member. Optionally, both the rigid mounting ring and the rigid mounting plate are fixed to the vibration dampening member by adhesive bonding and/or without mechanical fasteners. Optionally the vibration dampening member comprises a monolithic annular ring and further the rigid mounting ring and the rigid mounting plate may together encase the monolithic annular ring.

In non-limiting examples, methods are for installing a stern drive on a marine vessel, the marine vessel comprising a transom defining a mounting hole. The methods may comprise assembling as a single component a drive assembly configured to generate a thrust force in water, a powerhead configured to power the drive assembly, and a mounting assembly configured to couple the drive assembly to the transom outside of the marine vessel and to suspend the powerhead on the transom inside of the marine vessel. The methods may further comprise, from outside the marine vessel, inserting the powerhead into the marine vessel via the mounting hole until the mounting assembly engages the transom, and thereafter fastening the mounting assembly to the transom.

Optionally, the powerhead may comprise an electric motor. Optionally the methods may comprise configuring the stern drive to have a center of gravity which is aligned with the transom. Optionally the methods may comprise configuring the mounting assembly to have a vibration dampening member which isolates vibrations of the drive assembly and the powerhead relative to the transom. Optionally, the methods may comprise configuring the vibration dampening member as a monolithic annular ring extending around the stern drive.

These and combinations other than those summarized above are possible within the scope of the present disclosure, as would be apparent to one having ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure includes the following figures.

FIG. 1 is a starboard side perspective view of a stern drive according to the present disclosure.

FIG. 2 is a port side perspective view of the stern drive.

FIG. 3 is a starboard side perspective view of the stern drive.

FIG. 4 is a starboard side view of the stern drive.

FIG. 5 is a perspective view looking down at a universal joint of the stern drive which couples a powerhead, which in the illustrated example includes an electric motor, to a driveshaft of the stern drive.

FIG. 6 is an exploded view of the universal joint.

FIG. 7 is a starboard side sectional view of the stern drive.

FIG. 8 is a starboard side view of the stern drive in a trimmed-up position.

FIG. 9 is a starboard side sectional view of the stern drive in the trimmed-up position.

FIG. 10 is a starboard side perspective view of a mounting assembly which mounts the electric motor to the transom of a marine vessel.

FIG. 11 is a starboard side perspective view of the stern drive in the trimmed-up position and steered ninety degrees off center (straight-ahead) so that the drive assembly of the stern drive is trimmed fully out of the water.

FIG. 12 is a starboard side view of an example sound enclosure for the stern drive.

FIG. 13 is a starboard side sectional view of the example shown in FIG. 12.

FIG. 14 is an exploded perspective view of an embodiment of a mounting assembly for a stern drive that includes a rigid mounting plate, a rigid mounting ring, and a vibration dampening member.

FIG. 15 is a cross-sectional side view of the mounting assembly of FIG. 14.

FIG. 16 is an exploded perspective view illustrating the installation of a stern drive with the mounting assembly of FIG. 15 onto the transom of a marine vessel.

FIG. 17 is a cross-sectional side view of the stern drive of FIG. 16.

FIG. 18 is a cross-sectional side view of another embodiment of a mounting assembly including a rigid mounting plate, a rigid mounting ring, and a vibration dampening member.

FIG. 19 is a cross-sectional side view of another embodiment of a mounting assembly including a rigid mounting plate, a rigid mounting ring, and a vibration dampening member.

FIG. 20 is a cross-sectional side view of an embodiment of a mounting assembly that includes a vibration dampening member with locating protrusions.

FIG. 21 is a cross-sectional side view of another embodiment of a mounting assembly that includes a vibration dampening member with locating protrusions.

DETAILED DESCRIPTION

FIGS. 1-8 illustrate a stern drive 12 for propelling a marine vessel in a body of water. Referring to FIG. 1, the stern drive 12 has a powerhead, which in the illustrated example is an electric motor 14, a mounting assembly 16 which affixes the electric motor 14 to and suspends the electric motor 14 from the transom 18 of the marine vessel, and a drive assembly 20 coupled to the mounting assembly 16. The illustrated powerhead is not limiting and in other examples the powerhead may include an engine and/or a combination of an engine and an electric motor, and/or any other suitable means for powering a marine drive. The mounting assembly 16 is configured so that the powerhead which in the illustrated example is an electric motor 14 is suspended (i.e., cantilevered) from the interior of the transom 18, above the bottom of the hull of the marine vessel. As will be further explained below, the drive assembly 20 is trimmable up and down relative to the mounting assembly 16, including in non-limiting examples wherein a majority or an entirety of the drive assembly 20 is raised completely out of the water. The drive assembly 20 has a driveshaft housing 22 containing a driveshaft 24 and a gearcase housing 26 containing one or more output shaft(s) 28, e.g., one or more propulsor shaft(s). The output shaft(s) 28 extends from the rear of the gearcase housing 26 and support one or more propulsors(s) 30 configured to generate thrust in the water for propelling the marine vessel. The output shaft(s) 28 extend generally transversely to the driveshaft 24. In the illustrated example, propulsor(s) 30 include two counter-rotating propellers. However this is not limiting and the present disclosure is applicable to other arrangements, including arrangements wherein one or more output shaft(s) 28 are not counter-rotating and/or wherein the one or more output shaft(s) 28 extend from the front of the gearcase housing 26, and/or wherein the propulsor(s) 30 include one or more impellers and/or any other mechanism for generating a propulsive force in the water.

Referring to FIGS. 1 and 7, the gearcase housing 26 is steerable about a steering axis S (see FIG. 7) relative to the driveshaft housing 22. The gearcase housing 26 (see FIG. 1) has a steering housing 32 (see FIG. 7) which extends upwardly into the driveshaft housing 22, as well as a torpedo housing 34 which depends from the steering housing 32. An angle gearset 36 (see FIG. 1) in the torpedo housing 34 operably couples the lower end of the driveshaft 24 to the output shaft(s) 28 so that rotation of the driveshaft 24 causes rotation of the output shaft(s) 28, which in turn causes rotation of the propulsor(s) 30.

Referring to FIG. 7, upper and lower bearings 38, 40 are disposed radially between the steering housing 32 and the driveshaft housing 22. The upper and lower bearings 38, 40 rotatably support the steering housing 32 relative to the driveshaft housing 22. A steering actuator 42 is configured to cause rotation of the gearcase housing 26 relative to the driveshaft housing 22. In the illustrated example, the steering actuator 42 is an electric motor 44 located in the driveshaft housing 22. The electric motor 44 has an output gear 46 which is meshed with a ring gear 48 on the steering housing 32 so that rotation of the output gear 46 causes rotation of the gearcase housing 26 about the steering axis S. As further explained below, operation of the electric motor 44 can be controlled via a conventional user input device located at the helm of the marine vessel or elsewhere, which facilitates control of the steering angle of the gearcase housing 26 and associated propulsors(s) 30. This facilitates steering control of the marine vessel. The type and configuration of the steering actuator 42 can vary from what is shown and in other examples could include one or more hydraulic actuators, electro-hydraulic actuators, and/or any other suitable actuator for causing rotation of the gearcase housing 26. Other suitable examples are disclosed in the above-incorporated U.S. Pat. No. 10,800,502.

Referring to FIGS. 5-7, a universal joint 50 couples the electric motor 14 to the driveshaft 24 so that operation of the electric motor 14 causes rotation of the driveshaft 24, which in turn causes rotation of the output shaft(s) 28. The universal joint 50 is also advantageously configured to facilitate trimming of the drive assembly 20 an amount sufficient to raise at least a majority of the drive assembly 20 out of the water, for example during periods of non-use. The universal joint 50 has an input member 52 which is rotatably engaged with an output shaft 54 of the electric motor 14, an output member 64 which is rotatably engaged with the driveshaft 24, and an elongated body 66 which rotatably couples the input member 52 to the output member 64. The input member 52 has an externally-splined input shaft 62 and input arms 63 which form a U-shape. The output member 64 has an output shaft 68 and output arms 70 which form a U-shape. The elongated body 66 has a first pair of arms 74 which form a U-shape and an opposing second pair of arms 76 which form a U-shape. Input pivot pins 78, 80 pivotably couple the input arms 63 of the input member 52 to the first pair of arms 74 of the elongate body 66 along a first input pivot axis 82 and along a second input pivot axis 84 which is perpendicular to the first input pivot axis 82. Output pivot pins 86, 88 pivotably couple the output arms 70 of the output member 64 to the second pair of arms 76 of the elongated body 66 along a first output pivot axis 90 and along a second output pivot axis 92 which is perpendicular to the first output pivot axis 90.

Referring to FIG. 7, an internally splined sleeve 56 is rotatably supported in the mounting assembly 16 by inner and outer bearings 58, 60. The output shaft 54 of the electric motor 14 is fixed to the splined sleeve 56 so that rotation of the output shaft 54 causes rotation of the splined sleeve 56. The externally-splined input shaft 62 of the universal joint 50 extends into meshed engagement with the splined sleeve 56 so that rotation of the splined sleeve 56 causes rotation of the input member 52. The output shaft 68 of the universal joint 50 is coupled to the driveshaft 24 by an angle gearset 72 located in the driveshaft housing 22 and configured so that rotation of the output member 64 causes rotation of the driveshaft 24. Thus, it will be understood that operation of the electric motor 14 causes rotation of the universal joint 50, which in turn causes rotation of the driveshaft 24 and output shaft(s) 28. The splined engagement between the input member 52 and splined sleeve 56 also advantageously permits telescoping movement of the input member 52 during trimming of the drive assembly 20, as will be further described below with reference to FIGS. 8-9. A flexible bellows 94 encloses the universal joint 50 relative to the mounting assembly 16 and the driveshaft housing 22.

Referring now to FIGS. 1-4 and 7, the mounting assembly 16 has a rigid mounting plate 100, a vibration dampening (e.g., rubber or other pliable and/or resilient material) mounting ring 102, and a rigid mounting ring 103 which is fastened to the transom 18 by fasteners 105 and a fastening ring 107 to couple the vibration dampening mounting ring 102 and rigid mounting plate 100 to the transom 18. A pair of rigid mounting arms 104 extends rearwardly from the rigid mounting plate 100 and is pivotably coupled to a rigid, U-shaped mounting bracket 108 extending forwardly from the top of the driveshaft housing 22. The pivot joint between the rigid mounting arms 104 and mounting bracket 108 defines a trim axis T (see FIG. 2) about which the drive assembly 20 is pivotably (trimmable), up and down relative to the mounting assembly 16. The type and configuration of mounting assembly 16 can vary from what is shown, and a non-limiting example of the mounting assembly 16 is described herein below with reference to FIGS. 14-21.

Referring first to FIGS. 14-17, the example mounting assembly 16 is configured to couple the drive assembly 20 to the transom 18 outside of the marine vessel and suspend the powerhead 14 from the transom 18 inside of the marine vessel. As illustrated in FIGS. 16 and 17, the mounting assembly 16 resides in (and extends through) an opening 19 in the transom 18 of the marine vessel (FIGS. 16-17) and generally includes a rigid mounting ring 103 and a rigid mounting plate 100. The rigid mounting ring 103 extends around the perimeter of the opening 19 on the exterior of the transom 18. The rigid mounting plate 100 is supported in the opening 19 by the rigid mounting ring 103. The rigid mounting ring 103 includes an annular rim 140 that extends around the opening 19 and abuts the outer surface of the transom 18. A support surface 142 of the rigid mounting ring 103 extends from the annular rim 140 into the opening 19 along the periphery of the opening 19. A flange 146 extends from a distal end 144 of the support surface 142 inward towards the center of the rigid mounting ring 103 and the opening 19. Mounting holes 141 formed in the back surface of the annular rim 140 are configured to receive fasteners 105 that extend through through-bores 143 formed in the transom 18. The fasteners 105 engage a fastening ring 107 that extends around the opening 19 on the inside of the transom 18, thereby coupling the mounting assembly 16 to the transom 18 of the marine vessel. Referring to FIG. 15, an O-ring 138 may be positioned between the rigid mounting ring 103 and the transom 18 to form a seal therebetween. Other embodiments, however, may omit an O-ring.

Referring to FIGS. 14 and 15, the rigid mounting plate 100 is configured to support at least some of the various components of the drive assembly 20. The rigid mounting plate 100 is recessed into the hull of the marine vessel through the rigid mounting ring 103 and includes an interior space 148 defined by a front wall 150, a rear opening 152 defined by an annular flange 154, and sidewalls 156 that extend longitudinally between the front wall 150 and the annular flange 154. In the illustrated embodiments, the front wall 150 is in a generally vertical orientation and the annular flange 154 is formed at an angle so that it is generally coplanar with the transom 18. The drive assembly 20 is supported on the rigid mounting plate 100 via a pair of rigid mounting arms 104 that extend rearwardly from front wall 150 of the rigid mounting plate 100. As illustrated in FIG. 4, the rigid mounting arms 104 are pivotably coupled to the rigid, U-shaped mounting bracket 108 that extends forwardly from the top of the driveshaft housing 22. As further described herein below, the rigid mounting plate 100 also supports the powerhead, which is configured as an electric motor 14 suspended from the front wall 150 on the interior of the transom 18.

Referring to FIGS. 14, 15 and 17, a novel vibration dampening member 102 is positioned between the rigid mounting ring 103 and the sidewalls 156 of the rigid mounting plate 100. As will be described in more detail below, the vibration dampening member 102 is uniquely configured to isolate vibrations of the drive assembly 20 and the powerhead 14 relative to the transom 18. In the illustrated embodiments, the vibration dampening member 102 is configured as a monolithic annular ring which extends around the stern drive 12 and the sidewalls 156 of the rigid mounting plate 100. The shape and size of the cross-sectional profile of the vibration dampening member 102 may be consistent, or may vary along different segments of the vibration dampening member 102. Varying the cross-sectional profile may be useful, for example, to achieve the desired spring rate for the vibration dampening member 102 and/or to limit the deflections of the drive assembly 20 relative to the transom 18 and the rigid mounting plate 100. The illustrated vibration dampening member 102 has a horizontal lower segment 160 and vertical side segments 162 that are generally rectangular and an upper segment 164 having a profile that is generally in the shape of a right trapezoid. Additionally or alternatively, at least one of a width dimension 168 and a thickness dimension 169 (FIG. 14) may vary between different segments of the vibration dampening member 102. In the illustrated embodiment, the vertical side segments 162 are thicker than the lower and upper segments 160, 164. Other embodiments, however, may include at least one segment 160, 162, 164 that is differently shaped and/or sized than the segments 160, 162, 164 of the illustrated vibration dampening member 102. For example, at least one segment 160, 162, 164 of the vibration dampening member 102 may have a cross-sectional shape that changes along the length of the segment. In some embodiments, the material composition of the vibration dampening member may vary between different segments 160, 162, 164 and/or between different portions of a segment 160, 162, 164.

Referring to FIG. 15, the vibration dampening member 102 is sandwiched between the support surface 142 of the rigid mounting ring 103 and the sidewalls 156 of the rigid mounting plate 100, and between the flange 146 of the rigid mounting ring 103 and the annular flange 154 formed around the rigid mounting plate 100. Thus, the rigid mounting ring 103 and the rigid mounting plate 100 together encase the vibration dampening member 102. The annular flanges 146, 154 are dimensioned so that there is a gap 170 between the distal end of each annular flange 146, 154 and the corresponding one of the rigid mounting plate 100 and the rigid mounting ring 103. This may be useful, for example, so that the rigid mounting plate 100 does not contact the rigid mounting ring 103 when the vibration dampening member 102 is compressed, thereby preventing direct transfer of vibrations from the rigid mounting plate 100 to the rigid mounting ring 103.

In some embodiments, the vibration dampening member 102 may be secured to the rigid mounting ring 103 and/or the rigid mounting plate 100 via an adhesive or bonding agent. For example, the vibration dampening member 102 may be bonded to the annular flange 154 and/or sidewalls 156 of the rigid mounting plate 100 and/or the support surface 142 of the rigid mounting ring 103 with an adhesive prior to installation of the stern drive 12 on the transom 18. By bonding the vibration dampening member 102 to the rigid mounting plate 100 and/or the rigid mounting ring 103 prior to installation, the vibration dampening member 102 is secured thereto in a relaxed configuration. This may be useful, for example, to provide enhanced control over (i.e., tuning of) the spring rate of the vibration dampening member 102, and to better prevent a leak path from forming around the vibration dampening member 102. In some embodiments, at least one of the material(s) of the vibration dampening member 102, the shape of the vibration dampening member 102, and/or the dimensions of the vibration dampening member 102 may be selected based on the desired spring rate of the vibration dampening member 102 and/or any other desired parameter thereof.

In the illustrated embodiments, the vibration dampening member 102 is adhesively bonded to the rigid mounting plate 100 and the rigid mounting ring 103, without mechanical fasteners, such that the rigid mounting plate 100 is coupled to the rigid mounting ring 103 only via the vibration dampening member 102. Thus, the vibration dampening member 102 couples and supports the drive assembly 20, and electric motor 14, and any other components secured to the rigid mounting plate 100 such that all vibrations emanating from the stern drive 12 are transferred to the vibration dampening member 102 before being transferred to the transom 18. Other embodiments, however, may be configured with at least one fastener configured to couple the rigid mounting plate 100, the rigid mounting ring 103, and/or the vibration dampening member 102.

Referring to FIGS. 16 and 17, the stern drive 12 is uniquely and advantageously configured so that the drive assembly 20, the powerhead 14, and the mounting assembly 16 are installed on the marine vessel as a single component from outside the transom 18. The installation method may begin by assembling the stern drive 12 as a single component that includes a drive assembly 20 configured to generate a thrust force in water, a powerhead 14 configured to power the drive assembly 20, and a mounting assembly 16 configured to couple the drive assembly 20 to the transom 18 outside of the marine vessel and to suspend the powerhead 14 on the transom 18 inside of the marine vessel.

The mounting assembly 16 is assembled by inserting a fastener 105 into each of the mounting holes 141 on the back side of the rigid mounting ring 103 and mounting the rigid mounting plate 100 on the rigid mounting ring 103. In some embodiments, the mounting assembly 16 may be configured with the vibration dampening member 102 which isolates vibrations of the drive assembly 20 and the powerhead 14 relative to the transom 18. The vibration dampening member 102 may be configured as the monolithic annular ring that extends around the stern drive 12. The vibration dampening member 102 may be positioned in the mounting assembly 16 between the rigid mounting ring 103 and the rigid mounting plate 100 such that the rigid mounting plate 100 is supported on the rigid mounting ring 103 by the vibration dampening member 102. As illustrated in FIG. 15, the vibration dampening member 102 extends around the sidewalls 156 of the rigid mounting plate 100 and is sandwiched between the support surface 142 and the flange 146 of the rigid mounting ring 103 and the sidewalls 156 and the annular flange 154 of the rigid mounting plate 100. In some embodiments, the vibration dampening member 102 is adhesively bonded to at least one of the rigid mounting plate 100 and the rigid mounting ring 103. In such an embodiment, the vibration dampening member 102 may be adhesively bonded to the rigid mounting plate 100 and/or the rigid mounting ring 103 while no external forces are applied to the rigid mounting plate 100, the rigid mounting ring 103, or the vibration dampening member 102 so that the vibration dampening member 102 is bonded thereto while it is in a relaxed state.

Referring to FIGS. 16 and 17, once the mounting assembly 16 is assembled, the drive assembly 20 and the powerhead 14, which is configured as an electric motor in the illustrated embodiment, are mounted on the mounting assembly 16. The drive assembly 20 is suspended from the rigid mounting arms 104 on the exterior side of the mounting assembly 16. The powerhead 14 is coupled to the front side of the front wall 150 of the rigid mounting plate 100 such that the powerhead 14 is suspended from the interior-facing side of the mounting assembly 16. The drive assembly 20, the powerhead 14, and/or the mounting assembly 16 of the stern drive 12 may be configured so that the assembled stern drive 12 has a center of gravity 198 (see FIG. 13) which is aligned with a portion of the transom 18 when installed on the marine vessel. For example, as illustrated in FIG. 13, the center of gravity 198 of the stern drive 12 may be vertically aligned with the mounting assembly 16. This may be advantageous, for example, to balance the stern drive 12 so that the stern drive 12 produces fewer vibrations when the stern drive 12 is operating, thereby reducing the noise produced by the stern drive 12.

Referring to FIG. 17, after the stern drive 12 is assembled as a single component, it is mounted on the transom 18 of the marine vessel. From the exterior of the marine vessel, the powerhead 14 is inserted into the marine vessel via the mounting opening 19 in the transom 18 until the mounting assembly 16 engages the transom 18. As the powerhead 14 is inserted through the opening 19, the fasteners 105 extending from the annular rim 140 of the rigid mounting ring 103 are aligned with and inserted through corresponding through-bores 143 formed through the transom 18 around the opening 19. In some embodiments, an O-ring 138 may be positioned on the mounting assembly 16 such that the O-ring 138 is sandwiched between the annular rim 140 of the rigid mounting ring 103 and the exterior surface of the transom 18. The stern drive 12 may then be secured to the transom 18 by fastening the rigid mounting ring 103 to the transom 18. The fastening ring 107 is positioned on the interior side of the transom 18 such that the fastening ring extends around the stern drive 12 and the opening 19. The fastening ring 107 is moved into engagement with the fasteners 105 protruding through the transom 18, and a nut is received on each of the fasteners 105 in order to secure the stern drive 12 on the transom 18.

Some embodiments of a stern drive 12 may include a mounting assembly that is configured differently than the mounting assembly 16 of FIGS. 13-17. For example, FIGS. 18 and 19 illustrate other examples of a rigid mounting plate 500, 600 and a rigid mounting ring 503, 603 for a mounting assembly 16.

Referring to FIG. 18, the rigid mounting ring 503 includes an annular rim 540 that extends around the opening 19 of the transom 18 and a support surface 542 that extends from the annular rim 540 into the opening 19. A flange 546 extends from a distal end 544 of the support surface 542 inward towards the center of the rigid mounting ring 103 and the opening 19. In the illustrated embodiment, the support surface 542 of the rigid mounting ring 503 is thicker than the support surface 142 of FIGS. 13-17. This may be useful, for example, to reduce the amount of material needed for the vibration dampening member 502. Similarly to the rigid mounting plate 100 of FIGS. 13-17, the rigid mounting plate 500 includes sidewalls 556 that extend longitudinally between a front wall (see, e.g., front wall 150 and side walls 556 in FIG. 16) and an annular flange 554 that is configured to abut the exterior surface of the transom 18. However, the top sidewall 556a of the rigid mounting plate 500 of FIG. 18 includes a ramp surface 557 that is formed at an angle relative to the generally horizontal top sidewall 556a and extends forward from the annular flange 554. The ramp surface 557 is configured to be generally parallel to the support surface 542 and generally perpendicular to the annular rim 540 of the rigid mounting ring 503, the annular flange 554 of the rigid mounting plate 500, and the plane of the exterior surface of the transom 18. This may be useful, for example, so that the vibration dampening member 502 may be configured with a uniform rectangular cross-section. The annular rim 540 of the rigid mounting ring 503 and/or the annular flange 554 of the rigid mounting plate 500 may be dimensioned to leave a gap 570 between the rigid mounting plate 500 and the rigid mounting ring 503.

FIG. 19 illustrates other examples of a rigid mounting plate 600 and the rigid mounting ring 603 of a mounting assembly 16 for a stern drive 12. The rigid mounting plate 600, the rigid mounting ring 603, and the vibration dampening member 602 of FIG. 19 are similar to those of the embodiment of FIG. 18 in that the support surface 642 of the rigid mounting ring 603 is thicker than the support surface 142 of FIGS. 13-17 and the top sidewall 656a of the rigid mounting plate 600 includes a ramp surface 657. Unlike the mounting assembly of FIG. 18, the mounting assembly 16 of FIG. 19 is configured with a rigid mounting plate 600 that includes an interior flange 658 formed around at least a portion of the sidewalls 656. In the illustrated embodiment, the interior flange 658 is formed proximate the distal end of the ramp surface 657 and can be configured to retain the vibration dampening member 602 in the desired position by resisting movement and/or forces that could break the bond between the vibration dampening member 602 and the rigid mounting plate 600 and/or the rigid mounting ring 603. In some embodiments, the interior flange 658 may additionally or alternatively be formed around the lateral sidewalls and the bottom sidewall of the rigid mounting plate 600. The annular rim 640 of the rigid mounting ring 603 and/or the annular flange 654 and/or interior flange 658 of the rigid mounting plate 600 may be dimensioned to leave a gap 670 between the rigid mounting plate 600 and the rigid mounting ring 603.

Some embodiments of a stern drive 12 may be configured with a vibration dampening member, rigid mounting ring, and/or rigid mounting plate that include positioning features configured to retain the vibration dampening member in a desired position. For example, FIGS. 20 and 21 illustrate examples of mounting assemblies 16 that include a vibration dampening member 702a, 702b with elongated locating protrusions 780a, 780b formed around the vibration dampening member. Referring to FIGS. 20 and 21, the vibration dampening member 702 includes locating protrusions 780 formed on an exterior cross-sectional surface 782 and an interior cross-sectional surface 784 of the vibration dampening member 702. Each of the locating protrusions 780 is configured to be received in a corresponding recess 786 formed in the support surface 742 of the rigid mounting ring 703 and the ramp surface 757 and/or the top sidewall 756a of the rigid mounting plate 700. Engagement between the locating protrusions 780 and the corresponding recesses 786 may be useful, for example, to retain the vibration dampening member 702 in a desired position relative to the rigid mounting plate 700 and the rigid mounting ring 703, and to prevent a leak path from the exterior of the marine vessel to the interior of the marine vessel from forming between the vibration dampening member 702 and the rigid mounting plate 700 and/or the rigid mounting ring 703.

Embodiments of a vibration dampening member may be configured with various locating protrusions. Referring to FIG. 20, a vibration dampening member 702a may be configured with three semicircular locating protrusions 780a formed around the exterior cross-sectional surface 782 and the interior cross-sectional surface 784 thereof. Each semicircular locating protrusion 780a is configured to be received in a corresponding semicircular recess 786a formed in the rigid mounting plate 700 and the rigid mounting ring 703. Referring to FIG. 21, a vibration dampening member 702b may be configured with three elongated locating protrusions 780b formed around the exterior cross-sectional surface 782 and the interior cross-sectional surface 784 thereof. Each of the elongated locating protrusions 780b may extend from vibration dampening member 702b at an angle relative to the interior or exterior cross-sectional surface 782, 784. Each elongated locating protrusion 780b is received in a corresponding elongated recess 786b formed in the rigid mounting plate 700 and the rigid mounting ring 703. These embodiments may require different production and/or assembly methods, such as by separately molding the dampening members or molding the dampening members in place.

Some embodiments of a vibration dampening member may be configured with a different arrangement of locating protrusions formed thereon. For example, at least one of the exterior cross-sectional surface and the interior cross-sectional surface may be configured with a different number of locating protrusions, and at least one locating protrusion on the interior and/or exterior cross-sectional surface may have a different shape, size, and/or orientation than those of the illustrated embodiments. In some embodiments, a vibration dampening member may be asymmetrical such that the shape, size, number, and/or orientation of locating protrusions on the inward facing and outward facing surfaces are different. Further still, some embodiments of a mounting assembly may be configured with at least one locating protrusion formed on and extending from a sidewall of the rigid mounting plate and/or a support surface of the rigid mounting ring. In such an embodiment, the locating protrusion(s) on the rigid mounting plate and/or the rigid mounting ring would be received in a corresponding recess formed in the body of the vibration dampening member.

Referring back to FIGS. 1-4 and 7, trim cylinders 110 are located on opposite sides of the mounting assembly 16. The trim cylinders 110 have a first end 112 pivotably coupled to the rigid mounting plate 100 at a first pivot joint 114 and an opposite, second end 116 pivotably coupled to the drive assembly 20 at a second pivot joint 118. A hydraulic actuator 120 (which in this example includes a pump and associated valves and line components) is mounted to the interior of the rigid mounting plate 100. The hydraulic actuator 120 is hydraulically coupled to the trim cylinders 110 via a least one internal passage through the mounting assembly 16 and the first pivot joint 114, advantageously so that there are no other hydraulic lines located on the exterior of the stern drive 12, or otherwise outside the marine vessel so as to be subjected to wear and/or damage from external elements. The hydraulic actuator 120 is operable to supply hydraulic fluid to the trim cylinders 110 via the noted internal passage to cause extension of the trim cylinders 110 and alternately to cause retraction of the trim cylinders 110. Extension of the trim cylinders 110 pivots (trims) the drive assembly 20 upwardly relative to the mounting assembly 16 and retraction of the trim cylinders 110 pivots (trims) the drive assembly 20 downwardly relative to the mounting assembly 16. Examples of a suitable hydraulic actuator are disclosed in the above-incorporated U.S. Pat. No. 9,334,034.

By comparison of FIGS. 7-9, it will be seen that the universal joint 50 advantageously facilitates trimming of the drive assembly 20 about the trim axis T (see FIG. 2) while maintaining operable connection between the electric motor 14 and the output shaft(s) 28. In particular, as the drive assembly 20 is trimmed, the elongated body 66 is configured to also pivot about the first and/or second input pivot axes 82, 84 (via input pivot pins 78, 80), and the output member 64 is configured to also pivot about the first and/or second output pivot axes 90, 92 (via output pivot pins 86, 88). As explained above, the input shaft 62 is coupled to the internally splined sleeve 56 by a splined coupling so that the input shaft 62 is free to telescopically move outwardly relative to the internally splined sleeve 56 and mounting assembly 16 when the drive assembly 20 is trimmed up and so that the input shaft 62 is free to telescopically move inwardly relative to the mounting assembly 16 when the drive assembly 20 is trimmed down.

A controller 200 (see FIG. 1) is communicatively coupled to the electric motor 14, the steering actuator 42, and the hydraulic actuator 120. The controller 200 is configured to control operation of the electric motor 14, the steering actuator 42, and the hydraulic actuator 120. More specifically, the controller 200 is configured to control the electric motor 14 to rotate the universal joint 50, the driveshaft 24 and the output shaft(s) 28, thereby controlling the thrust force generated by the propulsor(s) 30 in the water. The controller 200 is configured to control the steering actuator 42 to rotate the gearcase housing 26 about the steering axis S. The controller 200 is configured to control the hydraulic actuator 120 to extend and alternately to retract the trim cylinders 110 to trim the drive assembly 20 about the trim axis T.

The type and configuration of the controller 200 can vary. In non-limiting examples, the controller 200 has a processor which is communicatively connected to a storage system comprising a computer readable medium which includes volatile or nonvolatile memory upon which computer readable code and data is stored. The processor can access the computer readable code and, upon executing the code, carry out functions, such as the controlling functions for the electric motor 14, steering actuator 42, and the hydraulic actuator 120. In other examples the controller 200 is part of a larger control network such as a controller area network (CAN) or CAN Kingdom network, such as disclosed in U.S. Pat. No. 6,273,771. A person having ordinary skill in the art will understand that various other known and conventional computer control configurations could be implemented and are contemplated by the present disclosure, and that the control functions described herein may be combined into a single controller or divided into any number of distributed controllers which are communicatively connected.

The controller 200 is in electrical communication with the electric motor 14, the steering actuator 42, and the hydraulic actuator 120 via one or more wired and/or wireless links. In non-limiting examples, the wired and/or wireless links are part of a network, as described above. The controller 200 is configured to control the electric motor 14, the steering actuator 42, and the hydraulic actuator 120 by sending and optionally by receiving said signals via the wired and/or wireless links. The controller 200 is configured to send electrical signals to the electric motor 14 which cause the electric motor 14 to operate in a first direction to rotate the universal joint 50, the driveshaft 24 and the output shaft(s) 28 in a first direction, thereby generating a first (e.g., forward) thrust force in the water via the propulsor(s) 30, and alternately to send electric signals to the electric motor 14 which cause the electric motor 14 to operate in an opposite, second direction, to rotate the universal joint 50, the driveshaft 24 and the output shaft(s) 28 in an opposite direction which generates a second (e.g., reverse) thrust force in the water via the propulsor(s) 30. The controller 200 is configured to send electric signals to the steering actuator 42 which cause the steering actuator 42 to rotate the gearcase housing 26 in a first direction about the steering axis S and alternately to send electric signals to the steering actuator 42 which cause the steering actuator 42 to rotate the gearcase housing 26 in an opposite direction about the steering axis S. The controller 200 is configured to send electrical signals to the hydraulic actuator 120 which cause the hydraulic actuator 120 to provide hydraulic fluid to one side of the trim cylinders 110 to extend the trim cylinders 110 and trim the drive assembly 20 upwardly relative to the mounting assembly 16 and alternately to send electric signals to the hydraulic actuator 120 which cause the hydraulic actuator 120 to provide hydraulic fluid to an opposite side of the trim cylinders 110 to retract the trim cylinders 110 and trim the drive assembly 20 downwardly relative to the mounting assembly 16.

A user input device 202 (see FIG. 1) is provided for inputting a user-desired operation of the electric motor 14, and/or a user desired operation of the steering actuator 42, and/or a user-desired operation of the hydraulic actuator 120. Upon input of the user-desired operation, the controller 200 is programmed to control the electric motor 14, and/or the steering actuator 42, and/or the hydraulic actuator 120 accordingly. The user input device 202 can include any conventional device which can be communicatively connected to the controller 200 for inputting a user-desired operation, including but not limited to one or more switches, levers, joysticks, buttons, touch screens, and/or the like.

Referring to FIG. 7, one or more sensor(s) 204 are provided for directly or indirectly sensing a rotational orientational position of the universal joint 50 and communicating this information to the controller 200. In non-limiting examples, the sensor 204 comprises one or more conventional magnetic pick-up coil(s), Hall-effect sensor(s), magneto-resistive element (MRE) sensor(s), and/or optical sensor(s), such as are available for purchase from Parker Hannifin Corp., among other places. The sensor(s) 204 may be configured to sense the orientational position of the universal joint 50 by sensing the rotational position of the output shaft of the electric motor 14 and/or the rotational position of the internally splined sleeve 56 and/or by sensing the rotational position of the input gear of the angle gearset 72, for example. In other examples, the sensor(s) 204 may also or alternately be configured to directly sense the orientational position of one or more rotatable component of the universal joint 50. The location of the one or more sensor(s) can vary, but preferably is located to be able to accurately sense a rotating part of the assembly for which an orientation between the splines and gears is known.

The controller 200 is configured to automatically cause the electric motor 14 to rotate the universal joint 50 into the neutral position shown in the figures (e.g., see FIGS. 5 and 7), wherein the first input pivot axis 82 and the first output pivot axis 90 are aligned with each other and generally parallel to the trim axis T. This advantageously facilitates trimming of the drive assembly 20 fully out of the water. More specifically, rotating the universal joint 50 into the neutral position with the first input pivot axis 82 and the first output pivot axis 90 oriented generally parallel to the trim axis T (i.e., with the first input pivot axis 82 and the first output pivot axis 90 oriented generally horizontally) thus permits the first pair of arms 74 of the elongated body 66 to pivot through a maximum allowable range about the first input pivot axis 82 within the U-shape formed by the input arms 63, as shown in FIG. 9. Similarly, rotating the universal joint 50 into the neutral position locates the output arms 70 of the output member 64 at a ninety-degree offset from the second pair of arms 76 of the elongated body 66 and thus permits the output arms 70 to pivot through a maximum allowable range about the first output pivot axis 90 within the U-shape formed by the second pair of arms 76, as shown in FIG. 9.

The controller 200 is advantageously programmed to automatically operate the electric motor 14 to rotate the universal joint 50 into the neutral position as indicated by the sensor 204 based upon an operational state of the stern drive 12. The operational state can for example include change in an on/off state of the electric motor 14 (for example a key on or key off event) and/or any other designated programmed request or request input to the controller 200 via the user input device 202.

In a non-limiting example, a user can actuate the user input device 202 to command the controller 200 to control the hydraulic actuator 120 to trim the drive assembly 20 into a fully raised, storage position. Upon receiving said command, the controller 200 is programmed to automatically control the electric motor 14 to rotate the universal joint 50 into the noted neutral position. As explained above, this advantageously facilitates trimming all or at least a majority of the drive assembly 20 out of the water. For example the majority may include all of the driveshaft housing 22 and a majority of the gearcase housing 26. Referring to FIG. 11, the controller 200 can be also configured to automatically operate the steering actuator 42 to steer (i.e., rotate) the drive assembly 20 about the steering axis S, for example into the position shown, which is ninety degrees offset to either one of the port or starboard sides. This can occur prior to, during, or after the drive assembly 20 is trimmed upwardly via the universal joint 50. Steering the drive assembly 20 into the position shown (or into the 180 degree opposite position of what is shown) advantageously further elevates the lowermost point of the drive assembly 20 (which typically is on the torpedo housing 34 or skeg of the gearcase housing 26) further above the waterline W, thus ensuring that the entirety of the drive assembly 20, including all of the driveshaft housing 22 and all of the gearcase housing 26, is positioned out of the body of water. Thus the present disclosure contemplates methods for operating the stern drive 12, including the steps of operating the electric motor 14 to rotate the universal joint 50 into the aforementioned neutral position, which facilitates trimming of the drive assembly 20 upwardly relative to the rest of the stern drive 12, and optionally also steering the gearcase housing 26 relative to the driveshaft housing 22, before, during or after the trimming of the drive assembly 20, thereby moving an entirety of the drive assembly 20 further upwardly relative to the stern drive 12 and ensuring that the entirety of the drive assembly 20 is positioned out of the body of water. This advantageously locates the majority or entirety of the drive assembly 20 out of the body of water during periods of non-use, thus preventing deleterious effects of the water on the drive assembly 20.

Referring to FIG. 7, the stern drive 12 has a cooling system for cooling various components thereof, including for example the electric motor 14. In the non-limiting example shown in the drawings, the cooling system includes an open loop cooling circuit for circulating cooling water from the body of water in which the stern drive 12 is situated and then discharging the cooling water back to the body of water. The open loop cooling circuit includes an intake inlet 300 (see FIG. 1) on the gearcase housing 26 which is connected to an annular cooling channel 302 defined between a lower annular flange 304 on the lower end of the driveshaft housing 22 and an annular flange 306 on the top of the gearcase housing 26. Reference is made to the above-incorporated U.S. Pat. No. 10,800,502. A flexible conduit 308 is coupled to the driveshaft housing 22 and configured to convey the cooling water from the annular cooling channel 302 to a cooling water pump 310 mounted on the outside of the rigid mounting plate 100. The cooling water pump 310 is configured to draw the cooling water in through the intake inlet 300, see FIG. 1, through the annular cooling channel 302, and through the flexible conduit 308. The cooling water pump 310 pumps the cooling water through the mounting assembly 16 to a heat exchanger 314 and then to an outlet 315 shown in FIG. 10. In the illustrated example, the stern drive 12 further includes a closed loop cooling circuit having a pump 312 for pumping cooling fluid such as a mixture of water and ethylene glycol through the heat exchanger 314, exchanging heat with the cooling water in the open loop cooling circuit. The mixture of water and ethylene glycol is circulated past the electric motor 14, an associated inverter 316, and one or more batteries for powering the electric motor 14, thus cooling these components.

Referring to FIGS. 12 and 13, in non-limiting examples, the stern drive 12 also has a sound absorbing enclosure 400 which encloses the inboard portions of the stern drive 12 and advantageously limits noise emanating from the stern drive 12. The sound absorbing enclosure 400 can be made of foam and/or any other conventional sound absorbing material, such as a sheet molding compound (SMC). In the illustrated example, the sound absorbing enclosure 400 completely encloses the inboard components of the stern drive 12 and is fixed to the mounting assembly 16. In other examples, the sound absorbing enclosure 400 is configured to only enclose some of the inboard components of the stern drive 12.

This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to make and use the invention. Certain terms have been used for brevity, clarity and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The patentable scope of the invention is defined by the claims, and may include other examples which occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have features or structural elements which do not differ from the literal language of the claims, or if they include equivalent features or structural elements with insubstantial differences from the literal languages of the claims.