A boat hull is provided that has a substantially seamless construction wherein the boat hull is an integral monolithic structure. In the formation of the boat, the boat interior components for example deck precursors are positioned in the mold prior to formation of the hull so that the boat hull can
A boat hull is provided that has a substantially seamless construction wherein the boat hull is an integral monolithic structure. In the formation of the boat, the boat interior components for example deck precursors are positioned in the mold prior to formation of the hull so that the boat hull can be made in a one shot molding process.
대표청구항▼
What is claimed is: 1. A method of making a boat hull with at least one integral working deck, said method including; placing reinforcement in contact with a relatively rigid first mold portion to form a layer of reinforcement for a boat hull precursor, placing a working deck forming insert on the
What is claimed is: 1. A method of making a boat hull with at least one integral working deck, said method including; placing reinforcement in contact with a relatively rigid first mold portion to form a layer of reinforcement for a boat hull precursor, placing a working deck forming insert on the first mold portion at a desired location, said insert extending along a substantial portion of the length of the layer of reinforcement for the boat hull precursor; placing a relatively flexible second mold portion adjacent the first mold portion capturing the insert and reinforcement in a mold area between portions of the first and second mold portions said second mold portion having a molding surface configured generally to a desired interior shape of the boat hull with at least one working deck; reducing pressure in the mold area below atmospheric and thereby compressing at least some of the reinforcement between the two mold portions and thereafter; infusing resin into the reinforcement and at least partially enrobing the insert in resin forming an integral boat hull and working deck structure comprised of reinforcement, resin and insert, said integral boat hull and working deck structure having a said boat hull and at least one said working deck with seamless construction between at least one junction therebetween said working deck having a generally upstanding sidewall member defining one side of a channel, said generally upstanding sidewall member extending from a stem portion to a bow portion and being continuous therebetween; hardening the resin; and removing the integral boat hull and working deck structure from the first mold portion. 2. The method as set forth in claim 1 including placing reinforcement on the insert and thereafter infusing resin into the reinforcement on the insert during the step of infusing into the layer of reinforcement for the boat hull precursor. 3. The method as set forth in claim 2 including forming a pair of said working decks and having said channel therebetween defined on opposite sides thereof by a pair of said generally upstanding sidewall members. 4. The method as set forth in claim 3 wherein the pair of generally upstanding sidewall members both being continuous between the bow portion and the stem portion. 5. The method as set forth in claim 4 wherein the channel is uninterrupted by a transverse partition. 6. The method as set forth in claim 4 wherein the generally upstanding sidewall members are characterized by an absence of a significant stress riser. 7. The method of claim 4 wherein the boat hull includes a pair of exterior sidewall portions, a stern portion a bow portion and a bottom wall portion and each said working deck including a respective said generally upstanding sidewall member and a respective top wall member, each said working deck including a respective said insert, and the method further including bonding each said insert to a respective generally upstanding sidewall member and top wall member, a respective exterior sidewall portion and the bottom wall portion. 8. The method of claim 4 wherein the working decks each including a generally horizontal top wall member and the method further including forming a longitudinally extending recess in each top wall member adjacent a respective said generally upstanding sidewall member. 9. The method of claim 8 including forming a longitudinally extending groove in at least one said recess. 10. The method of claim 9 including forming a seam between a generally upstanding sidewall member and a respective said top wall member at said groove. 11. The method of claim 8 including securing a cover to the formed working decks to extend across and cover at least a portion of the channel. 12. The method of claim 11 wherein edge portions of the cover are each positioned in a respective said recess and being adhesively attached therein. 13. The method of claim 8 including forming a slot in each said deck forming insert and placing a groove and recess forming mold insert into each said slot prior to infusing the resin. 14. The method as set forth in claim 3 including mounting a partition between said generally upstanding sidewall member after the hardening, said partition separating the channel into a plurality of chambers. 15. The method as set forth in claim 8 including placing a pair of said inserts on said first mold portion and forming a pair of working decks with a channel therebetween and mounting at least one divider in the channel between the working decks after the hardening step. 16. The method as set forth in claim 3 wherein the first mold portion being a female mold portion and the second mold portion being a male mold portion, said male mold portion having a relatively flexible portion defining a first side of the mold area and the female mold portion having a relatively rigid portion partially defining a second side of the mold area, the relatively flexible portion having a surface portion defining a portion of the mold area and having a preformed shape conforming generally to a substantial portion of an interior surface portion of the boat hull and working deck structure. 17. The method of claim 16 wherein the relatively flexible male mold portion being used to form a second integral boat hull and working deck structure. 18. The method of claim 17 wherein the relatively flexible male mold portion being made of at least one of polyurea and polyurethane. 19. The method of claim 18 wherein the relatively flexible male mold portion being made by spray forming. 20. The method of claim 18 wherein the relatively flexible male mold portion being made at least partially of polyurethane. 21. A boat hull with working deck produced by the method of claim 3. 22. The method as set forth in claim 2 including coating at least a portion of the first mold portion with boat hull exterior finish and at least a portion of the layer of reinforcement is formed on an interior surface of the exterior finish. 23. The method as set forth in claim 22 said reduced pressure being used to at least partially induce the resin to infuse into the reinforcement layer. 24. The method as set forth in claim 23 wherein the reinforcement layer includes fibers. 25. The method as set forth in claim 24 wherein the reinforcement layer at least partially includes chopped fibers. 26. The method as set forth in claim 25 wherein the reinforcement layer at least partially includes at least one of woven fibers and knit fibers. 27. The method as set forth in claim 24 wherein the resin is hardened by curing. 28. The method as set forth in claim 24 including forming a recess with a groove in the working deck, said groove extending along a substantial portion of the length of the working deck and forming a discontinuity between the generally upstanding sidewall member of the working deck and a portion of the recess. 29. The method as set forth in claim 28 including forming an access opening in a said working deck prior to hardening and mounting a cover over at least a portion of the access opening after hardening, said cover being mounted for movement between open and closed positions. 30. The method as set forth in claim 24 wherein said resin flows into the mold area for the infusing into the reinforcement. 31. The method as set forth in claim 30 including applying reinforcement to at least a portion of an exterior surface of the insert. 32. The method as set forth in claim 31 including applying reinforcement to at least a portion of the exterior surface of the insert prior to placing the insert on the first mold portion. 33. The method as set forth in claim 24 wherein the insert being formed at least partially of a polymeric closed cell foam. 34. A boat hull with working deck produced by the method of claim 24. 35. The method as set forth in claim 2 including forming a wall member on a first face of the insert and a floor member on a second face of the insert, with the wall and floor members comprising resin and reinforcement and said generally upstanding sidewall member being at least a portion of a stringer. 36. The method as set forth in claim 35 including forming a discontinuity in the resin and reinforcement between a top edge of the generally upstanding sidewall member and a side edge portion of the floor member. 37. A boat hull with working deck produced by the method of claim 1. 38. A boat hull with working decks comprising: hull components including a bottom wall portion, a bow portion, a stem portion and sidewall portions integral with one another and at least partially forming an open top cavity; a pair of working decks of reinforcement and resin material in the cavity extending a substantial portion the length of the cavity between the bow portion and stem portion each having a respective generally upstanding continuous sidewall member extending from adjacent the bow portion to the stem portion and forming at least one side of a channel, said generally upstanding continuous sidewall members each having a lower edge integral with and connected to the bottom wall portion and being in spaced apart relationship and facing one another forming opposite sides of the channel and each working deck having a top wall member, said working decks each having portions integral with at least two of the bottom wall portion, the sidewall portions, the bow portion and the stem portion forming a structure with an interior surface between a floor portion of the deck and at least some of the hull components, said pair of working decks partially defining respective interior chambers between portions of the respective working decks and at least some of the hull components and an insert in the chambers and attached to portions of the working decks and at least some of the hull components to form a structural element therewith to reinforce the hull; wherein there is a discontinuity in the reinforcement and resin material between the top wall member and respective generally upstanding continuous sidewall member providing a groove and seam in each working deck; and wherein said chambers are sealed from surrounding atmosphere. 39. The boat hull with working deck of claim 38 including at least one divider extending between and mounted to the working decks and at least partially positioned in said channel. 40. The boat hull with working deck of claim 39 wherein the at least one divider is adhesively secured to the working decks. 41. The boat hull of claim 38 including a generally upwardly facing recess in each working deck adjacent the channel and a floor member bridging at least a portion of the channel and having side edge portions each received in a respective said recess. 42. The boat hull of claim 41 wherein said floor member edge portions each being secured to a surface partially defining a respective said recess. 43. The boat hull of claim 42 wherein each said recess including a longitudinally extending groove positioned adjacent a respective side of the channel and said side edge portions of the floor member each being adhesively secured to a respective said recess surface and overlying a respective said groove. 44. A boat hull with working decks comprising: hull components including a bottom wall portion, a bow portion, a stem portion and sidewall portions integral with one another and at least partially forming an open top cavity; a pair of working decks of reinforcement and resin material in the cavity extending a substantial portion the length of the cavity between the bow portion and stem portion each having a respective generally upstanding continuous sidewall member extending between the bow portion and stern portion and forming at least one side of a channel, said generally upstanding continuous sidewall members being in spaced apart relationship and facing one another forming opposite sides of the channel and each working deck having a top wall member, said working decks each having portions integral with at least two of the bottom wall portion, the sidewall portions, the bow portion and the stern portion forming a structure with an interior surface between a floor portion of the decks and at least some of the hull components, said pair of working decks partially defining a respective interior chamber between portions of the respective working decks and at least some of the hull components and an insert in the chamber and attached to portions of the working deck and at least some of the hull components to form a structural element therewith to reinforce the hull. 45. The boat hull with working deck of claim 44 wherein each insert is bonded to a respective said generally upstanding continuous sidewall member, said top wall member and sidewall portions and bonded to the bottom wall portion. 46. The boat hull with working deck of claim 45 wherein the inserts are at least partially made of polymeric foam. 47. The boat hull with working deck of claim 46 wherein the polymeric foam includes closed cell polymeric foam. 48. The boat hull with working deck of claim 45 wherein the generally upstanding continuous sidewall members are characterized by an absence of a significant stress riser and are generally planar. 49. The boat hull with working deck of claim 45 wherein the channel is continuous extending from the stem portion to the bow portion. 50. The boat hull with working deck of claim 49 wherein the bonds are continuous between surfaces of the insert and abutting surfaces of the respective said generally upstanding continuous sidewall, said top wall member and sidewall portions and said bottom wall portion.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (29)
Hooper James R. (Palmdale CA), Apparatus for fabricating composite parts.
Dublinski Alex C. (Northford CT) Carstensen Thomas A. (Shelton CT) Ramey Philip J. (Milford CT), Composite molding apparatus for high pressure co-cure molding of lightweight honeycomb core composite articles having ra.
Seemann ; III William H. ; Tunis ; III George C. ; Perrella Andrew P. ; Haraldsson Rikard K. ; Everitt William E. ; Pearson Everett A., Large composite structures and a method for production of large composite structures incorporating a resin distribution.
Tunis, III, George C.; Seemann, III, William H., Large composite structures and a method for production of large composite structures incorporating a resin distribution network.
Seemann ; III William H. ; Tunis ; III George C. ; Perrella Andrew P. ; Haraldsson Rikard K. ; Everitt William E. ; Pearson Everett A., Large composite structures incorporating a resin distribution network.
Seemann ; III William H. (26 Montacilla Ocean Springs MS 39564), Plastic transfer molding techniques for the production of fiber reinforced plastic structures.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.