Process for manufacturing a boat hull

Abstract

A closed molded system uses reaction injection molding for producing large vessels with hulls, such as a boat hull or large containers. Inserts are used to create a cavity to produce a core. Thereafter the inserts are removed and the same mold is then used to make the other layers of the hull. Closed molding provides controlling the shape of both the outside and the inside of the part. Filler inserts can be used to section off the molds in order to allow for separate core densities.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 657,645, filed Mar. 1, 2005.FIELD OF THE INVENTION [0002] The present invention relates to a process of manufacturing a boat hull, deck, or other large laminate parts. The process utilizes a closed molded system for producing a unitary laminate part, whereby a pre-core and stringers are integrally molded during a reaction injection molding process. BACKGROUND AND SUMMARY OF THE INVENTION [0003] Large fiberglass parts, such as boat hulls and large containers use stringers and bulkheads inside the part to increase their strength. The ribs or stringers create sections or flat parts between them. These flat parts are where one of the improvements arises. In an attempt to increase the strength of the laminate a closed mold system has been utilized to optimize strength through thickness and shape. [0004] Traditionally, a fiberglass boat hull is fabricated using a one-s...

AI Technical Summary

Benefits of technology

[0003] Large fiberglass parts, such as boat hulls and large containers use stringers and bulkheads inside the part to increase their strength. The ribs or stringers create sections or flat parts between them. These flat parts are where one of the improvements arises. In an attempt to increase the strength of the laminate a closed mold system has been utilized to optimize strength through thickness and shape.

[0007] One form of the present invention creates a hull having one or both sides of the laminate that are dish shaped. The dish shape will enhance the strength of the laminate without increasing the core thickness or matt and resin thickness. If only one side of the laminate is dished then it would actually decrease the amount of the core material in the laminate. If both sides of the core are dish shaped, meaning one side is concave and one side is convex, then the core would be the same thickness assuming both convex and concave shapes are consistent in size and shape. This dish shaped portion of the hull reacts against the pressure that is being applied to the bottom of the boat by the waves, thus making the laminate stronger by shape.

[0008] A second form of the present invention provides an improved boat hull design with an integrally molded stringer, bulkhead, and gusset system for creating a one piece unitary structure. The resulting boat hull is stronger, takes less time to manufacture, has improved fit and finish from the inside of the boat hull, and eliminates the need for finishing the engine compartment, a typical additional step in the traditional method of manufacturing a hull.

Problems solved by technology

There are many disadvantages of the traditional open mold hand lay up process.

For example, it takes many labor hours to fabricate a hull using the traditional process because each layer is applied by hand.

Further, because the mold is open, workers are often exposed to toxic fumes from the resin.

Also, the old method creates voids in the laminate which can require post lamination repair.

Moreover, the traditional method only molds one side of the part at a time, which decreases the quality of the part.

Moreover, the old method is not very reproducible, which decreases consistency of the final hull thus making no two parts the same.

Further, the old method results in an unfinished interior surface, such as the headliner or engine compartment, which is labor intensive to later finish.

Images