Process for manufacturing a boat hull
OwnerLance Sonneveldtinventor
Life of this patent
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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.
Claims20
A method of manufacturing a boat hull using a two part closed molding process comprising the steps of:
- a. Building hull A and B molds, said molds having a top, bottom and a side;
- b. Installing all inserts into their respective molds;
- c. Introducing the hull bottom and hull sides with material;
- d. Venting excess coring agent out of the top of the mold to allow for expansion;
- e. Separating hull B mold from hull A mold;
- f. Sheeting hull bottom core with material;
- g. Pulling stringer inserts and blowing core agent;
- h. Pulling core;
- i. Draping core with mat;
- j. Pulling remaining inserts from molds;
- k. Spraying molds with protective agent;
- l. insert core into mold;
- m. Closing molds and injecting material;
- and
- n. Releasing part.
A method of manufacturing a boat hull comprising the steps of:
- Providing a hull core, string bulkhead transom (SBT), molds A and B, hull mold A and B inserts;
- Pulling and curing hull core;
- Separating molds A and B;
- Removing string bulkhead transom;
- Sheeting hull B;
- Joining molds A and B;
- Coring and curing a SBT core;
- Separating molds A and B;
- Removing SBT core;
- Removing hull core;
- Draping an outside of the hull core;
- Removing the hull mold A insert;
- Removing the hull mold B insert;
- Draping an inside of the hull core;
- Shooting hull mold A with a plastic;
- Shooting hull mold B with a plastic;
- Fixing SBT to hull core and draping;
- Draping hull core;
- Shooting and installing hull core into hull mold A;
- Shooting hull core top;
- Joining hull mold B and hull mold A;
- and
- Curing the boat hull for a predetermined time period.
A boat hull constructed using a closed mold processes, comprising:
- a first layer of composite material;
- a core layer adjacent to the first layer;
- and
- a second layer of composite material.
A hull constructed using a closed mold processes, comprising:
- a first layer of composite material that is shaped in a concave configuration;
- a core layer adjacent to the first layer;
- a second layer of composite material that is shaped in a flat configuration;
- and
- at least one stringer formed with one of said layers.
Dependencies are inferred from the claim text.