Boat deck

Abstract

To provide a lightest boat deck in this industry which is lighter than the existing boat deck made of a fiber-reinforced plastic.SOLUTION: A boat deck 1 made of a fiber-reinforced plastic with the thicker plate thickness is obtained by laminating tabular deck body 2 so that a honeycomb skeleton body 21 is sandwiched, and by molding it without laminating the multiple layers of a sheet-like fiber body 22. The boat deck weight becomes lighter than the existing boat deck made of the fiber-reinforced plastic by reducing the number of the laminating layers of the fiber body than the existing boat deck made of the fiber-reinforced plastic and by reducing the thickness of the fiber body. The boat deck weight becomes lighter by making the inside of the skeleton body hollow despite the thicker plate thickness of the deck body.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a boat deck that can be attached to or removed from a boat when doing boat fishing such as bass fishing, and particularly relates to the lightest boat deck in the industry, which is lighter than existing boat decks made of fiber-reinforced plastics.

Background Art

[0002] As boat decks, wooden and fiber-reinforced plastic boat decks are actually used. And as boat decks, wooden boat decks are common. However, for several years, boat decks made of fiber-reinforced plastics, which are lighter than wooden boat decks and do not grow mold or rot like wooden boat decks even when exposed to rain, have begun to be used by replacing the material from wood with fiber-reinforced plastics.

[0003] Although not a boat deck, a windsurfing board in which fiber-reinforced plastic is laminated on a foam core and reinforced with a paper honeycomb (also called a honeycomb) - shaped structure (also called a paper honeycomb) has been proposed (see, for example, Patent Document 1). In this windsurfing board, by reinforcing the fiber-reinforced plastic with a paper honeycomb, it is possible to avoid laminating multiple layers of fiber-reinforced plastic.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the wooden boat decks currently in use, the thickness of the planks must be increased to ensure sufficient strength to support an adult male, which makes the boat deck heavy. Similarly, in the fiber-reinforced plastic boat decks currently in use, the thickness of the planks must be increased to prevent flexing when an adult male stands on them, which also makes the boat deck heavy. Therefore, fiber-reinforced plastic boat decks currently in use are not significantly lighter than wooden boat decks.

[0006] In the windsurfing board described in Patent Document 1, the board becomes heavy because resin is filled inside the paper honeycomb (referred to as the empty space in Patent Document 1).

[0007] Therefore, the objective of this invention is to solve the aforementioned problems and provide the lightest boat deck in the industry, which is lighter than existing fiber-reinforced plastic boat decks. [Means for solving the problem]

[0008] To solve the aforementioned problems, the invention according to claim 1 provides a boat deck that can be attached to and removed from a boat, in which a flat deck body is formed by laminating a sheet-like fibrous material with a honeycomb-shaped frame sandwiched in between, and then solidifying it with resin.

[0009] In the invention according to claim 2, the honeycomb-shaped skeleton is made hollow inside.

[0010] In the invention according to claim 3, the honeycomb-shaped skeleton is made vacuum-sealed inside.

[0011] In the invention according to claim 4, the honeycomb-shaped skeleton is filled with a material that is lighter than the resin used to solidify the sheet-like fibrous material.

[0012] In the invention according to claim 5, the honeycomb-shaped skeleton is made into a shape in which three-dimensional figures are arranged without gaps.

[0013] In the invention according to claim 6, the honeycomb-shaped skeleton is made of paper. [Effects of the Invention]

[0014] According to the invention of claim 1, in a boat deck made of fiber-reinforced plastic, a flat deck body is formed by laminating a honeycomb-shaped frame between layers, so that the thickness of the deck body can be increased without laminating multiple layers of sheet-like fiber material. Therefore, according to the invention of claim 1, the weight of the boat deck can be reduced by reducing the number of laminated fiber materials or by making the fiber material thinner than that of existing fiber-reinforced plastic boat decks. Furthermore, according to the invention of claim 1, by forming the deck body by laminating a thick honeycomb-shaped frame between layers, the thickness of the deck body can be increased compared to existing fiber-reinforced plastic boat decks, so that the deck body does not sag even when an adult male is standing on it.

[0015] According to the invention of claim 2, since the inside of the skeletal structure is hollow, even if the deck body is formed by laminating it with the honeycomb-shaped skeletal structure sandwiched in between, the amount of resin used to solidify the fibers does not increase significantly. Therefore, according to the invention of claim 2, the weight of the boat deck can be reduced despite the thickness of the deck body plates.

[0016] According to the invention of claim 3, since the inside of the skeletal structure is made into a vacuum, the inside of the skeletal structure can be filled with gas at a pressure lower than atmospheric pressure. Therefore, according to the invention of claim 3, the gas inside the skeletal structure is less likely to expand in volume due to rising temperature. Thus, according to the invention of claim 3, even if the boat deck is left in a car under high temperatures, for example in the scorching sun of midsummer, it is possible to prevent the adhesive between the honeycomb-shaped skeletal structure and the sheet-like fiber from peeling off or deforming.

[0017] According to the invention of claim 4, the inside of the skeletal structure is filled with a material lighter than the resin that solidifies the sheet-like fibers, so that no air remains inside the skeletal structure. Therefore, according to the invention of claim 4, even if the boat deck is left in a car under high temperatures, for example in the scorching sun of midsummer, it is possible to prevent the adhesive between the honeycomb-shaped skeletal structure and the sheet-like fibers from peeling off or deforming. Furthermore, according to the invention of claim 4, since the inside of the skeletal structure is filled with a material lighter than the resin that solidifies the sheet-like fibers, if a light material such as foamed urethane is used, the weight of the boat deck can be reduced despite the thickness of the deck itself.

[0018] Furthermore, according to the invention of claim 4, the inside of the skeletal structure is filled with a material lighter than the resin used to solidify the sheet-like fibrous material, thereby increasing the strength of the skeletal structure. Therefore, according to the invention of claim 4, the weight of the boat deck can be further reduced by decreasing the number of layers of fibrous material or by making the fibrous material thinner, in accordance with the increased strength of the skeletal structure.

[0019] According to the invention of claim 5, since the honeycomb-shaped frame is made up of three-dimensional figures arranged without gaps, existing honeycomb-shaped products such as spheres, triangular pyramids, and cubes can be repurposed as the frame of a boat deck, in addition to the shape of a beehive (also called a regular hexagon or regular hexagonal prism).

[0020] According to the invention of claim 6, since the honeycomb-shaped skeleton is made of paper, resin can be impregnated into the paper skeleton. Therefore, according to the invention of claim 6, the strength of the skeleton can be further increased by impregnating the paper skeleton with resin, and the bond between the paper skeleton and the sheet-like fibrous body can be made stronger.

[0021] Thus, according to the invention according to claims 1 to 6, even without laminating multiple layers of the sheet-like fibrous body, the plate thickness of the deck body can be increased, so that the weight of the boat deck can be made lighter than that of an existing fiber-reinforced plastic boat deck. Therefore, according to the invention according to claims 1 to 6, since the boat deck is light, in addition to the transportation and storage of the boat deck, the burdens such as attachment and detachment of the boat deck, loading and unloading on a vehicle can be reduced. Therefore, according to the invention according to claims 1 to 6, even a woman with weak strength or a middle-aged or elderly person whose strength is beginning to decline can use the boat deck without difficulty.

Brief Description of the Drawings

[0022] [Figure 1] It is a perspective view of a boat deck made of fiber-reinforced plastic according to an embodiment. [Figure 2] (a) is an exploded perspective view of part A of FIG. 1 in a perspective view for explaining the structure of a boat deck made of fiber-reinforced plastic according to an embodiment, and (b) is an exploded perspective view of part B of FIG. 1. [Figure 3] (a) is a perspective view before attaching the boat deck in a perspective view for explaining attaching and detaching a boat deck made of fiber-reinforced plastic according to an embodiment to and from a boat, (b) is a perspective view when the boat deck is attached, and (c) is a perspective view when the boat deck is partially folded. [Figure 4] It is a rear-side perspective view of a boat deck made of fiber-reinforced plastic according to another embodiment. [Figure 5] It is an exploded perspective view of part A of FIG. 1 of a boat deck made of fiber-reinforced plastic according to another other embodiment. [Figure 6] It is an exploded perspective view of part A of FIG. 1 of a boat deck made of fiber-reinforced plastic according to yet another other embodiment.

Mode for Carrying Out the Invention

[0023] First, let me briefly explain the basis for this invention. The applicant undertakes the repair of luxury foreign cars, such as German cars. Many luxury foreign cars use aluminum bodies, and unlike the sheet metal commonly used in Japanese cars, aluminum bodies cannot be repaired by hammering. Therefore, sheet metal painting of aluminum bodies is difficult without specialized skills. Since its founding, the applicant has accumulated experience in repairing aluminum bodies as a subcontractor for dealerships, and possesses the skilled techniques to provide high-quality sheet metal painting comparable to that offered by dealerships.

[0024] The applicant, whose representative director is a passionate fan of foreign cars, has undertaken the repair of luxury foreign cars for many years since the company's founding. Based on this experience, the applicant has strived to ensure that customers can enjoy their cherished luxury foreign cars for many years to come, by finishing aluminum bodywork and painting to a like-new condition. More specifically, they have strived to provide a more meticulous finish than dealerships, at a lower cost and with greater speed. Perhaps due to this commitment, the applicant receives entrusted vehicles from customers not only in Saitama Prefecture, where their repair shop is located, but also from Tokyo and Kanagawa Prefectures. This invention was created based on the applicant's fundamental approach to repairs: a passion that leads to customer satisfaction, at a lower cost and with greater speed.

[0025] The inventor is the representative director of the applicant company. Looking to the future, the inventor is eager to take bold steps to restructure the business, such as expanding into new fields, in order to respond to the changes in the economic and social landscape in the post-COVID and "with-COVID" era. As a result, the inventor, who is a big fan of bass fishing, established the "ULCUS" business division (trademark application 2020-149376) in October of last year to conduct fishing-related businesses.

[0026] The inventor, who regularly enjoys bass fishing from rental boats, found the burden of carrying his gear to be a problem. While some black bass fishing spots, like Kameyama Dam, allow cars to drive right up to the pier or provide electric carts to transport gear to the boat, at many fishing spots, anglers have to carry their gear by hand from the parking lot to the boat, and the heavy boat decks make this a burden.

[0027] The inventor was using existing fiber-reinforced plastic boat decks, but these weren't as light as he had hoped, and because they were made to order, he had to wait several months to get his hands on them.

[0028] The inventor then began building his own boat deck, leveraging his skills in repairing luxury foreign cars and his connections with suppliers. He discovered that pursuing lightness and strength by using dry carbon fiber resulted in an exorbitantly high cost, and the deck became unnecessarily high-performance and impractical for real life.

[0029] The inventor then discovered that if the honeycomb structure core material used in aircraft could be repurposed for boat decks, even with wet carbon or glass fiber reinforced plastic, it would be possible to increase the thickness of the boat deck without making it heavier, leading to the creation of this invention.

[0030] Next, embodiments of this invention will be described in detail with reference to the drawings as appropriate. Figure 1 is a perspective view of a fiber-reinforced plastic boat deck according to an embodiment. As shown in Figure 1, the boat deck 1 according to the embodiment consists of a flat deck body 2, and here it is configured to include a raised platform 3 and a waterproof sheet 4.

[0031] Boat deck 1 is a deck that is attached to and detached from a boat when fishing from a boat, such as for bass fishing. It can be placed on the boat's beam (called a middle deck) or placed across the boat's edge (called a high deck). In this case, boat deck 1 is a middle deck, which is placed on the boat's beam.

[0032] The deck body 2 is a broad, flat board made of fiber-reinforced plastic, which is divided into three sections.

[0033] The raising platform 3 is a rectangular platform attached to the corner of the underside of the deck body 2, and in this case, it is made of fiber-reinforced plastic.

[0034] The waterproof sheet 4 is a waterproof cloth that covers the surface of the deck body 2. Here, the waterproof sheet 4 connects the deck body 3 so that it can be folded by covering the three sections of the deck body 2 with a single piece of cloth.

[0035] Figure 2(a) is an exploded perspective view of part A of Figure 1, which is a perspective view illustrating the structure of a fiber-reinforced plastic boat deck 1 according to an embodiment. As shown in Figure 2(a), the boat deck 1 according to the embodiment (see Figure 1) consists of part A of Figure 1, in other words, the deck body 2, which is composed of a skeletal body 21 and a fiber body 22.

[0036] The skeletal structure 21 is a framework with a honeycomb-like structure, more specifically, a structure in which regular hexagons or regular hexagonal prisms are arranged without gaps. In this case, the skeletal structure 21 is a paper honeycomb.

[0037] The fibrous material 22 is made by processing glass fibers, carbon fibers, or resin fibers such as aramid into a sheet. For example, glass fibers processed into a sheet include glass cloth, which is made by weaving glass threads into a cloth, and glass mat, which is made by randomly layering short pieces of glass fiber to form a mat. In this case, the fibrous material 22 is a glass mat.

[0038] As shown in Figure 2(a), in the embodiment of the boat deck 1 (see Figure 1), part A in Figure 1, in other words, the deck body 2, is formed by solidifying sheet-like fibrous material 22, which is laminated so as to sandwich a honeycomb-shaped frame 21, with a resin (not shown). In this way, in the boat deck 1 of the embodiment, because the deck body 2 is formed by laminating a thick honeycomb-shaped frame 21 so as to sandwich it, the thickness of the deck body 2 can be increased without laminating many layers of sheet-like fibrous material 22.

[0039] Therefore, in the boat deck 1 according to this embodiment (see Figure 1), fewer layers of fiber 22 are required than in existing fiber-reinforced plastic boat decks. In this case, only two layers are needed on the front and back surfaces, resulting in a lighter weight for the boat deck 1 compared to existing fiber-reinforced plastic boat decks. In this configuration, two sheets of the fiber 22 are laminated on the front and back surfaces to prevent the deck body 2 from tearing even if a sharp object strikes it.

[0040] Furthermore, as shown in Figure 2(a), the boat deck 1 according to this embodiment (see Figure 1) has a hollow interior in the skeletal structure 21. In this way, in the boat deck 1 according to this embodiment, because the interior of the skeletal structure 21 is hollow, or in other words, because the resin that solidifies the fiber body 22 does not penetrate the interior of the skeletal structure 21, even if the deck body 2 is formed by laminating the honeycomb-shaped skeletal structure 21 in between, the amount of resin used to solidify the fiber body 22 does not increase significantly. Therefore, in the boat deck 1 according to this embodiment, the weight of the boat deck 1 is light despite the thickness of the deck body 2.

[0041] Figure 2(b) is an exploded perspective view of part B of Figure 1, which is a perspective view illustrating the structure of the fiber-reinforced plastic boat deck 1 according to the embodiment. As shown in Figure 2(b), in the boat deck 1 according to the embodiment (see Figure 1), part B of Figure 1, in other words, the riser base 3, is formed by solidifying sheet-like fiber bodies 32, which are laminated so as to sandwich a honeycomb-shaped skeleton 31, with a resin (not shown). In this way, in the boat deck 1 according to the embodiment, because the riser base 3 is formed by laminating a thick honeycomb-shaped skeleton 31, which in this case is twice as thick as the skeleton 21, the thickness of the riser base 3 is increased without having to laminate many layers of sheet-like fiber bodies 32.

[0042] Therefore, in the boat deck 1 according to this embodiment (see Figure 1), it is not necessary to increase the thickness of the riser by laminating multiple layers of sheet-like fiber material, as is the case with existing fiber-reinforced plastic boat decks, resulting in a lighter weight for the boat deck 1 compared to existing fiber-reinforced plastic boat decks. Here, two sheets of sheet-like fiber material 32 are laminated on the back side to prevent the riser 3 from tearing even if a sharp object hits it.

[0043] Figure 3 is a perspective view illustrating the attachment and removal of a fiber-reinforced plastic boat deck 1 according to an embodiment from a boat. Figure 3(a) is a perspective view before the boat deck is attached, Figure 3(b) is a perspective view when the boat deck is attached, and Figure 3(c) is a perspective view when the boat deck is partially folded.

[0044] As shown in Figure 3, the boat deck 1 according to this embodiment is a middle deck that is placed on the ribs b,b of boat B. In the boat deck 1 according to this embodiment, the deck body 2 is formed by laminating a thick honeycomb-shaped frame 21 in between (see Figure 2), so the thickness of the deck body 2 can be increased without laminating many layers of sheet-like fiber material 22. Therefore, the boat deck 1 according to this embodiment requires fewer layers of sheet-like fiber material 22 than existing fiber-reinforced plastic boat decks, and the weight of the boat deck 1 is lighter than existing fiber-reinforced plastic boat decks. As a result, the burden of transporting and storing the boat deck 1, as well as attaching and detaching it from boat B, and loading and unloading it from a vehicle is reduced in the boat deck 1 according to this embodiment.

[0045] Furthermore, in the boat deck 1 according to this embodiment, since the raised platform 3 is attached to the corner of the underside of the deck body 2, the line of sight is higher, which is advantageous for sight fishing where you catch fish that you can see. In addition, in the boat deck 1 according to this embodiment, since the raised platform 3 is attached to the corner of the underside of the deck body 2, a gap is created between the boat beams b,b and the deck body 2. Therefore, in the boat deck 1 according to this embodiment, cables and the like can be passed through this gap. Moreover, in the boat deck 1 according to this embodiment, since the deck body 3 can be folded, when the boat deck 1 is folded, it is easier to transport and store the boat deck 1, as well as to attach and detach it from the boat B, and to load and unload it from a car.

[0046] Figure 4 is a rear side perspective view of a fiber-reinforced plastic boat deck according to another embodiment. As shown in Figure 4, in the boat deck 1' according to the other embodiment, a reinforcing member 5 is attached to the back surface of the deck body 2'. In the boat deck 1' according to the other embodiment, instead of reducing the number of fiber layers or the thickness of the fiber compared to the fiber body 22 (see Figure 2(a)), a wooden reinforcing member 5 is attached so that the deck body 2' does not sag even when an adult male is standing on it.

[0047] Figure 5 is an exploded perspective view of part A of Figure 1 of a fiber-reinforced plastic boat deck according to another embodiment. As shown in Figure 5, in the fiber-reinforced plastic boat deck according to another embodiment, the inside of the frame 21 is a vacuum v. Therefore, in the fiber-reinforced plastic boat deck according to another embodiment, the inside of the frame 21 is filled with gas at a pressure lower than atmospheric pressure. Therefore, in the fiber-reinforced plastic boat deck according to another embodiment, the gas inside the frame 21 does not easily expand in volume due to rising temperature. Therefore, in the fiber-reinforced plastic boat deck according to another embodiment, even if the boat deck is left in a car under high temperatures, for example, in the scorching sun of midsummer, the adhesive portion between the honeycomb-shaped frame 21 and the sheet-like fiber 22 is less likely to peel off and is less likely to deform.

[0048] Figure 6 is an exploded perspective view of part A of Figure 1 of a fiber-reinforced plastic boat deck according to another embodiment. As shown in Figure 6, in the fiber-reinforced plastic boat deck according to another embodiment, the inside of the frame 21 is filled with a material lighter than the resin that solidifies the sheet-like fiber 22, in this case foamed urethane i, so that no air remains inside the frame 21. Therefore, in the fiber-reinforced plastic boat deck according to another embodiment, even if the boat deck is left in a car under high temperatures, for example in the scorching sun of midsummer, the adhesive between the honeycomb-shaped frame 21 and the sheet-like fiber 22 is less likely to peel off and is less likely to deform.

[0049] Furthermore, in another embodiment of a fiber-reinforced plastic boat deck, the interior of the frame 21 is filled with foamed urethane i, which is a lighter material than the resin used to solidify the sheet-like fiber body 22. As a result, despite the thickness of the deck body 2'', the weight of the boat deck is reduced.

[0050] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above. For example, although the fiber-reinforced plastic boat deck 1 in the embodiment was described as a middle deck, it may also be a high deck.

[0051] Furthermore, although it was explained that the boat deck 1 made of fiber-reinforced plastic according to the embodiment is divided into three sections, it may also be made from a single piece of material.

[0052] Furthermore, while it was explained that the skeletal structures 21 and 31 of the fiber-reinforced plastic boat deck 1 according to this embodiment are made of paper honeycomb, they may also be made of metal such as aluminum, or non-metallic materials such as plastic.

[0053] In addition, although it was explained that the fiber 22 in the fiber-reinforced plastic boat deck 1 according to the embodiment is a glass mat, it may also be a glass cloth.

[0054] In this invention, "honeycomb shape" refers not only to the shape of a beehive (also called a regular hexagon or regular hexagonal prism), but also to a shape in which three-dimensional figures such as spheres, triangular pyramids, and cubes are arranged without gaps.

[0055] In this invention, the term "sheet-like fibrous material" refers to fibrous materials such as glass fibers, carbon fibers, and resin fibers such as aramid.

[0056] In this invention, a vacuum refers to a state filled with a gas at a pressure lower than atmospheric pressure. [Explanation of symbols]

[0057] 1. Boat deck (middle deck) 2. Deck body 21 Skeleton 22 Fibers 3. Raising platform 4 Waterproof sheet

Claims

1. A boat deck made of fiber-reinforced plastic that can be attached to and removed from a boat, The aforementioned boat deck consists of a flat deck body, The deck body is formed by solidifying a sheet of glass mat, which is made by layering honeycomb-shaped skeletal structures directly sandwiched from above and below, with resin. The aforementioned skeletal structure is a boat deck characterized by having a hollow interior within the honeycomb structure.

2. A boat deck made of fiber-reinforced plastic that can be attached to and removed from a boat, The aforementioned boat deck consists of a flat deck body, The deck body is formed by solidifying a sheet of glass mat, which is made by layering honeycomb-shaped skeletal structures directly sandwiched from above and below, with resin. The aforementioned skeletal structure is a boat deck characterized by a vacuum inside the honeycomb structure.

3. The boat deck according to claim 1 or 2, characterized in that the skeletal structure has a shape in which three-dimensional figures are arranged without gaps.

4. The boat deck according to claim 1 or 2, characterized in that the skeletal structure is made of paper.

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