3D Vacuum Infusion Hull Manufacturing
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Solution Overview
Problem
Conventional yacht hull manufacturing methods involve secondary bonding after vacuum infusion, leading to poor structural performance and increased weight due to the hand lay-up process, which is time-consuming and costly.
Innovation Solution
The method employs three-dimensional structure type fiber clothes and a three-dimensional vacuum infusion process, where longitudinal and transverse structural materials are integrated with resin within a mold using vacuum pipes and resin pipes to form a lightweight, high-strength hull without secondary bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hand lay-up process is used for secondary bonding of structural materials, then ease of manufacture is improved, but structural performance deteriorates and weight increases
Solution Approach 1:
The patent merges the vacuum infusion process with structural material bonding into a single integrated process. Structural materials are placed within the mold cavity before vacuum infusion, allowing resin to penetrate and bond them simultaneously with hull formation. This eliminates the separate hand lay-up secondary bonding step while achieving superior structural performance through integrated manufacturing.
2Ease of manufacture
If hand lay-up process is used for secondary bonding, then ease of manufacture is improved, but production time increases
Solution Approach 1:
The patent combines multiple operations into a single vacuum infusion process step. Structural materials are positioned in the mold cavity beforehand, and the vacuum infusion simultaneously forms the hull and bonds the structural materials with resin. This eliminates the sequential hand lay-up bonding step, significantly reducing production time while maintaining manufacturing simplicity.
3Device complexity
If conventional vacuum infusion with secondary bonding is used, then manufacturing simplicity is maintained, but fiber content decreases and resin usage increases
Solution Approach 1:
The patent integrates structural material placement into the vacuum infusion setup, allowing resin to flow through and bond structural materials during the same process that forms the hull. This simultaneous bonding eliminates the need for additional resin applications in secondary hand lay-up, increasing overall fiber content while reducing total resin consumption.
4Device complexity
If conventional vacuum infusion with secondary bonding is used, then manufacturing simplicity is maintained, but environmental impact worsens due to volatile organic compound volatilization
Solution Approach 1:
The patent consolidates all resin application and bonding operations into a single vacuum infusion process. Resin is applied once and used efficiently to form both the hull and bond structural materials, eliminating multiple resin application steps. This reduction in total resin usage and process steps directly decreases volatile organic compound emissions, improving environmental performance while maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces volatile organic compound volatilization, increases fiber content, decreases resin usage, and enhances structural strength while shortening production time and weight by about 8%, improving surface quality and reducing environmental impact.
Implementation Method 1
the vacuum pipes are used to generate a vacuum suction force on the two sides of the mold
Implementation Method 2
the vacuum pipes are used to generate a vacuum suction force on the two sides of the mold, and the first and second resin pipes are used to sequentially inject a resin and fill the resin in the internal space of the lamination
Data Source
AI summary
A method for manufacturing an integrated hull by using 3D structure type fiber clothes and 3D vacuum infusion process includes: sequentially stacking at least one first fiber cloth, at least one core material and at least one second fiber cloth on a mold; deploying structural materials on the second fiber cloth; stacking the third fiber clothes to cover the structure materials and a part of the second fiber cloth, whereby the first fiber cloth, the core material, the second fiber cloth and the third fiber clothes are formed to a lamination; determining a pipe arrangement of vacuum pipes and first and second resin pipes; deploying a vacuum bag on the lamination and covering the first and second resin pipes and the vacuum pipe; executing the 3D vacuum infusion process; curing the resin; and executing a mold release process to complete an integrated hull.