Composite Marine Decking Surface Texturing for Slip Resistance
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Solution Overview
Problem
Existing marine deck materials deteriorate in harsh marine environments and lack sufficient traction, leading to maintenance needs and safety concerns due to slipperiness.
Innovation Solution
The use of sandwich-type, compression-molded composite panels with a cellular core and thermoplastic skins, where debossing or embossing techniques enhance surface traction by creating uneven cooling patterns during the molding process, and the application of pressurized gas or vacuum pressure to create debossments or embossments matching the core's cell shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional marine deck materials (fiberglass, aluminum, treated plywood, vinyl, or perforated rubber) are used, then the deck can be made with acceptable initial cost and structural integrity, but the material deteriorates over time in harsh marine environments requiring repair or replacement
Solution Approach 1:
The patent employs a composite structure consisting of a foam core material sandwiched between two thermoplastic skin layers. This composite construction combines the buoyancy and shock absorption properties of the foam core with the durability, weather resistance, and structural integrity of the thermoplastic skins, creating a marine deck material that resists deterioration from sunlight, heat, rain, and humidity while maintaining long service life.
2Ease of operation
If smooth surface materials are used for marine decks, then the deck can be made with simple construction and low cost, but the surface becomes slippery creating safety concerns
Solution Approach 1:
The patent applies local quality by creating a textured surface pattern on the thermoplastic skin layer through the compression molding process. The mold incorporates a patterned surface that imprints a non-slip texture onto the deck material during manufacturing. This localized surface modification provides enhanced traction and grip where needed for safety, while the bulk of the material maintains its structural and protective properties.
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
The solution provides marine deck materials with a high strength-to-weight ratio, buoyancy, and significantly improved surface traction, making them suitable for boat decks, swim platforms, and docks while reducing maintenance needs.
Implementation Method 1
The air in the core cavities causes thermal gradients relative to the cell walls that result in uneven cooling over the surface area of the skin.
Implementation Method 2
The resultant uneven cooling is manifested as 'debossing' (or, 'sink marks') on the surfaces of the skins.
Implementation Method 3
The debossing effect can be accentuated by applying pressurized gas, e.g., pressurized nitrogen or air, onto the outer surface of the first skin as it cools in the compression mold.
Implementation Method 4
Alternatively, the uneven cooling phenomenon can be used to 'emboss' the surface of the skin be application of vacuum pressure while the skin is cooling in the mold.
Data Source
AI summary
A marine deck member with enhanced surface traction and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be effected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be effected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.