Deformable Laminate for Mould-Free Boat Hull Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing fiber-reinforced three-dimensional molded parts with curved surfaces, such as boat hulls and rotor blades, are costly due to the need for expensive negative molds, and result in heavy or inefficiently produced components.
Innovation Solution
A manufacturing method using a deformable laminate with a foam layer and a fluid-tight carrier layer, where groove-shaped slits are introduced to allow deformation, and a template framework is used to shape the laminate, allowing for the infusion of reaction resin without a full-surface negative mold, enabling the production of lightweight, high-quality molded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a full-surface negative mold is used to produce fiber-reinforced molded parts, then the production of complex curved surfaces is enabled, but the manufacturing cost increases significantly
Solution Approach 1:
The invention divides the traditional full-surface negative mold into a framework of discrete bar templates (Mallen framework) spaced apart from each other. These segmented templates only define the critical cross-sectional contours of the molded part, eliminating the need for a complete closed-surface mold while maintaining shape accuracy. This segmentation dramatically reduces material consumption and manufacturing cost.
Solution Approach 2:
The bar templates are strategically positioned and dimensioned to provide shaping only where structurally critical, rather than providing continuous surface contact throughout. The spacing and distribution of templates are optimized to deliver sufficient geometric definition with minimal material, applying the principle of local quality by concentrating mold resources only where needed for structural integrity.
2Adaptability or versatility
If traditional rigid foam bodies connected by paper are used to create deformable panels, then three-dimensional deformation is enabled, but the structural strength and dimensional stability deteriorate
Solution Approach 1:
The invention creates a composite structure by bonding fiber-reinforced mats (providing strength and stiffness) to foam bodies (providing deformability). This composite construction combines the advantages of both materials: the fiber reinforcement maintains structural integrity while the foam core enables three-dimensional deformation. The paper or fabric connecting layers are replaced with this stronger composite architecture.
Solution Approach 2:
The invention changes the physical parameters of the foam structure by using rigid foam with specific density and elasticity characteristics that can be deformed elastically during molding but maintain their shape afterward. The foam bodies are dimensioned and positioned to provide the required deformability while the fiber reinforcement ensures the deformed configuration maintains sufficient strength for structural applications.
3Strength
If glass fiber reinforced mats impregnated with matrix are used between foam bodies, then structural strength is improved, but the production complexity and material usage increase
Solution Approach 1:
Instead of completely impregnating all fiber mats with matrix material before assembly, the invention applies matrix material only in the spaces between the foam bodies after assembly. This partial action approach reduces pre-processing complexity and allows the foam structure to be assembled in its deformable state, with the matrix serving primarily as a bonding and strengthening agent in critical regions rather than a complete impregnation medium.
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 method allows for the cost-effective production of highly stressable, lightweight three-dimensional molded parts without the need for expensive molds, with improved dimensional stability and reduced material usage, enabling the creation of complex shapes like boat hulls and facade elements.
Implementation Method 1
the foam layer has a tendency to spring back after deformation
Implementation Method 2
Casting the free spaces remaining in the slots after insertion into the template frame with reaction resin using the infusion method, in particular the vacuum infusion method
Implementation Method 3
allowing the reaction resin to harden
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The present invention relates to a deformable structural panel (10) for the formless production of a fiber-reinforced three-dimensional molded part, in particular a boat hull, rotor blade, or facade element. The structural panel (10) has a laminate structure comprising a foam layer (13) and a first fiber-reinforced support layer (11) bonded to a first side of the foam layer (13). The structural panel (10) has one or more groove-shaped slots (26) on one side, forming a slot pattern (20), wherein the slots (26) penetrate the foam layer (13) completely or partially, but do not penetrate the first support layer (11).The invention further relates to a manufacturing process for the free-form production of a fiber-reinforced three-dimensional molded part with at least a partially curved surface, in particular a boat hull, rotor blade or facade element, using one or more construction panels (10) or a laminate according to the invention, which are placed in a template frame and subsequently cast in an infusion process or provided on the side opposite the first support layer (11) with a fiber matrix semi-finished product or a fiber fabric reaction resin hand laminate.