Closed-Cell Foam Bunk Board Underlayment for Dry Hull Support
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Solution Overview
Problem
Conventional boat trailer bunk board covers made of carpet material absorb water, leading to weakening, tearing, and prolonged drying, which can cause damage to the boat and bunk boards, especially when submerged for extended periods, and existing thermoplastic covers lack cushioning and protection during loading, unloading, and transit.
Innovation Solution
Implementing a closed cell foam device as bunk board padding or underlayment, which can be used alone or with a covering layer, providing anti-microbial properties and quick drying capabilities, and is configurable in various materials and thicknesses to fit different bunk board sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carpet material is used for bunk board covers, then cushioning and protection are provided, but water absorption increases leading to weakening and tearing
Solution Approach 1:
The patent changes the material parameter from carpet to closed cell foam, fundamentally altering the water absorption characteristics while maintaining protective functions. The closed cell foam's cellular structure prevents water penetration, resolving the contradiction between cushioning protection and water absorption.
Solution Approach 2:
The invention uses composite construction with closed cell foam as the core padding material, potentially combined with other materials for the cover layer. This composite approach maintains the cushioning benefits while eliminating the water absorption problems of single-material carpet construction.
2Reliability
If carpet material is used for bunk board covers, then protection is provided, but drying time increases when saturated
Solution Approach 1:
The patent changes the material's hydrophilic properties to hydrophobic by using closed cell foam, which inherently repels water. This parameter change eliminates the prolonged drying time issue while maintaining protection capabilities, as the material never becomes saturated in the first place.
3Quantity of substance
If thermoplastic covers are used instead of carpet, then water absorption is reduced, but cushioning and protection are diminished
Solution Approach 1:
The patent employs closed cell foam as a composite material that combines the water resistance of thermoplastics with the cushioning properties of flexible foam structures. This resolves the contradiction by providing both low water absorption and adequate cushioning protection simultaneously.
Solution Approach 2:
The closed cell foam utilizes a controlled porous cellular structure that prevents water absorption while maintaining flexibility and cushioning. The closed cells prevent water penetration while the foam structure provides compression resistance for protection during loading and transit.
4Area of stationary object
If conventional bunk board covers are used, then coverage is provided, but rot and structural degradation occur when saturated
Solution Approach 1:
The patent changes the material composition from water-absorbing carpet to water-resistant closed cell foam, fundamentally altering the moisture content parameter. This prevents the conditions that lead to rot and structural degradation while maintaining full coverage area.
Solution Approach 2:
The closed cell foam cover is designed as a durable, long-lasting replacement that eliminates the need for frequent replacement due to rot and degradation. While the initial material may be similar in cost to carpet, its extended service life and resistance to structural breakdown provide long-term value.
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 closed cell foam solution prevents water absorption, reduces the risk of tearing and rot, provides cushioning during loading and transit, and ensures quick drying of the bunk boards, minimizing damage and extending their lifespan.
Implementation Method 1
The invention is a method of creating a bunk board padding and underlayment that has little to no absorption of water through the use of a closed cell foam device
Implementation Method 2
provides cushioning for when the boat trailer is loaded/unloaded with a boat, and while the trailer loaded with a boat is in transit
Data Source
AI summary
The method and use of the padding and underlayment device and method disclosed is directed to method and device for supporting the hull of a watercraft using a bunk board with an underlayment pad or cushion attached to the bunk board, the underlayment pad cushion is constructed with an closed cell foam structure that has little to no water absorption and is 2.5 mm to 12 mm thick, the method also includes the option utilizing closed cell foam as bunk board cover over the bunk board padding and underlayment closed cell foam.