Foam Component Hull Assembly with Polyurea Bonding

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Solution Overview

Problem

The existing methods for manufacturing boat hulls are limited by the need for specialized equipment and expertise, high upfront costs, and lack of design flexibility due to the use of molds, which restricts size and shape options and increases production time.

Innovation Solution

A method involving the arrangement of foam components such as cross-members, stringers, and planks to form a hull shape, bonded together with polyurea, eliminating the need for a mold and allowing for greater design flexibility and reduced production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional mold-based manufacturing methods are used, then structural strength and impact resistance are improved, but manufacturing cost and time increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The hull is divided into multiple foam components (cross-members, stringers, planks) that are arranged and bonded together using polyurea, eliminating the need for a single large mold while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite materials combining foam components with polyurea bonding agent to achieve both strength and cost-effectiveness, replacing traditional mold-based fiberglass construction

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional mold-based manufacturing methods are used, then structural strength and impact resistance are improved, but design flexibility deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoiddesign flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

By segmenting the hull into modular foam components, the invention enables easy reconfiguration and customization of hull designs without being constrained by mold dimensions, achieving both strength and design flexibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular foam component system allows dynamic adjustment of hull design parameters (size, shape, configuration) by rearranging components, providing adaptability that fixed molds cannot offer

Inventive Principle:

Principle #15Dynamics

3Strength

If vacuum infusion methods are used, then structural strength is improved, but device complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidequipment complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention replaces expensive, complex vacuum infusion equipment with simpler, more accessible polyurea spray application equipment, achieving sufficient structural strength without specialized machinery

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention substitutes the mechanical vacuum infusion system with a chemical bonding system using polyurea spray, eliminating the need for vacuum pumps, seals, and specialized equipment while maintaining structural integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If traditional mold-based manufacturing methods are used, then manufacturing precision is improved, but productivity deteriorates

Engineering Contradiction:

Improveshape precisionVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Foam components are pre-formed and then quickly assembled using spray-applied polyurea bonding agent, enabling rapid construction without the time-consuming mold preparation and curing processes, maintaining precision while accelerating production

Inventive Principle:

Principle #10Preliminary action

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 provides a lightweight, high-strength, and impact-resistant composite material for boat hulls, enabling the production of various sizes and shapes without the need for specialized equipment or molds, thus reducing production time and costs.

Implementation Method 1

applying polyurea along intersection lines of the foam components and covering a surface of the shape, thereby bonding the components together

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20240017796A1Method of manufacturing a body of a structure

Publication Date: 2024.01.18 SV BUSINESS GRP INC

AI summary

A method of manufacturing a body of a structure includes arranging a plurality of foam components of the body such that each one of the foam components abuts at least one other of the foam components to form a shape. The method also includes applying polyurea along intersection lines of the foam components and covering a surface of the shape, thereby bonding the components together and providing a composite material forming the body of the structure.