Sandwich Composite Marine Decking With Molded Non-Slip Traction
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Solution Overview
Problem
Existing marine deck materials deteriorate over time due to environmental factors and lack sufficient traction, leading to maintenance needs and safety concerns.
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, and the application of pressurized gas or vacuum pressure during molding.
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 provide basic structural support and surface coverage, but the materials deteriorate over time due to environmental factors (sun light/heat, rain, humidity) and require repair or replacement
Solution Approach 1:
The patent employs a composite structure consisting of a cellular core material (such as foam or honeycomb structure) sandwiched between two outer skin layers. This composite construction combines the lightweight properties of cellular materials with the protective and aesthetic qualities of skin layers, creating a deck material that resists environmental deterioration while maintaining structural integrity over extended service life.
Solution Approach 2:
The patent utilizes thermoplastic materials that undergo phase changes during processing. The thermoplastic skins and core materials are heated to become moldable, then cooled in a mold to achieve the desired deck shape and surface characteristics. This parameter change approach allows for integration of non-slip surfaces and precise dimensional control, enhancing durability and resistance to environmental factors.
2Ease of operation
If smooth surface materials are used for marine decks, then the deck provides easy cleaning and aesthetic appearance, but the surface becomes slippery and creates safety concerns
Solution Approach 1:
The patent applies different surface qualities to different regions of the deck material. The outer skin layers can have smooth areas for aesthetic appeal and easy cleaning, while incorporating raised patterns, textures, or non-slip coatings in specific zones where foot traffic occurs. This local differentiation allows the deck to simultaneously provide ease of maintenance and safety against slipping.
Solution Approach 2:
The patent incorporates curved or rounded surface features such as raised domes, bubbles, or textured patterns on the deck surface. These curved geometries increase surface area and create friction points that improve traction, while maintaining an aesthetically pleasing appearance. The three-dimensional surface features effectively reduce slipperiness without compromising visual appeal.
3Strength
If heavy materials are used for marine decks, then the deck provides sufficient structural strength and stability, but the weight increases and affects buoyancy and ease of installation
Solution Approach 1:
The patent utilizes a composite construction with a cellular core (such as foam or honeycomb structure) sandwiched between thin outer skin layers. This composite structure provides high strength-to-weight ratio, delivering the necessary structural strength and stability while keeping the overall weight low. The cellular core acts as a lightweight structural element that maintains rigidity without adding excessive mass, thereby preserving buoyancy and facilitating easier installation.
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 high strength-to-weight ratio, buoyancy, and improved traction, making them suitable for boat decks, swim platforms, and docks, reducing maintenance and enhancing safety.
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 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. 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 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, 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 affected 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 affected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.