Marine Sandwich Decking With Textured Composite Skins for Wet Traction
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Solution Overview
Problem
Marine deck materials face challenges such as deterioration from environmental factors, slipperiness, high cost, weight, strength, and buoyancy, with existing non-slip solutions not adequately addressing these issues.
Innovation Solution
The use of sandwich-type, compression-molded composite panels with a cellular core and thermoplastic skins, enhanced by debossing or embossing techniques to improve surface traction, and the application of pressurized gas or vacuum pressure during cooling to create patterns that enhance grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials (fiberglass, aluminum, treated plywood) are used for marine decking, then the deck can provide structural strength and durability, but the materials deteriorate over time due to environmental factors and require repair or replacement
Solution Approach 1:
The patent applies composite materials by combining a cellular core (made of closed-cell foam or similar material) with outer skin layers (such as polyethylene or polypropylene). This composite structure provides superior resistance to environmental degradation from sunlight, rain, and humidity while maintaining structural strength, thereby extending the service life of marine decking without requiring frequent repairs or replacements.
2Ease of operation
If traditional smooth surfaces are used for marine decking, then the deck is easy to clean and maintain, but the surfaces become slippery and pose safety hazards in wet conditions
Solution Approach 1:
The patent applies local quality by incorporating a textured or patterned surface layer on the marine decking that provides localized non-slip characteristics in areas where foot traffic occurs, while maintaining smooth surfaces in other areas for ease of cleaning. This selective application of different surface qualities allows the deck to simultaneously achieve safety through improved traction and ease of maintenance through cleanability.
3Strength
If solid construction materials are used for marine decking, then the deck provides high strength and durability, but the deck becomes heavy and reduces buoyancy
Solution Approach 1:
The patent applies porous materials by using a cellular core structure with closed cells that provides high strength-to-weight ratio. The cellular architecture delivers structural integrity comparable to solid materials while significantly reducing the overall weight of the decking. This weight reduction enhances buoyancy and makes the marine deck easier to install and maneuver, particularly in applications like pontoon boats and floating docks.
4Strength
If conventional compression molding processes are used for sandwich-type composite panels, then the panels can be manufactured with good structural properties, but the process requires high energy input and complex equipment
Solution Approach 1:
The patent applies self-service by utilizing the inherent properties of thermoplastic materials that soften at elevated temperatures and bond together under pressure, eliminating the need for additional adhesives or complex bonding equipment. The materials essentially perform their own bonding function when subjected to heat and pressure during compression molding, reducing energy requirements and simplifying the manufacturing process while maintaining strong structural integrity.
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 applications like boat decks, swim platforms, and docks.
Implementation Method 1
The stack may be pre-heated outside the mold or heated inside the mold to a softening temperature
Implementation Method 2
The application of pressurized gas or vacuum pressure during cooling to create patterns that enhance grip
Data Source
AI summary
A marine deck member and the process for forming the same are provided. 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.