Multi-layer Hatch Cover Support Pad Cost Reduction
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Solution Overview
Problem
Hatch cover support pads on cargo ships are expensive due to high abrasion resistance materials, and it is difficult to inspect and determine wear, leading to potential damage from uneven force transfer and high replacement costs.
Innovation Solution
A multi-layer hatch cover support pad with a thin, high-abrasion-resistant wear layer made from expensive materials and a thicker, less expensive base layer, along with wear indicators and a locking mechanism to secure the pad, allowing for easier identification of wear and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If high abrasion resistant plastic material is used for the entire hatch cover support pad, then the pad has long lifetime and can support large loads, but the cost is high
Solution Approach 1:
The support pad is divided into two distinct layers: a wear layer made of expensive high-abrasion-resistant plastic material and a base layer made of less expensive polymer material. This segmentation allows the expensive material to be used only where it is most needed (at the wear surface) while reducing overall material costs.
Solution Approach 2:
Different parts of the support pad have different material properties tailored to their specific functions. The wear layer has high abrasion resistance for durability, while the base layer uses cost-effective material for structural support, optimizing both performance and cost.
2Difficulty of detecting and measuring
If the hatch cover support pad is made visible for inspection, then wear can be determined, but the inspection is still difficult due to sea environment conditions
Solution Approach 1:
Wear indicators are provided in the form of colored elements (such as colored fibers, particles, or distinct color layers) that become visible when the wear layer is worn away. The color contrast makes it easy to detect wear conditions even in the challenging sea environment where visual inspection is already difficult.
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 multi-layer design reduces material costs by using less expensive materials for the base layer, extends pad life through improved wear detection, and enhances security with a locking mechanism, thereby reducing replacement frequency and potential damage.
Implementation Method 1
Hatch cover support pads moulded from abrasion resistant plastics typically have high abrasion resistance and low friction
Data Source
Figure 1
Figure 2~3A
Figure 3B~3C
AI summary
The invention provides a multi-layer hatch cover support pad (50) for supporting a hatch cover (8) on a coaming structure (10) of a ship (2). The multi-layer hatch cover support pad (50) comprises an outer wear surface (54) for sliding against a mating surface (14) provided on the hatch cover (8) or the coaming structure (10), a wear layer (52) comprising first and second opposite sides (54, 56), the first side defining the outer wear surface (54), the wear layer -{32} comprising a first plastic material and, a base layer (58) comprising third and fourth opposite sides (80, 82), the third side (60) being joined to the second side; (56). The base layer (58): comprises a second polymer material which is less abrasion resistant than the first plastic material. By making the base layer (58), which in practice makes up the main part of the multi-layer hatch cover support pad (50), out of the second polymer mate- rial, the cost of the multi-layer hatch cover support pad (SO) is decreased. The multi-layer Hatch cover support pad may (50) further comprise an interna! wear indicator body (80) for indicating wear of the wear layer (52) and/or an identification unit (110) for identifying: the multi-layer hatch cover support pad (50), A method cf producing the multi-layer hatch cover support pad (50), as well as a use of the multi-layer hatch cover support pad (50), is also provided.