Prefabricated Deck Mounting with Calculated Leveling Layer
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Solution Overview
Problem
Existing methods for preparing boat decks for prefabricated decks are labor-intensive and result in uneven surfaces, particularly when targeting water drainage or curved designs, leading to increased weight and reduced accuracy in achieving the desired height profile, with materials like rigid foam lacking sufficient fatigue strength.
Innovation Solution
A method involving the creation of a leveling layer that compensates for the existing boat deck surface to match the desired contour, using a leveling agent with calculated strength to ensure accurate assembly and reduced weight, which can be integrated into or applied separately to the deck elements, allowing for precise alignment and reduced material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filler is spread and distributed by hand to achieve the desired height profile, then the mounting surface accuracy is improved, but the work time and labor intensity increase significantly
Solution Approach 1:
The boat deck surface is pre-measured to determine the actual height profile, and this information is used to calculate the required filler thickness in advance. This preliminary measurement and calculation allows for optimized filler application, reducing the time needed for manual spreading while maintaining accuracy.
Solution Approach 2:
The method incorporates measurement of the actual height profile as feedback to determine the precise filler thickness required. By continuously comparing the actual surface profile with the target profile and adjusting the filler application accordingly, the process achieves high accuracy without requiring excessive manual adjustment time.
2Manufacturing precision
If filler is continuously applied while comparing with the desired target profile, then the mounting surface accuracy is improved, but the filler layer thickness increases unnecessarily, thus increasing weight
Solution Approach 1:
The required filler thickness is calculated in advance based on the measured actual height profile and the desired target profile. This preliminary calculation allows for precise control of filler application, ensuring that only the minimum necessary thickness is applied to achieve the desired surface profile, thereby avoiding unnecessary weight increase.
Solution Approach 2:
The method changes the parameter of filler thickness from a variable continuous application to a calculated specific value. By determining the exact thickness needed based on the height profile difference, the process achieves the desired surface accuracy while minimizing the filler quantity and corresponding weight.
3Manufacturing precision
If rigid foam is used to compensate for unevenness through plastic deformation, then the mounting surface accuracy is improved, but the fatigue strength decreases, particularly under salt water influence
Solution Approach 1:
The method changes the material parameter from rigid foam to a material with sufficient fatigue strength. By selecting materials that maintain their structural integrity under salt water exposure and cyclic loading, the solution achieves the required surface accuracy compensation while ensuring long-term reliability and resistance to salt water damage.
4Ease of manufacture
If a curved surface or defined height profile is created for targeted water drainage, then the water drainage performance is improved, but the complexity of checking and achieving the target profile increases
Solution Approach 1:
The desired height profile for water drainage is determined in advance based on the boat deck geometry and drainage requirements. This preliminary determination allows for straightforward comparison with the actual surface profile, simplifying the checking process while achieving effective water drainage through the defined contour.
Data Source
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AI summary
The invention relates to a method for mounting a prefabricated deck (31) on a boat deck (36), said prefabricated deck comprising one or more deck elements (02) and the method comprising the following steps: setting a target height profile (11) for the upper face of the prefabricated deck (01); generating a mounting height profile (22), which is spaced apart from, in particular spatially parallel to, the target height profile (11) in the direction of the boat deck (36) by the thickness of the deck element (02); measuring the upper face of the boat deck (36) as the actual height profile (21); determining the height difference (23) between the actual height profile (21) and the mounting height profile (22); producing at least one leveling means (38) per deck element (02), said leveling means having a material thickness that corresponds to the height difference (23); mounting, in particular gluing, the leveling means (38) and the deck element (02) to the boat deck (36), the surface of the mounted prefabricated deck (31) substantially corresponding to the target height profile (11).