Vessel Mould Covering Element Integration
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Solution Overview
Problem
The existing methods for manufacturing vessels, such as sailing boats and motorboats, disrupt finishing operations due to the need to arrange and adhere covering elements like anti-slip elements after the hull and superstructure are joined, which requires time for surfaces to be cleaned and adhesive to cure, leading to potential imperfections and increased production time.
Innovation Solution
Integrating covering elements into the mould before arranging the plastic composite layers, allowing them to be connected via the gel coat or plastic composite, eliminating the need for separate adhesion and reducing the disruption to finishing operations by having the superstructure already equipped with covering elements when removed from the mould.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If covering elements are arranged on the hull and superstructure after joining using adhesive, then the surfaces are protected and anti-slip functionality is achieved, but the finishing operations are disrupted and production time increases due to cleaning and adhesive curing requirements
Solution Approach 1:
The covering elements are arranged in the mould before the plastic composite layers are applied, rather than after the vessel parts are manufactured and joined. This preliminary arrangement allows the covering elements to be integrated into the moulding process itself, eliminating the need for separate adhesive application and curing steps, thereby reducing production time and avoiding disruption to finishing operations
Solution Approach 2:
The arrangement of covering elements is merged with the moulding process of the hull and superstructure. By placing covering elements in the mould before applying plastic composite layers, the covering elements become an integrated part of the moulding process rather than a separate post-processing step, combining multiple operations into one unified process
2Reliability
If adhesive is used to attach covering elements after manufacturing, then the covering elements are securely fixed, but additional material is required and the process becomes more complex with separate adhesion steps
Solution Approach 1:
The attachment of covering elements is merged with the structural manufacturing process. The plastic composite layers serve dual purposes: they form the structural hull/superstructure and simultaneously attach the covering elements, eliminating the need for separate adhesive materials and simplifying the overall process
Solution Approach 2:
The adhesive layer is extracted from the process by using the plastic composite layers themselves as the attachment medium. The separate adhesion step using dedicated adhesive materials is removed, reducing material requirements and process complexity while maintaining secure fixation
3Manufacturing precision
If covering elements are arranged after the hull and superstructure are joined, then the covering elements can be applied to the final surface, but the surfaces must be completely cleaned and adhesive must cure, causing delays in finishing operations
Solution Approach 1:
Covering elements are positioned in the mould before the plastic composite is applied, allowing proper positioning to be established during moulding rather than after manufacturing. This eliminates the need for subsequent surface cleaning and adhesive curing steps that would cause delays in finishing operations
Solution Approach 2:
The manufacturing process is segmented into distinct phases: covering elements are arranged in the mould during the moulding phase, then the plastic composite is applied and cured, and finally the integrated structure is removed from the mould. This segmentation allows positioning to be done early while eliminating subsequent time-consuming adhesion steps
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 approach reduces overall production time, minimizes the risk of imperfections, and results in lighter vessel parts due to the absence of a separate adhesive layer, allowing for less material usage and improved connection quality between the covering elements and the vessel.
Implementation Method 1
After curing of the plastic composite and the gel coat the thus formed hull and superstructure are removed from the respective moulds
Data Source
Figure 1~3
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Figure 7A~7B
AI summary
The present invention relates to a method for manufacturing a part of a vessel, comprising of - arranging a plastic composite (11) in a number of layers in a mould (5) with a surface (7) forming a reverse form of the part of the vessel to be manufactured, and - arranging covering elements (4) in the mould (5) before the step of arranging the layers of the plastic composite (11) so that the layers of the plastic composite are connected to the covering elements.