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1. 发明授权

US4142265A Plastics boat hull 失效
标题翻译：塑料船体
公开(公告)号：US4142265A
公开(公告)日：1979-03-06
申请号：US805170
申请日：1977-06-09
申请人： Albert Pfleger
发明人： Albert Pfleger
IPC分类号： B63B3/18 , B63B5/24 , B63B9/06 , B63B3/00
CPC分类号： B63B3/18 , B63B5/24 , Y02T70/143 , Y10T156/1052 , Y10T156/1082
摘要： This invention relates to a self-supporting plastics shell construction, particularly to a multilayered boat shell constructed of elongate thermoplastic shapes disposed in a form-locking arrangement adjacent one another in the shape of a basic shell and covered with laminates of fiber-reinforced thermosetting plastics, and further concerns a method for producing such plastics shell construction with the aid of a form frame determining the final shape.A known type of boat hull shell is constructed as a sandwich structure of individual foam plastics plates, with their butt joints sealed with a filler and their surfaces covered with fiber-reinforced thermosetting plastics laminates. The forming frame employed in this case is a positive core which is removed after the outer laminate has become set, so that the interior surfaces can also be covered with a laminate. The assembly of the positive core and the time-consuming manufacturing process result in high production costs of such boat hull shells. In addition, there are further operations required to provide the basic shell with other structural parts such as bulkheads, decks, and superstructures.Another known type of boat shells is produced with the aid of a negative form by first applying the eventual outer skin, or varnish coat, respectively, of the boat hull to the glazed or polished interior wall surface of the form, and then applying a sufficient number of layers of a glass fiber reinforced thermosetting plastics laminate to obtain a fully-laminated shell having sufficient self-supporting strength. Also in this case, further installations and additional interior stiffeners are required to obtain a self-supporting boat hull shell. The fabrication of such negative forms, which have to be very stable, is very expensive. Further a non-separable negative form of this type is unsuitable for forming boat shells having reentrant ribs, a reentrant stern frame, or possibly a negative deck jump. In addition, a negative form of this type has to remain occupied for a long period of time for allowing the shell to become set, whereby the profitability of this production method is put into question, particularly in the case of smaller boatbuilding enterprises.Further known are self-supporting plastics shells of the initially-named type, particularly for employ in the building and sanitary installations fields, consisting of individual thermoplastic shapes having in most cases a circular or rounded cross section. The shapes are placed side by side in direct contact with one another or with spacer elements for providing a three-dimensional curvature of the finished shell inserted therebetween, and embedded between laminates of glass fiber reinforced thermosetting plastics. A substantial excess of the thermosetting plastics material is provided for filling the unavoidable interstices or grooves between individual shapes and for obtaining a highly form-retaining finished structure in connection with the laminates. Due to its design and method of construction, a shell of this type has insufficient form-retaining strength for employ as a boat hull. A self-supporting boat hull shell can only be obtained by integrating additional stiffening structural element commonly employed in boatbuilding.It is an object of the invention to provide a self-supporting boat hull shell also for bigger boats, which is extremely light and particularly shape-retaining in its wall portions, and to propose a method for profitably producing such boat hull shells at minimum construction expense.For attaining this object, the invention provides that the basic shell consists of elongate flexible shapes having a uniform cross section and forming outwardly opening longitudinal grooves along their areas of mutual contact, that the longitudinal grooves are filled with a thermosetting filler material, and that the so-formed basic shell surfaces are covered with laminates of fiber-reinforced thermosetting plastics.A boat hull shell of this type comprises particularly longitudinally effective stiffeners formed by the thermosetting filler material filling the longitudinal grooves below the outer laminates.For further enhancing the shape-retaining properties of a boat hull shell, a particular embodiment of the invention provides that the surfaces of the basic shell have embossed therein further grooves extending transversely i.e. perpendicularly or obliquely to the direction of the longitudinal grooves, that these grooves are filled with a thermosetting filler material, and that the so-formed basic shell surfaces are covered with laminates. In this manner, the boat hull shell comprises an integral stiffening framework formed of longitudinally and transversely extending cords of said thermosetting filler material and adapted to absorb high loads in the longitudinal and transverse directions as well as strong warping forces.In a further embodiment of the boat hull shell according to the invention, the surface of the basic shell is empossed with further grooves in the shapes extending parallel to the longitudinal grooves, the longitudinal grooves, the transverse grooves and the additional grooves are filled with a thermosetting filler material, and the so-formed surfaces are covered with laminates. The stiffening framework thus formed by intersecting cords of thermosetting filler material confers very good shape-retaining properties to the boat hull shell of this embodiment, which may therefore be used as a warp-resistant, rugged shell also for bigger boats.In a further embodiment of a boat hull shell the invention provides that openings or cutouts in the form of flutes, grooves, channels or recessed areas extending from one shape wall up to the opposite shape wall are milled or cut in the basic shell, filled with a thermosetting filler material, and covered with laminates at the surface of the basic shell.The filler material introduced in these openings or cutouts forms a particularly solid connection with the shapes as it partially penetrates into the cavities thereof prior to becoming set. In addition, these areas are particularly shape-retaining and stiffened, since the thus-integrated filler material is homogenuously linked with the outer laminate.In an advantageous embodiment of the boat hull shell according to the invention, even more effective stiffening is provided by removing both shape walls in the area of the openings or cutouts, filling said openings or cutouts with filler material, and covering them with laminates at both surfaces of the basic shell. In this case, the very strong and dense mass of the filler material forms rigid webs in the boat hull shell homogenuously linked with the laminates on both surfaces of the basic shell. In the respective areas, the walls of the soft thermoplastic shapes are completely removed. The optical impression of a smooth surface of the boat hull is nevertheless retained, since the location of the rigid webs of solid thermosetting filler material is not visible from the outside. These areas may preferably be employed for fastening fittings, enabling very high loads to be introduced into the boat hull through the thermosetting filler material. In another aspect, these webs divide the hollow shapes into separate hermetically sealed chambers, with their sealing effect unimpaired by any fastening elements for the fixtures anchored in the filler material.In a preferred embodiment of the boat hull shell according to the invention, the filler material filling said grooves has reinforcements embedded therein. These reinforcements are applied in an intersecting pattern and may be intertwined, knotted or interwoven at their points of intersection, so that they are extremely well suited to absorb any warp forces and tension loads applied to the boat hull shell, whereby said boat hull shell has shape-retaining properties otherwise found only in boat hulls with structurally expensive stiffening elements.Boat hull shells according to the invention may be produced particularly profitable and also by relatively unskilled personell by applying the following production method of the invention with the aid of a form frame determining the final shape of the boat hull shell. Such method according to the invention is characterized in that the shapes are applied to said form frame with their longitudinal sides engaging one another, affixed to said form frame at individual points, and clamped together in sections to form said basic shell, specifically forming said longitudinal grooves along their mutually engaging longitudinal sides, before said thermosetting filler material is introduced into said longitudinal grooves and the so formed surfaces are covered and thereby linked with said fiber-reinforced thermosetting plastics laminate.In order to provide a boat hull shell having a stiffening frame consisting of longitudinal and transverse cords, the invention provides that prior to filling said longitudinal grooves, the surfaces of the basic shell are embossed with a plurality of grooves extending transversely e.i. perpendicularly or obliquely to the longitudinal direction of the shapes by means of a heated embossing tool, and that the grooves are subsequently filled with a thermosetting filler material.Since in certain cases a boat hull shell according to the invention is to be provided with additional, longitudinally stiffening cords in areas subjected to particularly high loads, the method according to the invention further provides that additional longitudinal grooves are embossed in the shapes, and that the grooves are then simultaneously filled with a thermosetting filler material.In an advantageous embodiment of the inventive method, the surface of the basic shell may be cut out or milled down to the opposite wall of the shapes, and the so formed flutes, grooves, channels or cutout areas filled with a thermosetting filler material prior to applying the covering laminates.This process step is readily accomplished with the aid of conventional milling or cutting machines and results in stiffening webs dividing the shapes into separately sealed sections. The filling material penetrates into a part of the shapes' cavities and provides a good sealing effect. After becoming set, the filler material filling these areas forms solid anchoring points for fittings or other elements of the boat hull. The openings or cutouts may be milled or cut from the outside or the inside of the boat hull shell, as desired.In a slightly modified embodiment of the method according to the invention it may be convenient to apply a laminate to one surface of the basic shell, and to remove both walls of the shapes by milling or cutting from the opposite surface, whereupon the so formed cutout is filled with a filler material and covered with a laminate.The first-named laminate acts as a supporting layer during cutting or milling and subsequent filling of the so formed recess. After filling of the recesses and covering the other surface of the basic shell with the laminate, the boat hull shell is formed with very stiff transverse webs which may serve as integral ribs. It is also possible, of course, to bolt the ribs provided in the interior of the boat hull shell to these areas, since the homogenuous integrated ribs of hardened thermosetting filler material provide for a better anchoring of the fastening elements than the compound body formed of the thermoplastic material of the shapes and the thermosetting filler material.In a further embodiment of the inventive method, resulting in substantially improved shape-retaining properties of the produced boat hull shell, the invention provides that reinforcements of carbon fibers, plastics fibers, glass fibers, glass fiber rovings or metal having a high tensile strength are embedded in the filler material for the grooves. Such reinforcements are suitably in the form of strips, ribbons, cords, rods, tubes, shapes and the like. The employed reinforcing material, or the form of the reinforcement, respectively, is to be matched to the loads to be expected for the boat hull shell produced. Obviously mixtures of different materials or mixtures of different materials in different forms may also be employed. It is thus possible, for instance, to employ different types of reinforcements in the longitudinal and transverse or oblique directions of the hull.For the performance of the method according to the invention for producing self-supporting boat hull shells it is advantageous to employ shapes of uniform section having two substantially parallel lateral surfaces connected at their upper edges by a shallow V-shaped channel, and at their lower edges, by a U-shaped rounded bottom, so that each profile may have its bottom surface engaged with the channel of the adjacent shape, and one of its lateral surfaces with the form frame. This feature of the inventive method permit boat hull shells having various three-dimensional curvatures to be constructed in a simple manner, ensuring at all times that the longitudinal grooves for forming the stiffening frame for obtaining the required shape-retaining properties are formed between the shapes.According to the invention it is also possible, however, to employ shapes in which the channel and the bottom surface are unilaterally offset with respect to the symmetry axis of the shape's section, and to employ shapes in which the height of the rounded bottom surface is greater than the depth of the V-shaped channel. Such shapes ensure in a simple manner that even in areas of extreme curvature of the boat hull shell there are formed longitudinal grooves for receiving the filler material and possibly, the reinforcements embedded therein, forming the stiffening frame for the boat hull shell.Since the boat hull shell according to the invention has to be very light and should have good floating properties, and since the boat hull shells according to the invention may have strongly curved sections in the longitudinal direction which should also be perfectly shaped, the method according to the invention proposes to employ extruded tubular shapes which are divided into individual separate chambers on embossing the longitudinal and transverse grooves. In this case the transverse grooves, which are to be filled with the filler material and possibly, with the reinforcement, are embossed to such a depth that one sidewall of the shape section is engaged with the opposite sidewall and is possibly welded thereto to form a fluid-tight seal. The formation of such chambers ensuring sufficient buoyancy of the boat hull shell even in case of damage of the boat shell's skin is facilitated by the thermoplastic material of the tubular shapes. The operartion of welding the sidewalls of the shapes together in the area of the transverse grooves may of course be facilitated by applying an adhesive to the interior surfaces of the shapes.In another embodiment of the outlined method the invention provides that the tubular shapes are divided into individual, separately sealed chambers by the openings or cutouts filled with a thermosetting filler material. This leads to the formation of transverse ribs for stiffening the boat hull shell, with the filler material partially penetrating into the cavities of the shapes to become integrally locked therewith and providing a reliable sealing effect.Storing and handling of the employed tubular shapes as well as the performance of the method according to the invention may be considerably facilitated, if the tubular shapes are assembled in the longitudinal direction of individual lengths by forming at least one longitudinal slit in one end of one such length, compressing the shape along the length of said slit, applying an adhesive thereto and introducing it into an end of an adjacent individual length. In this case the boatbuilder does not have to consider the length of available tubular shapes, but is able to assemble the shapes for any desired size of a boat hull shell.According to a further feature of the method according to the invention, applicable in particular to facilitating the production of boat hull shells, it is proposed that at least one shape is clamped to the adjacent and already fastened shapes by means of at least one U-shaped assembly clamp adapted to be bent to the contour of that portion of the form frame to which the respective shape is to be attached, whereupon the clamped shape is affixed at predetermined points to the form frame and/or connected to the adjacent shape before the assembly clamps are removed. The assembly clamps may be formed of a resilient metal or plastics material. They may replace additional tools or helpers, so that a single boatbuilder is enabled to perform the method according to the invention.Since the boat hull shell requires additional structures and provisions for being transformed into a servicable boat, which structures have to be adapted to the shape of the boat hull shell, and since a form frame determining the final shape is in any case required for performing the method according to the invention, it is proposed that the form frame consists of parts to be functionally integrated into the finished boat hull shell, such as ribs, bulkheads, transverse walls, stringers, keel, stern frame stem etc., which parts are operatively connected to the shell at areas of mutual contact. This feature serves to considerably lower the production costs of a boat built from the boat hull shell, and the time for building the boat is appreciably shortened.In order to conform to these requirements, the invention provides that prior to beginning the assembly of the boat hull shell, at least two strips of reinforcing fiber fabric are applied to the edges of the form frame coming into contact with the shell, said strips projecting beyond said edges at both sides thereof and being provissionally attached to said form frame, and that during application of the laminate to the interior surface of the basic shell, said strips are laid down on the inside of the shell and connected in an overlapping manner to the laminate, or individual layers thereof, respectively, and that finally corner strips of reinforcing fiber fabric are glued into the thus formed inside corners.As a further preferred feature of the method according to the invention it is proposed that the openings or cutouts filled with the thermosetting filler material are located at such portions of the basic shell provided for the later integration of the form frame elements, and that said elements are connected, preferably bolted, to such portions of the basic shell.At these portions, the said elements are anchored very firmly to the boat hull shell, since the applied forces are absorbed only by the thermosetting filler material. The elements in this case may be selectively fastened from the inside or from the outside. By this feature it is also avoided that bolts or other fasteners penetrating into the cavities of the tubular shapes form leaks therein, through which condensed moisture or water from the outside might permeate between the shape walls.In another embodiment the invention provides that the form frame is a reusable positive form core or a negative form shell to be removed subsequently. This modification of the method according to the invention is particularly suitable in cases in which the interior structures for the boat hull shell are fabricated at another location and are to be installed subsequently into the finished shell. The positive form core or the negative form shell may thus be employed for a series production of the boat hull shells according to the invention.Since the overall optical impression is of particular importance for a modern boat hull shell, and since the cruising properties and the overall performance of a boat depend to a large extent on a faultless surface, particularly below the waterline, the method according to the invention is further characterized in that irregularities appearing on the surfaces of the basic shell are smoothed by hot ironing before the grooves are filled and possibly reinforced.In a later stage of the method the invention provides that a deck structure consisting of juxtaposed shapes covered with laminates is mounted adjacent the stringers, with the laminate of the lower shell portions being extended without interruption to the laminate of the deck structure. The employ of the shapes also for the deck structure saves additional expensive materials and results in a lightweight deck structure improving the buoyancy of a boat and its stability with respect to the location of its center of gravity. The uninterrupted expanse of the laminate increases the resistance of the juncture between the boat hull shell and the deck structure against damage and intrusion of water.Boats constructed with the boat hull shell according to the invention and by the method according to the invention are characterized by the following advantageous properties:The boat hull shell has a resistant, lightweight and unsinkable skin of non-rotting plastics material.In relation to its weight, the boat hull shell has exceptionally high strength against tensile forces, warp forces and impact loads.The boat hull shell is constructed without the employ of expensive forms, lost auxiliary parts and expensive apparatus. Such boats may be profitably produced as individual designs as well as in a series production. The subsequent and mostly rather difficult installation of interior structures and fittings is for the major part anticipated by the construction method.The boat hull shell and the deck structure are combined to form a seamless boat hull.At a relative low weight, the structure of the boat hull shell has a high displacement of its own and comprises a considerable volume of entrapped air contributing to making the boat unsinkable.Sound and thermal insulation values of the boat hull shell are at an optimum.Boat hull shells of the type described are likewise suitable for extremely light, small boats as well as for ship's hulls of conditionally unlimited size.The performance of the inventive method for producing a boat hull shell is diagrammatically represented in the drawings and described hereinafter with reference thereto.
摘要翻译：本发明涉及一种自支撑塑料外壳结构，特别涉及一种多层船壳，其由细长的热塑性形状构成，该细长的热塑性形状被布置在形状相互相邻的形状锁定装置中，呈基本壳体的形状并被纤维增强的热固性塑料并且还涉及一种通过确定最终形状的形式框架来制造这种塑料外壳结构的方法。

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