Ships – Boats – boat component – or attachment – Hull construction
Reexamination Certificate
1999-09-15
2001-09-11
Swinehart, Ed (Department: 3617)
Ships
Boats, boat component, or attachment
Hull construction
Reexamination Certificate
active
06286448
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to boats. More particularly, the present invention relates to boats having fiberglass hulls and to methods for manufacturing such boats.
BACKGROUND OF THE INVENTION
Boat hulls have historically been made of many different types of material such as aluminum, steel or wood. Another common material used in the manufacture of boat hulls is a laminate material made of fiberglass-reinforced resin.
Open face molds are frequently used to manufacture fiberglass hulls. To make a hull with an open face mold, a layer of gel coat is frequently first applied to the mold. Next, a barrier layer is often applied to the gel coat. Finally a layer of fiberglass-reinforced resin is applied to the barrier layer. When the hull is removed from the mold, the gel coat provides a smooth, aesthetically pleasing outer surface of the hull. The barrier layer prevents the fiberglass from printing or pressing through the gel coat. The fiberglass provides the hull with structural rigidity.
With fiberglass boats, it is often desirable to inject foam into foam compartments formed within the boats. The injection of foam presents several problems. For example, when foam is injected into a boat, pressure generated by the foam injection process can cause portions of the boat to bow or buckle outward thereby negatively affecting the appearance and structural integrity of the boat. This can be particularly problematic with respect to unsupported parts manufactured by injection molding or resin transfer molding operations. Also, to access foam chambers within a boat, it is often necessary to drill holes through portions of the boat. This is problematic because the drilling of holes can cause the aesthetically pleasing outer gel coat surface to be damaged. The repair of such damage can be time consuming.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a boat including a hull having an interior region. The boat also includes an insert mounted within the hull. The insert includes a bottom piece having a bottom side that complements and nests within the interior region of the hull. The insert also includes a top piece secured to the bottom piece. The top and bottom pieces cooperate to define an inner foam chamber. The insert further includes a volume of foam positioned within the foam chamber.
Another aspect of the present invention relates to a method for manufacturing a boat. The method includes providing a hull. The method also includes providing an insert having a top piece and a bottom piece that cooperate to define a foam chamber. The method further includes injecting foam into the foam chamber of the insert, and securing the insert within the hull.
A further aspect of the present invention relates to a method for making a boat including providing a boat structure including a hull and a deck, supporting the boat structure between at least two mold pieces, and injecting foam into a foam chamber defined within the boat structure. The foam is injected in the foam chamber while the boat structure is concurrently supported by the at least two mold pieces.
A variety of advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practicing the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
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Brown Bradley James
Johnson Jerry Lee
Sahr Ronald C.
Glastron Larson
Merchant & Gould P.C.
Swinehart Ed
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