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With over two decades of experience in marine journalism, Lenny Rudow has contributed to publications including YachtWorld, boats. Boat Reviews. Basic Navigation Steve Colgate. Boating Guides. Boat Buyer's Guide. Boat Seller's Guide. While vacuum continues to be applied a fiberglass matting and resin mixture is applied to the inner surface of the reinforcing material and hull mold, bonding the fiberglass mixture to the reinforcing material by curing, thereby obtaining a reinforced hull structure.
Conventional fiberglass hull construction is obtained by providing a mold, laying fiberglass matting and bonding compound inside the mold to form the exterior shape of the hull, placing a vacuum bag over the mold inner space, evacuating the air inside the mold interior under the bag so as to cause the bag to collapse against the freshly applied fiberglass mixture and thus forcing it against the mold inner surface.
The vacuum, hence pressure for hull forming, cannot be applied until the entire fiberglass matting and bonding compound is applied over all the mold form and access to the matting-compound mixture is denied while the vacuum bag is in place and vacuum applied.
Installing reinforcing materials or adjusting the matting-compound mixture is not possible while the vacuum is present.
Moreover, attaching reinforcing materials, as ultra high molecular weight polyethylene UHMW to the exterior surface of the hull is currently accomplished by the use of mechanical fasteners, screws, etc.
It is a principal objective of the present invention to provide an improved procedure for forming reinforced boat hulls and improved boat hull constructions which conveniently enables one to obtain a fully bonded, laminate construction, and especially to enable one to conveniently attach reinforcing materials to the external surface of the hull while obtaining a fully bonded laminate.
Further objects and advantages of the present invention will be apparent from the following discussion. In accordance with the present invention, the foregoing objects and advantages are readily obtained. In accordance with the present invention, reinforced boat hulls are obtained by: providing a boat hull mold with an inner surface and a mold cavity, wherein said mold cavity has the shape of a boat hull and with multiple vacuum ports communicating with said inner surface; positioning reinforcing material in said mold, with a lower surface thereof facing the inner surface of the mold and an upper surface thereof facing the mold cavity; applying vacuum to said vacuum ports to hold the reinforcing material firmly against the inner surface; positioning a fiberglass-resin mixture in the mold over the reinforcing material upper surface and over the mold inner surface; placing a vacuum bag over the fiberglass mixture; evacuating the vacuum bag to press the fiberglass mixture against the reinforcing material and bonding the fiberglass mixture to the reinforcing material, to form a bonded, reinforced hull structure.
An improved, reinforced boat hull is also provided having: an outer reinforcing material with an inner face; an inner fiberglass-resin mixture bonded to said inner face of said reinforcing material and forming the shape of said boat hull, wherein said reinforcing material is fiber backed polyolefin, preferably ultra high molecular weight UHMW polyethylene, with the fiber backing in the form of a woven mesh to provide a bonding site for the fiberglass mixture.
The present invention also provides an improved, reinforced boat hull having: an outer reinforcing material with an inner face; an inner fiberglass-resin mixture bonded to said inner face of said reinforcing material and forming the shape of said boat hull; and at least one layer affixed to the inner face of said reinforcing material to provide an anchor for the fiberglass mixture.
Further features and advantages of the present invention will appear hereinbelow. The present invention will be more readily understood from a consideration of the following illustrative drawings, wherein:.
Further features of the present invention will appear hereinbelow. The mold cavity inner surface 16 has the desired shape of a boat hull. A vacuum bag 18, which may be any desired flexible material as rubber, is stretched over open side 20 of mold cavity 14 and fastened to mold edges 22, as by using double-sided masking tape. Hose 24, connected on the downstream side to vacuum bag 18 is connected on the upstream side to a vacuum source not shown. The vacuum bag 18 is forced against the fiberglass mixture 12 compressing said mixture against mold inside surface 16 and thereby forming the desired hull shape.
After curing of the resin and solidifying the fiberglass-resin mixture, the vacuum is released and the vacuum bag removed leaving the formed boat hull. In accordance with the present invention, as shown in FIGS.
Multiple vacuum ports One Off Fiberglass Boat Construction Company 36 are arranged around the hull mold inner surface at locations where reinforcing materials are desired to be located. Vacuum ports 36 are connected via hoses 38 to one or more vacuum sources not shown such that when vacuum is applied the reinforcing materials 40 positioned on mold inner surface 34 are held firmly against mold inner surface 34 as shown in FIG.
The exact number of vacuum ports is not especially critical, except that they should be sufficient to firmly hold the reinforcing material against the mold inner surface. Vacuum can be applied selectively to permit adjustment of materials at the selected sites, and vacuum is applied continuously to maintain the reinforcing materials firmly against the mold inner surface during application of the fiberglass matting-resin mixture 42 to the reinforcing material upper surface 44 and to the mold inner surface 34 as shown in FIG.
Thus, personnel have access to the inside of mold 32 while vacuum is applied externally to the mold to firmly hold the reinforcing material against the mold inner surface during placement of the fiberglass mixture and during adjustment of same. Next, the vacuum bag 46 is fastened to mold edges 48 in a manner after FIGS. After curing the vacuum is released from the vacuum bag and from the vacuum ports and the composite hull is removed from the mold.
The fiber reinforced plastic is readily cured and with some resins may be cured at room temperature, but some may require elevated temperature.
A wide variety of reinforcing materials may be used, as polyolefins such as polyethylene or polypropylene; however, desirably the reinforcing material is fiber backed ultra high molecular weight UHMW polyethylene. Next, two or more layers of wood veneers are attached to the hull in opposite directions using screws with epoxy resin in between.
Once the epoxy has cured, fiberglass can be added and the shape is faired and sanded. The hull is then flipped and much of the jig removed and discarded so fiberglass or structural reinforcements can be fitted to the hull interior, and interior construction can begin.
The deck and cabin are built in much the same way. Fiberglass boat construction became popular in the s and today is perhaps the most common way production boats are built.
Upsides to this method include relatively low maintenance, high strength, ease of repair, and generally low cost when compared to Small Boat Construction Methods Solution other boatbuilding materials. Primary downsides are osmotic blistering in some hulls and sometimes heavy weight unless used with composite materials.
Most fiberglass boats are built from a female mold that accepts multiple layers of fiberglass cloth or matt and resin that eventually cure together to form a hull shape. First, the mold is cleaned and prepped with a mold release wax that allows what will become the fiberglass hull to be pulled from the mold without sticking. Next, a thick layer of high-quality resin called gelcoat is sprayed into the mold. This is the tough, glossy, exterior finish that protects the fiberglass from ultraviolet rays, salty spray, fish guts, beer, and abrasion.
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