TWI770495B - 利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法及製造設備以及一體成型之殼體 - Google Patents

利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法及製造設備以及一體成型之殼體 Download PDF

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TWI770495B
TWI770495B TW109113367A TW109113367A TWI770495B TW I770495 B TWI770495 B TW I770495B TW 109113367 A TW109113367 A TW 109113367A TW 109113367 A TW109113367 A TW 109113367A TW I770495 B TWI770495 B TW I770495B
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Taiwan
Prior art keywords
fiber cloth
layer
vacuum
resin
pipes
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TW109113367A
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TW202140248A (zh
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呂佳揚
陳凱琳
洪主頌
詹侑霖
楊名梧
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先進複材科技股份有限公司
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Priority to TW109113367A priority Critical patent/TWI770495B/zh
Priority to US16/925,971 priority patent/US11760044B2/en
Publication of TW202140248A publication Critical patent/TW202140248A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
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Abstract

一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法包括：依序鋪設至少一層第一纖維布、至少一層芯材及至少一層第二纖維布於模具之模穴表面；放置多個結構材於該第二纖維布上；層疊鋪設多層第三纖維布以覆蓋該多個結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成積層；決定多個真空抽氣管與多個第一及第二樹脂材料管的佈管策略；舖設一層真空用膠膜於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管；進行三維立體真空灌注製程；硬化樹脂；以及進行離模製程，以完成一體成型之殼體。

Description

利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的 製造方法及製造設備以及一體成型之殼體
本發明是有關於一體成型殼體的製造方法及製造設備，且特別是有關於一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法及製造設備。
高附加價值的遊艇生產，往往伴隨著較高的技術含量，由於對成品表面的品質呈現的要求較為嚴苛，所以遊艇業花費很多時間與成本來達到高規格的船殼表面品質。
複合材料遊艇船殼的成型概念主要是以積層(Lamination)製作，由多次堆疊類似布匹之玻璃纖維布(Woven Roving or Chopped Strand Mat or stitched fabric or combi-mat)達成。手積層主要程序為逐次塗佈樹脂、貼附纖維布，運用刷、滾筒、刮刀等工具使樹脂浸潤(Impregnation)玻璃纖維，且不起皺褶、不留氣泡。
目前，真空灌注製程，例如真空輔助樹脂灌注成型法(Vacuum Assisted Resin Transfer Molding，簡稱VARTM)，可先完成纖維布與芯材的佈置，再將樹脂藉由抽真空造成之負壓吸入纖維空隙，以製作船殼本體。然而，傳統船殼製造方法在真空灌注製程後仍採用手積層製程，將結構材以二次接著的方式結合在真空灌注製程後的船殼本體上，因此整個船殼成品的結構性能較差，重量也會因為使用重量較重的製程而比較重。
因此，便有需要提供一種一體成型殼體的製造方法及製造設備，以解決前述的問題。
本發明之一目的是提供一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法及製造設備。
依據上述之目的，本發明提供一種一體成型殼體的製造方法，其步驟包括：提供一模具，該模具包括一模穴；依序鋪設至少一層第一纖維布、至少一層芯材及至少一層第二纖維布於該模具之模穴表面；放置多個縱向及橫向結構材於該第二纖維布上；層疊鋪設多層第三纖維布以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，其中該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；根據該積層之設計及樹脂流動性，決定多個真空抽氣管與多個第一及第二樹脂材料管的佈管策略，其中該些真空抽氣管之抽氣孔設置於該積層之兩側位置，該些第一樹脂材料管之注入孔設置於該積層之中間位置，且該些第二樹脂材料管之注入孔設置於該些第一樹脂材料管之注入孔與該些真空抽氣管之抽氣孔之間；舖設一層真空用膠膜於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管，其中該真空用膠膜舖設範圍會完全涵蓋該多層第三纖維布的範圍並予以密封該積層；進行三維立體真空灌注製程：經由該些真空抽氣管使該積層之兩側位置產生一真空吸力，經由該些第一及第二樹脂材料管使一樹脂順序注入並充滿該積層之內部空隙；硬化該樹脂，以形成包覆該多個縱向及橫向結構材的一體成型之殼體；以及進行離模製程：分別拆除該層真空用膠膜、該些真空抽氣管、及該些第一及第二樹脂材料管，並將該殼體與該模具分離，以完成一體成型之殼體。
本發明更提供一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造設備，包括：一模具，其中至少一層第一纖維布、至少一層芯材及至少一層第二纖維布 依序鋪設於該模具之模穴表面，多個縱向及橫向結構材放置於該第二纖維布上，多層第三纖維布層疊鋪設以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；多個真空抽氣管之抽氣孔設置於該積層之兩側位置；多個第一及第二樹脂材料管，該些第一樹脂材料管之注入孔設置於該積層之中間位置，且該些第二樹脂材料管之注入孔設置於該些第一樹脂材料管之注入孔與該些真空抽氣管之抽氣孔之間；一層真空用膠膜舖設於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管，該真空用膠膜舖設範圍會完全涵蓋該多層第三纖維布的範圍並予以密封該積層；以及，一三維立體真空灌注裝置，其中經由該些真空抽氣管使該積層之兩側位置產生一真空吸力，經由該些第一及第二樹脂材料管使一樹脂順序注入並充滿該積層之內部空隙，其中該樹脂被硬化，以形成包覆該多個縱向及橫向結構材的一體成型之殼體。
本發明又提供一種一體成型之殼體，包括：至少一層第一纖維布、至少一層芯材及至少一層第二纖維布，依序設置；多個縱向及橫向結構材，設置於該第二纖維布上；多層第三纖維布，層疊設置以覆蓋該多個縱向及橫向結構材及及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，其中該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；以及一樹脂，充滿該積層之內部空隙，以形成包覆該多個縱向及橫向結構材的一體成型之殼體。
2:殼體
20:樹脂
20a:兩側位置
20b:兩側位置
20c:中間位置
20:積層
21:樹脂
22:第一纖維布
23:芯材
24:第二纖維布
25a:縱向結構材
25b:橫向結構材
25a’:縱樑
25b’:橫樑
251:預留孔
26:第三纖維布
31:模具
311:模穴
32:真空抽氣管
321:抽氣孔
331:第一樹脂材料管
3311:注入孔
332:第二樹脂材料管
3321:注入孔
34:真空用膠膜
35:黏性膠帶
36:真空耗材
37:加熱裝置
S10~S18:步驟
圖1為本發明之一實施例之一體成型殼體的製造方法之流程圖。
圖2為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示提供一模具。
圖3為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示依序鋪設至少一層第一纖維布、至少一層芯材及至少一層第二纖維布於該模具之模穴表面。
圖4為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示放置多個縱向及橫向結構材於該第二纖維布上。
圖5為本發明之一實施例之多個縱向及橫向結構材之部分立體剖面示意圖。
圖6為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示層疊鋪設多層第三纖維布以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布。
圖7a為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示決定多個真空抽氣管與多個第一及第二樹脂材料管的佈管策略。
圖7b為本發明之一實施例之一體成型殼體的製造方法之另一剖面示意圖，其顯示決定多個真空抽氣管與多個第一及第二樹脂材料管的佈管策略。
圖8為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示舖設一層真空用膠膜於該積層上。
圖9為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示一層真空耗材介於一層真空用膠膜與多層第三纖維布之間。
圖10a及10b為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示進行三維立體真空灌注製程。
圖10c為本發明之一實施例之第一至第三纖維布之部分立體剖面示意圖。
圖11為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示硬化該樹脂。
圖12為本發明之一實施例之一體成型殼體的製造方法之剖面示意圖，其顯示進行離模製程。
為讓本發明之上述目的、特徵和特點能更明顯易懂，茲配合圖式將本發明相關實施例詳細說明如下。
圖1為本發明之一實施例之利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法之流程圖。
請參考圖2，在步驟S10中，提供一模具31，該模具31包括一模穴311。該模穴311即為後續殼體的部份外形。該模具31之材質可為玻璃纖維強化塑膠(fiber-reinforced plastic，FRP)。舉例，使用五軸機加工機開模，製程可以分成四個步驟：第一步驟：五軸機進行100K高密度發泡塊的粗細切削，完成模具本體的加工。第二步驟：模具表面玻璃纖維積層，以提升模具的強度和硬度第三步驟：模具表面補土整順。第四步驟：模具表面噴模用膠殼既完成模具製作。
請參考圖3，在步驟S11中，依序鋪設至少一層第一纖維布22、至少一層芯材23及至少一層第二纖維布24於該模具31之模穴311表面，其中該第一纖維布22及該第二纖維布24具有三維立體結構之內部空隙。該芯材23之材質可為發泡材料或木質材料，該第一纖維布22之材質可為玻璃纖維。
請參考圖4及圖5，在步驟S12中，放置多個縱向及橫向結構材25a、25b於該第二纖維布24上，其中該多個縱向結構材25a及橫向結構材25b是一種多個縱樑25a’及橫樑25b’的配置設計。該多個縱向及橫向結構材25a、25b的材質為PU發泡 材。在此步驟中，可對該多個縱向及橫向結構材25a、25b所形成的預留孔251進行處理，作為日後管線穿過的預留孔。
請參考圖6，在步驟S13中，層疊鋪設多層第三纖維布26以覆蓋該多個縱向及橫向結構材25a、25b及部份之該第二纖維布24，藉此該第一纖維布22、該層芯材23、該第二纖維布24及該多層第三纖維布26形成一積層20之設計，其中該多層第三纖維布26也具有三維立體結構之內部空隙。舉例，本發明之該第一纖維布22、該第二纖維布24及該多層第三纖維布26可選用Vitrulan公司、CHOMARAT公司、Vectorply公司等所製造具有三維立體結構的纖維布，例如：HighFlow,G FlowTM,VectorFusionTM的產品。
請參考圖7a及圖7b，在步驟S14中，根據該積層20之設計及樹脂流動性，決定多個真空抽氣管32與多個第一及第二樹脂材料管331、332的佈管策略，其中該些真空抽氣管32之抽氣孔321設置於該積層20之兩側位置20a、20b，該些第一樹脂材料管331之注入孔3311設置於該積層20之中間位置20c附近，且該些第二樹脂材料管332之注入孔3321設置於該些第一樹脂材料管331之注入孔3311與該些真空抽氣管32之抽氣孔321之間。圖7a及圖7b所示之該些第一樹脂材料管331及該些第二樹脂材料管332的數目並非用以限制本發明；就大型構件而言，佈管策略會需要更多數目的樹脂材料管。該佈管策略是指：該些真空抽氣管32之抽氣孔321與該積層20之內部空隙連通以提供真空吸力；該些第一及第二樹脂材料管331、332之注入孔3311、3321皆與該積層20之內部空隙連通，用以後續灌注時，根據樹脂流動性而順序灌注樹脂，並將原先僅限於2D流動的技術，精進到可以控制樹脂3D上下流動的技術。
請參考圖8，在步驟S15中，舖設一層真空用膠膜34於該積層20上，並覆蓋該些第一及第二樹脂材料管331、332及該真空抽氣管32，其中該真空用膠膜34舖設範圍會完全涵蓋 該多層第三纖維布26的範圍並予以密封該積層20。為了增加該真空用膠膜34與該多層第三纖維布26的密封性，於該多層第三纖維布26的周圍以密封膠帶(sealant tape)35將該真空用膠膜34貼附於該模具31上。
請參考圖9，在舖設該真空用膠膜34之步驟前，根據該積層20之設計及需求，鋪設一層真空耗材36於該多層第三纖維布26上，並涵蓋該多層第三纖維布26的範圍，使該層真空耗材36介於該層真空用膠膜34與該多層第三纖維布26之間。該層真空耗材36可包括離模布(peel ply)、離模紙(release film)、導流網(flow mesh)等真空耗材，依序使用以幫助樹脂流動。
請參考圖10a及10b，在步驟S16中，進行三維立體真空灌注製程：經由該些真空抽氣管32使該積層20之兩側位置產生真空吸力，經由該些第一及第二樹脂材料管331、332使一樹脂21順序注入並充滿該積層20之內部空隙。該些第一及第二樹脂材料管331、332之注入孔3311、3321可根據樹脂流動性而該些第一及第二樹脂材料管331、332順序灌注該樹脂21，例如該些第一樹脂材料管331先使該樹脂21注入並充滿該積層20之部分之內部空隙(如圖10a所示)，然後該些第二樹脂材料管332再使該樹脂21注入並充滿該積層20之剩餘之內部空隙(如圖10b所示)，以避免該積層20內產生封包(dry spot)。在該樹脂21之灌注過程中，監控該樹脂21之膠化狀況及溫度，以計算後續灌注時之樹脂流動性。另外，請參考圖10c，當該些真空抽氣管使該積層20之兩側位置產生真空吸力時，本發明所選用之該第一纖維布22、該第二纖維布24及該多層第三纖維布26仍具有三維立體結構之內部空隙，不會真空吸力而壓縮變形。因此，該第一纖維布22、該第二纖維布24及該多層第三纖維布26具有較高之樹脂流動性。
另外，灌注該樹脂21前，可依據當天天氣狀況與灌注策略決定硬化劑與促進劑比例，並將硬化劑與促進劑加入該樹脂21中。舉例，該樹脂21可採用不飽和聚酯樹脂(例如長興化 工的不飽和聚酯樹脂)。硬化劑可採用united Initiators公司的Andonox產品，與促進劑可採用united Initiators公司的Norox產品。
請參考圖11，在步驟S17中，硬化該樹脂21，以形成包覆該多個縱向及橫向結構材25a、25b的一體成型之殼體。根據選用後樹脂21的硬化方式，決定以自然硬化、加熱後硬化或照UV光等方式硬化該樹脂21。舉例，提供一加熱裝置37，加熱硬化該樹脂21，以形成包覆該多個縱向及橫向結構材25a、25b的一體成型之殼體。
請參考圖12，在步驟S18中，進行離模製程：分別拆除該層真空用膠膜34、該些真空抽氣管32、及該些第一及第二樹脂材料管331、332，並將該殼體2與該模具31分離，以完成一體成型之殼體2。詳言之，本發明之一體成型殼體2包括：至少一層第一纖維布22、至少一層芯材23及至少一層第二纖維布24依序設置；多個縱向及橫向結構材25a、25b設置於該第二纖維布24上；多層第三纖維布26層疊設置以覆蓋該多個縱向及橫向結構材25a、25b及及部份之該第二纖維布24，藉此該第一纖維布22、該層芯材23、該第二纖維布24及該多層第三纖維布26形成一積層20之設計，其中該第一纖維布22、該第二纖維布24及該多層第三纖維布26皆具有三維立體結構之內部空隙；以及一樹脂21充滿該積層20之內部空隙，以形成包覆該多個縱向及橫向結構材25a、25b的一體成型之殼體2。在本實施例中，該殼體2可為遊艇船殼。
另外，本發明更提供一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造設備，包括：一模具，其中至少一層第一纖維布、至少一層芯材及至少一層第二纖維布依序鋪設於該模具之模穴表面，多個縱向及橫向結構材放置於該第二纖維布上，多層第三纖維布層疊鋪設以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該 芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；多個真空抽氣管之抽氣孔設置於該積層之兩側位置；多個第一及第二樹脂材料管，該些第一樹脂材料管之注入孔設置於該積層之中間位置，且該些第二樹脂材料管之注入孔設置於該些第一樹脂材料之注入孔與該些真空抽氣管之抽氣孔之間；一層真空用膠膜舖設於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管，該真空用膠膜舖設範圍會完全涵蓋該多層第三纖維布的範圍並予以密封該積層；一三維立體真空灌注裝置，其中經由該些真空抽氣管使該積層之兩側位置產生一真空吸力，經由該些第一及第二樹脂材料管使一樹脂順序注入並充滿該積層之內部空隙，其中該樹脂被硬化，以形成包覆該多個縱向及橫向結構材的一體成型之殼體。
本發明的特點在於：本發明之一體成型殼體的製造方法的三維立體真空灌注製程為利用大氣與真空之間的壓力差，讓樹脂導流到模具內，充滿該積層之內部空隙，並包覆該多個縱向及橫向結構材，可大幅避免傳統手積層製程之揮發性有機物揮發的現象；再者，可提高纖維含有率，減少樹脂用量，進而減重。相較於傳統船殼製造方法在真空灌注製程後仍採用手積層製程(將結構材以二次接著的方式結合在真空灌注製程後的船殼本體上)，本發明之一體成型殼體的製造方法可避免結構材二次接著的方式，進而避免結構材接著失效及殼體結構性能較差的風險，可縮短生產工期。
相較於傳統船殼製造方法，本發明之一體成型殼體的製造方法，具有：第一、製造過程大幅降低約85%的有機溶劑揮發，減少環境的汙染。第二、殼體的縱向與橫向結構材一體成型真空灌注，可提高約40%結構強度。第三、船殼的縱向與橫向結構材一體成型真空灌注可減少二次接合的機會，進而減輕約8%成品重量。第四、製程原材料(纖維布與芯材)鋪設後連同結構 材一體成型真空灌注，因此表面材與芯材可完美結合。第五、根據樹脂流動性與樹脂管路佈置策略，殼體成品的纖維含有率可提高至65%。第六、全自動真空灌注設備全程監控製程所有參數，確保穩定的高品質殼體成品。
綜上所述，乃僅記載本發明為呈現解決問題所採用的技術手段之較佳實施方式或實施例而已，並非用來限定本發明專利實施之範圍。即凡與本發明專利申請範圍文義相符，或依本發明專利範圍所做的均等變化與修飾，皆為本發明專利範圍所涵蓋。
S10、S18:步驟

Claims (9)

  1. 一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其步驟包括：提供一模具，該模具包括一模穴；依序鋪設至少一層第一纖維布、至少一層芯材及至少一層第二纖維布於該模具之模穴表面；放置多個縱向及橫向結構材於該第二纖維布上，其中該多個縱向結構材及橫向結構材是一種多個縱樑及橫樑的配置設計，且該多個縱向及橫向結構材的材質為PU發泡材；層疊鋪設多層第三纖維布以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，其中該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；根據該積層之設計及樹脂流動性，決定多個真空抽氣管與多個第一及第二樹脂材料管的佈管策略，其中該些真空抽氣管之抽氣孔設置於該積層之兩側位置，該些第一樹脂材料管之注入孔設置於該積層之中間位置，且該些第二樹脂材料管之注入孔設置於該些第一樹脂材料管之注入孔與該些真空抽氣管之抽氣孔之間；舖設一層真空用膠膜於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管，其中該真空用膠膜舖設範圍會完全涵蓋該多層第三纖維布的範圍並予以密封該積層；進行三維立體真空灌注製程：經由該些真空抽氣管使該積層之兩側位 置產生一真空吸力，經由該些第一及第二樹脂材料管使一樹脂順序注入並充滿該積層之內部空隙；硬化該樹脂，以形成包覆該多個縱向及橫向結構材的一體成型之殼體；以及進行離模製程：分別拆除該層真空用膠膜、該些真空抽氣管、及該些第一及第二樹脂材料管，並將該殼體與該模具分離，以完成一體成型之殼體。
  2. 如請求項1所述的利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其中該佈管策略是指：該些真空抽氣管之抽氣孔與該積層之內部空隙連通以提供一真空吸力，該些第一及第二樹脂材料管之注入孔皆與該積層之內部空隙連通，用以根據樹脂流動性而該些第一及第二樹脂材料管順序灌注該樹脂。
  3. 如請求項2所述的利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其中在該樹脂之灌注過程中，監控該樹脂之膠化狀況及溫度，以計算後續灌注樹脂時之樹脂流動性。
  4. 如請求項1所述的利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其步驟更包括：在舖設該真空用膠膜之步驟前，根據該積層之需求，鋪設一層真空耗材於該多層第三纖維布上，並涵蓋該多層第三纖維布的範圍。
  5. 如請求項4所述的利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其中該層真空耗材包括剝離層、離型膜及導流網依序使用。
  6. 如請求項2所述的利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造方法，其中當該些真空抽氣管使該積層之兩側位置產生該真空吸力時，該第一纖維布、該第二纖維布及該多層第三纖維布仍具有三維立體結構之內部空隙。
  7. 一種利用三維立體結構纖維布及三維立體真空灌注製程之一體成型殼體的製造設備，包括；一模具，其中至少一層第一纖維布、至少一層芯材及至少一層第二纖維布依序鋪設於該模具之模穴表面，多個縱向及橫向結構材放置於該第二纖維布上，該多個縱向結構材及橫向結構材是一種多個縱樑及橫樑的配置設計，該多個縱向及橫向結構材的材質為PU發泡材，多層第三纖維布層疊鋪設以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；多個真空抽氣管之抽氣孔設置於該積層之兩側位置；多個第一及第二樹脂材料管，該些第一樹脂材料管之注入孔設置於該積層之中間位置，且該些第二樹脂材料管之注入孔設置於該些第一樹脂材料管之注入孔與該些真空抽氣管之抽氣孔之間；一層真空用膠膜舖設於該積層上，並覆蓋該些第一及第二樹脂材料管及該真空抽氣管，該真空用膠膜舖設範圍會完全涵蓋該多層第三纖維布的範圍並予以密封該積層；以及一三維立體真空灌注裝置，其中經由該些真空抽氣管使該積層之兩 側位置產生一真空吸力，經由該些第一及第二樹脂材料管使一樹脂順序注入並充滿該積層之內部空隙，其中該樹脂被硬化，以形成包覆該多個縱向及橫向結構材的一體成型之殼體。
  8. 一種一體成型之殼體，包括：至少一層第一纖維布、至少一層芯材及至少一層第二纖維布，依序設置；多個縱向及橫向結構材，設置於該第二纖維布上，其中該多個縱向結構材及橫向結構材是一種多個縱樑及橫樑的記置設計，且該多個縱向及橫向結構材的材質為PU發泡材；多層第三纖維布，層疊設置以覆蓋該多個縱向及橫向結構材及部份之該第二纖維布，藉此該第一纖維布、該芯材、該第二纖維布及該多層第三纖維布形成一積層之設計，其中該第一纖維布、該第二纖維布及該多層第三纖維布皆具有三維立體結構之內部空隙；以及一樹脂，充滿該積層之內部空隙，以形成包覆該多個縱向及橫向結構材的一體成型之殼體。
  9. 如請求項8所述的一體成型之殼體，其中該殼體為遊艇船殼。
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