WO2002018200A1

WO2002018200A1 - Apparatus for constructing an article having a complex surface

Info

Publication number: WO2002018200A1
Application number: PCT/GB2001/003910
Authority: WO
Inventors: John Maxwell Hemmens
Original assignee: John Maxwell Hemmens
Priority date: 2000-09-01
Filing date: 2001-08-31
Publication date: 2002-03-07
Also published as: GB0021369D0; AU2001282363A1

Abstract

Apparatus for assembling a frame structure comprises a jig (2) having a plurality of slots (4) adjacent to one another and a plurality of frame members for forming part of the frame structure, wherein the slots (4) are adapted to receive the frame members, and adapted to hold the frame members in position for the application of a cover or support beam to the frame structure, at least part of which cover or support beam is spaced from the jig (2).

Description

APPARATUS FOR CONSTRUCTING AN ARTICLE HAVING A COMPLEX SURFACE

The present invention relates to an apparatus for constructing an article having a complex surface and, particularly, although not exclusively, relates to an apparatus and method of machining bulkheads and arranging them to build the hull of a boat, for example, a model boat.

Traditionally, the popular pass-time of building model boats involves a technique in which bulkheads (supporting ribs) are spaced equally along the length of the hull of the boat and are fixed to the keel by glue, metal or some other means. When the bulkheads are arranged in the correct order and attached to . the keel, they make a "frame"-like structure which defines the external surface of the hull and the inboard contour. The bulkheads are bevelled to the desired contour of the hull and provide a flush surface for planks of wood which are subsequently attached to the outer surface thereof. These so called "plank-on-frame" boat kits have been commercially available for many years.

Some "plank-on-frame kits" supply the frames cut to shape with some spars present to hold the frames in place as the planks are attached. However, this leaves the modeller the onerous task of ensuring that the frame maintains rigidity as the planks are applied thereto. Problems arise as the bulkheads and keel flex under the weight of the boat which make the application of the planks very difficult. The majority of "plank-on-frame" kits are static models being built only for viewing and, as a consequence, the internal features of the hull are generally left closed off with a spar across the top of the hull which would not normally be present, so that access could be gained to the lower interior of the hull. When making fully working models, which have engines and other moving parts located inside the boat, the modeller would have to cut away certain parts of the bulkhead to make space for the engine etc and to allow access. Cutting away part of these bulkheads is a very fiddly and time-consuming process and also results in further flexing of the keel and frame often resulting in further damage to the planks.

With a view to addressing the problems above, it is an aim of an embodiment of the present invention to provide an apparatus and method for making objects with complex surfaces. Furthermore, it is an aim of the invention to provide an apparatus and a method for making frames for a plank-on-f ame boat model kit. Finally, it is still a further objective of the invention to provide frames for plank-on-frame model boat kits.

According to a first aspect of the present invention apparatus for assembling a frame structure comprises a jig having a plurality of slots adjacent to one another and a plurality of frame members for forming part of the frame structure, wherein the slots are adapted to receive the frame members, and adapted to hold the frame members in position for the application of a cover or support beam to the frame structure, at least part of which cover or support beam is spaced from the jig. The frame structure may be a covered frame structure.

The frame structure may be a model, preferably a working model. Most preferably the covered frame structure is at least part of a boat hull.

According to a second aspect of the present invention, there is provided an apparatus for constructing an article having at least one contoured surface, the apparatus comprising a jig having a plurality of slots extending substantially along its length, and a set of frame members, the frame members being positioned, in use, in the slots such that the surfaces of the frame members facing substantially away from the slots together form the undulating surface.

Preferably, the slots are substantially . parallel with one another. Preferably there are at least as many slots as frame members .

The slots may be spaced apart at an interval of less than about 50 mm, preferably less than about 25 mm, most preferably at about 20 mm intervals. The width of each slot may be less than about 10 mm and may be about 6 mm. The depth of the slots may be about 5 mm.

Preferably, the jig comprises a support member and a guide member. The guide member may be secured to the. support member by any suitable means. Preferably, the guide member is secured to the support member by a series of bolts which pass through corresponding apertures in the two members. The guide member may be a keel of a boat hull, against which the frame members may abut. The frame members may be adhered to the guide member with adhesive.

Preferably, the set of frame members are machined to have differing profiles . The frame members may be machined using any suitable means, for example, routing, milling, laser, water-jet cutting, chemical milling (etching), compressing etc. The frame members may be machined on a CNC router to form the shape of the final frames . Preferably, each of the set of the frame members is positioned into a specific slot of the jig. Preferably, the jig supports each of the members of the frame. Preferably, the undulating surface defines a specific contour or curvature. Each of the frame members may be marked to thereby facilitate positioning of said frame member in specific slots of the jig. Each of the ^' frame members' may have cutting lines which, preferably, .present points of weakness which may be subsequently cut thereby leaving a portion of the frame member.-

Preferably, a majority of the surfaces of the frame members facing substantially away from the slots is covered, preferably with cover portions, which may be planks. The cover portions may be discrete sections. The cover portions are preferably laid generally across the length of at least two frame members. The cover portions may be laid perpendicular to the length of the frame members, preferably across a plurality of frame members. Preferably, the cover portions are abutted against each other.

A support beam may be used in conjunction with the set of frame members to provide further support as the cover portions are attached to the frame members. The support beam is preferably spaced from the jig. The support beam preferably comprises slots or openings therein at substantially the same spacing as the slots in the jig. The slots in the support beam are preferably arranged to maintain the spacing of upper portions of the frame members. The jig preferably maintains the spacing of lower parts of the frame members. The support beam is preferably located on an opposite side of the frame members to the jig. The support beam may form a part of a deck section of the frame, when the frame is a boat hull.

The apparatus may be used in the construction of half of the whole of a boat.

Once the frame members have been positioned in the slots of the j g, a set of. plank members , .may be attached thereto. Each frame member may be a different size and/or shape to the other frame members .

The invention extends to a frame structure, preferably a covered frame structure, made with the apparatus of the first or second aspects.

According to a third aspect of the present invention, a method of assembling a covered frame structure comprises placing a plurality of frame members adjacent to each other in a jig, the jig holding the frame members in position for the application of a cover to the frame structure. The covered frame structure may comprise half of a hull of a boat. Two halves of the hull may be assembled with the jig for subsequent attachment to one another.

A guide member may be placed in the jig to which the frame members are secured. The guide member may be a boat keel, or part thereof.

A support beam may be used to maintain the spacing of parts of the frame members spaced from the jig. The support beam may form an edge of a deck section of the boat hull.

All of the features described herein may be combined with any of the above aspects, in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which :-

Figure la is a perspective view from above of a jig and one half of a keel of a hull of a boat;

Figure lb is a perspective view from above of the keel in position in the jig;

Figure lc is a partial perspective view from above and to one side of the jig;

Figure 2 is a schematic plan view of a set of machined bulkheads for use in a model boat kit; Figure 3 is a perspective view from above of one half of the bow end of a model boat hull in position in the jig with frame sections in position in the jig and plank sections secured to the frame sections;

Figure 4 is a similar view to that of Figure 3, but showing one half of the stern end of the model boat hull in position in the jig;

Figure 5 is a perspective view from the above of one half of the bow of the model boat hull in position in the jig showing the frame sections and planking;

Figure 6 is a perspective view from above and to one side of the middle section of one half of the model boat hull in position in the jig;

Figure 7 is a perspective view from above of one complete half of the model boat hull in position in the jig;

Figure 8 is a perspective view from below of the complete hull of the model boat without planking;

Figure 9 is a perspective view from the side of the stern end of the hull of the model boat without planking;

Figure 10 is a perspective view from above of the bow end of the hull of the model boat;

Figure 11 is a perspective view from above of the middle section of the hull of the model boat; and Figure 12 is a perspective view from above of the bow end of the hull of the model boat;

The figures 1-12 illustrate the apparatus with which a model boat kit may be constructed by a modeller. More specifically, the figures show how the hull 14 of the model boat is constructed in conjunction with a jig 2 which is supplied as part of the boat kit. The method of construction comprises the following steps : -

(a) One half of the hull 14a is constructed by spacing a set of pre-cut bulkheads (supporting ribs) 6 along the length of a jig 2 thereby forming a "frame".

(b) Pre-cut planks of wood 8 are affixed to the outer surface of the "frame" of bulkheads, forming the outer surface of the hull. This method is the so called "plank- on-frame" technique which is known in the art. Once completed, the first half of the hull 14a is removed from the jig 2 and put to one side.

(c) The second half 14b of the hull 14 is constructed in the same way as the first half 14a (steps 1 and 2 above) .

(d) The two halves of the hull, 14a and 14b, are then aligned and securely attached together thereby forming a complete hull 14 of the model boat.

The figures will now be described in more detail below.

Referring to figures la to lc, a jig 2 is shown comprising a generally flat keel 5 having a series of slots 4 which are evenly spaced apart along the total. length thereof. One half of what will eventually form the keel 16 of the hull 14 is shown and, is accommodated by the jig 2 at a pre-deter ined position. In the embodiment shown in the accompanying figures, the slots 4 of the jig 2 are 20mm apart, each slot being 6mm wide. The keel 16 has holes 3a through which bolts (not shown) or some other appropriate fixing means may pass into corresponding holes 3b in the jig 2 thereby fixing the two components together.

A computer controlled router (CNC; not shown) is programmed to cut a series of half bulkheads 6, a set of which is shown in Figure 2. However, the half bulkheads 6 may be machined using any suitable means, for example, routing, milling, laser, water-jet cutting, chemical milling (etching) or compressing etc. The half bulkheads 6 shown- in figure ^■ 2 will constitute, one half of the boat hull 14a. When attached to their other corresponding half, the bulkheads 6 form the complete boat hull 14. The half bulkheads 6 are formed by scanning the shape of a model boat hull into a computer and taking cross-sectional "slices" of the hull as the shape of the bulkheads 6. Tabs 9 are included to add strength to the bulkheads during assembly of a boat. The remaining parts will form the ribs 11 of the boat.

Referring to figure 3, the bow end of one half of the model boat hull 14a is shown in position in the jig 2. The half bulkheads 6 are marked with numbers 7 or some other appropriate markings which quickly and simply illustrate to the modeller in which slot 4 along the jig 2 each bulk head 6 must be placed during the construction process. The tabs 9 of the bulkheads 6 are placed in the appropriate slot 4 along the jig 2. The outer surfaces (ribs 11) are contoured such that their outer faces together form a smooth, continuous surface upon which planks 8 may be fixed. The planks 8 may be fixed so as to tightly abut each other onto the bulkheads 6 by glue or tacks or some other means etc.

Referring to figure 4, the stern end 12 of one half of the model boat 14a is shown in position in the jig 2. One can clearly see the slots 4 of the jig 2 maintain the bulkheads 6 in a fixed position while the planks 8 are applied to the contoured surface thereof. It will be appreciated that the purpose of the jig 2 is to act as a firm support for the bulkheads 6 such that little or no flexing or twisting of the hull 14 under construction occurs, and that the planks 8 assume their correct positions, tightly abutting one- another, on the surface 'of the bulkheads 6. The modeller does not need to worry too much about the stability of the frame formed by the bulkheads 6 during hull 14 construction and can concentrate solely upon the precise positioning of the layer of planks 8 thereon. One half of the keel 16 is shown at the lower part of the hull 14.

Figure 5 illustrates how the bulkheads 6 at different positions along the jig 2 have different shapes and profiles thereby forming a continuous surface onto which the planks 8 are fixed. It will be apparent to the skilled technician that the shapes of the bulkheads 6 and their respective positioning along the jig 2 determine the shape and surface of the finished product and that the apparatus shown in the figures is not restricted to the construction of the hull 14 of a boat. The jig 2 and bulkheads 6 can be designed to produce any article having a complex outer surface, for example, . an aeroplane fuselage. Furthermore, even though the apparatus is shown here used to construct a model boat, the size of the apparatus may easily be scaled up so that a full size boat or some other article may be made.

Figure 6 is an alternative view of the hull 14 with all of the bulkheads 6 in position along the jig 2. A support beam 18 is shown in position extending along substantially the entire length of the hull 14 and is present to give further support to the bulkheads 6, ie the slots 4 of the jig 2 support the "base" of each bulkhead 6 in position maintaining a constant separation, and the support beam 18 maintains the same constant separation at the. "top" of

^' each bulkhead 6. Cutting lines 20 can be seen on some of the bulkheads 6, between the tabs 9 and the • part which forms the ribs 11 of the boat. The cutting lines 20 are present on all bulkheads. The cutting lines are present to aid in the subsequent cutting out of the tabs 9 from inside the hull 14. This will allow the modeller to work on the inside of the boat hull 14 relatively unencumbered.

Figure 7 shows one half of the hull 14a still in position in the jig 2 having been completely covered in planks 8. At this stage, this half of the hull 14a is removed from the jig 2 by carefully sliding the bulkheads 6 from out of the- slots 4.

Once the first half of the hull 14a has been completed, the second half 14b is constructed in the same manner using the jig 2. Once the two halves, 14a and 14b, are completed, they are then joined together by appropriate means, eg glue, tacks and/or bolts passing through the holes 3 in the two halves of the keel 16.

Figure 8 illustrates the two halves, 14a and 14b, having been fixed together thereby forming a complete hull 14 of the boat . For clarity, the two halves have not been shown covered with planks 8. It will be appreciated that it is preferable to attach the planks 8 to the frame formed by the bulkheads 6 prior to fixing the two halves, 14a and 14, together so that the modeller can take advantage of the firm support provided by the jig 2.

Referring to figures 9-12, the hull 14 can be seen comprising the two halves, 14a and 14b, from a number of different angles. Once the two halves have been fixed together, the modeller then removes the support beam 18 and 'the tabs 9 of the bulkheads 6 so. that there is ample space in which to finish the internal parts of the hull 14. For example, a steam engine (not shown) may be fitted into the hull 14 so that the model can be fully functional. At this stage in the construction, the strengthening effect of the tabs 9 is not needed to provide support against twisting and flexing since the planks 8 have already been fixed thereto.

During the preparation of the bulk head 6, the cutting lines 20 were incorporated at specific positions on each bulkhead 6 to provide "weak points" which may be easily cut by the modeller (see Figure 2) . Figures 10-12 clearly illustrate where the cutting line 20 on the bulkheads 6 have been cut thereby removing the tabs of the bulkheads 6. Removal of these sections makes substantial space in which internal features may be located. In addition, excess and unnecessary weight is removed from the hull 14 of the boat.

Referring to figures 11 and 12, upper deck planking 22 is shown covering regions of the upper surface of the hull 14.

The use of a jig allows more bulkheads to be used, which may be thinner than used with previous models, and so cheaper and easier to make and work. The provision of more bulkheads allows a more complex hull structure to be created, with more surface contours. The use of the jig allows the frame of bulkheads to be held firmly in position to allow planking to be secured to the bulkheads.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) , may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment (s) . The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , or to any novel one, or any novel combination, of the steps of any method or process so - disclosed.

Claims

1. Apparatus for assembling a frame structure comprises a jig having a plurality of slots adjacent to one another and a plurality of frame members for forming part of the frame structure, wherein the slots are adapted to receive the frame members, and adapted to hold the frame members in position for the application of a cover or support beam to the frame structure, at least part of which cover or support beam is spaced from the jig.

2. Apparatus for assembling a frame structure according to claim 1 , wherein the frame structure is a covered frame structure .

3. Apparatus for assembling a frame structure according to either claim 1 or 2, wherein the frame structure is .a model .

4. Apparatus for assembling a frame structure according to either claim 2 or 3, wherein the covered frame structure is at least part of a boat hull.

5. An apparatus for constructing an article having at least one contoured surface, the apparatus comprising a jig having a plurality of slots extending substantially along its length, and a set of frame members, the frame members being positioned, in use, in the slots such that the surfaces of the frame members facing substantially away from the slots together form the undulating surface.

6. Apparatus for assembling a frame structure according to any preceding claim, wherein the slots are substantially parallel with one another.

7. Apparatus for assembling a frame structure according to any preceding claim, wherein there are at least as many slots as frame members.

8. Apparatus for assembling a frame structure according to any preceding claim, wherein the jig comprises a support member and a guide member.

9. Apparatus for assembling a frame structure according to claim 8, wherein the guide member is secured to the support member by any suitable means.

10. Apparatus for assembling a frame structure according- to either claim 8 or 9, wherein the guide member is secured to the support member by a series of bolts which pass through corresponding apertures in the two members.

11. Apparatus for assembling a frame structure according to any of claims 8 to 10, wherein the guide member is a keel of a boat hull, against which the frame members abut.

12. Apparatus for assembling a frame structure according to any of preceding claims 8 to 11, wherein the frame members are adhered to the guide member with adhesive.

13. Apparatus for assembling a frame structure according to any preceding claim, wherein the set of frame members are machined to have differing profiles.

14. Apparatus for assembling a frame structure according to any preceding claim, wherein each of the set ■ of the frame members is positioned into a specific slot of the jig.

15. Apparatus for assembling a frame structure according to any preceding claim, wherein the jig supports each of the members of the frame .

16. Apparatus for assembling a frame structure according to any preceding claim, wherein each of the frame members are marked to thereby facilitate positioning of said frame member in specific slots of the jig.

17. Apparatus for assembling a frame structure according to any preceding claim, wherein each of the frame members

^■ have cutting lines which present points of weakness which may be subsequently cut thereby leaving a portion of the frame member.

18. Apparatus for assembling a frame structure according to any preceding claim, wherein a majority of the surfaces of the frame members facing substantially away from the slots is covered with cover portions.

19. Apparatus for assembling a frame structure according to claim 18, wherein the cover portions are discrete sections .

20. Apparatus for assembling a frame structure according to either claim 18 or 19, wherein the cover portions are laid generally across the length of at least two frame members .

21. Apparatus for assembling a frame structure ' according to any of claims 18 to 20, wherein the cover portions are laid perpendicular to the length of the frame members.

22. Apparatus for assembling a frame structure according to any of claims 18 to 21, wherein the cover portions are abutted against each other.

23. Apparatus for assembling a frame structure according to any of claims 18 to 22, wherein a support beam is used in conjunction with the set of frame members to provide further support as the cover portions are attached to the f ame members .

24. Apparatus for assembling a ' frame ^■ structure according to claim 23, wherein the support, beam is spaced from the jig-

25. Apparatus for assembling a frame structure according to either claim 23 or 24, wherein the support beam comprises slots or openings therein at substantially the same spacing as the slots in the jig.

26. Apparatus for assembling a frame structure according to claim 25, wherein the slots in the support beam are arranged to maintain the spacing of upper portions of the frame members .

27. Apparatus for assembling a frame structure according to any of claims 23 to 26, wherein the support beam is located on an opposite side of the^' frame members to the jig.

28. Apparatus for assembling a frame structure according to any of claims 5 to 27, wherein the apparatus is used in the construction of half of the whole of a boat.

29. A method of assembling a covered frame structure comprises placing a plurality of frame members adjacent to each other in a jig, the jig holding the frame members in position for the application of a cover to the frame structure.

30. Apparatus for assembling a frame structure according to claim 29, wherein the covered frame structure comprises half of a hull of a boat.

31. Apparatus for assembling a frame structure according to either 29 or 30, wherein two halves of the hull are assembled with the jig for subsequent attachment to one another.

32. Apparatus for assembling a frame structure according to any . of claims 29 to 31, wherein a guide member is placed in the jig to which the frame members are secured.

33. Apparatus for assembling a frame structure according to claim 32, wherein the guide member may be a boat keel, or part thereof.

34. Apparatus for assembling a frame structure according to any of claims 29 to 33, wherein a support beam is used to maintain the spacing of parts of the frame members spaced from the jig.

35. An apparatus for assembling a frame structure as substantially herein described with reference to, and as illustrated by, the accompanying drawings.

36. An apparatus for constructing an article having at least one contoured surface as substantially herein described with reference to, and as illustrated by, the accompanying drawings .

37. A method for assembling a covered frame structure as substantially herein described with reference to, and as illustrated by, the accompanying drawings.