WO2022015195A1

WO2022015195A1 - Boat hull (device and method of manufacture)

Info

Publication number: WO2022015195A1
Application number: PCT/RU2021/000262
Authority: WO
Inventors: Борис Муратович КУЧУКОВ
Original assignee: Борис Муратович КУЧУКОВ
Priority date: 2020-07-14
Filing date: 2021-06-21
Publication date: 2022-01-20
Also published as: RU2020123363A

Abstract

A method of constructing a hull of a waterborne vessel, in which patches of fibreglass cloth (carbon cloth) are saturated with resin and attached to the framework of a boat. The sides of a patch are wrapped around at least two frames. The other two sides can be wrapped around stringers. The patches are secured inside a vacuum bag, preventing contact between the resin and the framework, and are screwed to the side surfaces of the framework using clamps or bolts. Once hardened, the resulting elements are removed from the framework and subsequently glued in the same position to the same surfaces. Unsealed openings in the hull are sealed with sheets of a composite material. In another embodiment, grooves are cut out of the sides of the patches or of the hardened elements or of prepregs, to allow the tongues of adjacent elements to be glued in place. Thereafter, other layers are glued to the resulting body, then caulked and painted.

Description

Name of the invention

Vessel hull (device and manufacturing method)

Technical field

The claimed invention relates to shipbuilding.

Prior Art

From the prior art, several options for the construction of ships are known. However, only two methods are actively used in commercial shipbuilding. This is the welding of a metal body on a slipway and the molding of a composite (carbon fiber or fiberglass) body in a matrix. Wooden shipbuilding is also used to a limited extent. With this method, the wooden set of the vessel is sheathed with wooden slats. Various more exotic methods are also known. For example, an armocement or clay body. But they are not used in commercial shipbuilding, since such hulls are significantly inferior to the first two methods in many respects.

Small boats were originally made by molding a plastic hull in a matrix. Currently, this method is the main one for the manufacture of pleasure yachts, boats and motor boats. We also know of several relatively large ships (more than 60 meters), the hulls of which were glued in the matrix. However, for large ships, welding a metal hull on a slipway is the main method of construction. And for very large ships (tankers, cruise ships, etc.), welding is currently the only possible way to build.

The reason for this is obvious. Large ships require a large matrix. It also requires very powerful cranes to lift the hull out of the matrix. It is easy to imagine what colossal investments will be required, for example, to mold the hull of a large-tonnage fiberglass or carbon tanker in a matrix.

The method claimed in this application solves the described problems of manufacturing housings in a matrix. At the same time, the performance of the claimed method is not lower than the alternative method in the form of welding a metal case on a slipway. Also, this method provides a stronger adhesive bond than in matrix molding. In particular, with matrix molding, the quality of the case is very often extremely poor. Of the latest examples, it is enough to recall the egregious case of the Polina Star III (OYSTER YACHTS), when a practically new hull of a 28-meter sailboat worth £5 million fell apart as a result of a manufacturing defect.

The claimed method will avoid the described disadvantages, which makes it industrially applicable and in demand in shipbuilding. In small shipbuilding, the claimed method will provide a better assembly quality; in large-tonnage shipbuilding, it will also provide the possibility of manufacturing large composite hulls, which is impossible with alternative technology.

Disclosure of invention

For the manufacture of the vessel by the claimed method, it is necessary to make a set of hull. The set can be made of any material (composite, wood or metal). The set can be made by any method known in shipbuilding, and can be made according to any scheme (combination) of stringers and frames: longitudinal, transverse, longitudinal - transverse. After the manufacture of the power set (welding on the slipway, gluing, etc.), the manufacture of the skin begins. It is this process that distinguishes the claimed method from all previously known. The lining is glued in layers. In this case, the primary skin layer is formed from a plurality of separate pieces of fiberglass (carbon fiber, etc.), each of which connects at least two adjacent frames. The contours of the vessel are set by the frames, which is why the gluing of the elements of the primary skin is carried out to the frames. Additionally, you can glue to stringers, but gluing only to stringers is not correct.

The main problem when connecting the skin to the set is to ensure a strong connection. In the matrix manufacturing of the ship's hull, the skin (hull) is first made and only then the elements of the power set are glued with an overlap. The use of such a method for gluing the skin to the hull would mean that the skin is only glued to the outer sides of the stringers and frames. This option has low efficiency, since the strength of such a connection between the skin and the set is significantly lower than that of proposed in this application. Thus, a local technical problem is also to increase the strength and reliability of the connection of the set with the skin.

The simplest solution is to glue the fiberglass directly to the set. This can be done if, for example, the glass fabric is made in the form of a prepreg (combined with a glass fabric curing component that is activated by heating).

Another solution to this problem is the following method. First, the pieces of fiberglass are shaped and cured, and only then glued. The originality of the idea lies in the fact that the connection of the element of the primary skin with the set occurs twice. The first time it is necessary to give the necessary shape. And only when reconnecting, the element is glued to the set. To do this, a piece of rectangular or cruciform fiberglass is placed in a vacuum bag and impregnated with resin. Next, not yet cured (plastic) fiberglass impregnated with resin directly in the bag is combined with the elements of the set. Thus, the resin in the fiberglass at this stage does not come into contact with the set, since the polymer film separates them. The connection of a piece of fiberglass in a bag with a set is carried out with an envelope at least along the frames. The bent sides are pressed down with overlays and tightened with clamps or otherwise. For example, bolts through specially made holes. After the resin has cured, the structure is removed from the kit and the resulting cured element of the primary skin is removed from the vacuum bag. Subsequently, it is glued to the same places with which it was connected for the first time. With this method, the glued sections of the ship's hull alternate with those that are not glued and resemble a chessboard.

Several variants of primary skin elements are described. In one embodiment, the elements are made from cross-shaped pieces of fiberglass and connected to frames and stringers. In the second version, the elements are made from rectangular pieces of fiberglass and connected only to the frames. Further, in the first case, after the elements are glued to the set, it is necessary to close the non-glued areas. To do this, overlays made of already cured fiberglass (fiberglass) are glued to the elements. If the elements of the primary skin were bent only along the frames, then elements that connect along the outer and side sides can be used to close the gaps that are not sealed. stringers, and they are also glued to the central part of the elements glued to the frames. Instead, the elements may not go around the stringers, but stick to the elements that go around the frames.

In addition to individual elements, each of which closes one "window", elements can be made that close several adjacent "windows" at once, vertically and (and) horizontally. Those. in this case, the edges of the segment can go around not adjacent frames, but located through several spacings. Or the edges of the segment can go around two adjacent frames, but at the same time close several stringers.

In addition, the elements of the primary skin can be made with grooves and protrusions along the edges. In this case, unlike the previous versions of the "chessboard", all non-closing (non-glued) "windows" between the frames are closed by these elements.

With any variant of the skin, gaps may remain between the elements or elements and the set. The slots are glued from the inside and / or outside with other layers of fiberglass. In this case, the curing of a layer of glass fabric (carbon fiber) on the skin already obtained can be used, for example, using vacuum infusion. Or, an already cured sheet of fiberglass (GRP) or carbon fabric (CFRP) can be glued onto the skin.

Thus, the impregnation of fiberglass with resin occurs under double pressure - first in a vacuum bag, then under pressure from linings tightened with clamps. The result is a high-quality resin-impregnated element of the primary skin of the desired shape. In addition, in contrast to the method of manufacturing the hull in the matrix, with the claimed method, the connection of the set with the skin is much stronger, since the bent sides of the primary skin, glued at least to the sides of the frames, guarantee better peel strength. The method of gluing also significantly increases the strength. In matrix molding, the set pressure on the skin during gluing is provided by a vacuum bag and a pump. With the claimed method, the pressure created by tightened clamps or bolts is many times higher.

After gluing all the layers, the body continues to be made in almost the same way as when welding on a slipway - putty and paint are applied to the body. Further, the essence of the claimed method is disclosed in more detail on the examples and drawings.

Brief description of the drawings

Fig.1 An isometric view of the power set of a part of the ship's hull is shown. A part of the set of the port side of the vessel is shown, while the elements of the set (frames, stringers and keel set) are shown in a cliff. Elements of the primary skin are also shown. One element is glued to the side surfaces of the frames and stringers, another element is shown without connection to the set.

Fig.2 A cruciform piece of fiberglass (carbon fiber) is shown for gluing to the outer and side surfaces of frames and stringers, and pieces of a polymer film similar in shape for vacuum impregnation with resin.

Fig.3 Shown is an isometric view of the element of the primary skin, glued to the outer and side surfaces of the frames and stringers with clamps through the lining. Frames and stringers are shown in a cliff. The side part of the primary skin element closest to the viewer is shown with through holes for bolts that fasten the pressure pad (the pad, bolts and nuts for them are shown without connection).

Fig.4 The load-bearing set of the ship's side is shown with pieces of fiberglass (carbon fabric) glued in a checkerboard pattern to the outer and side surfaces of the frames and stringers, which are the primary skin. Also shown is a cruciform piece of fiberglass before the sides are folded and cured. Also shown is a square piece of fiberglass, which, after curing, will close one of the holes.

Fig.5 The load-bearing set of the ship's side is shown with pieces of fiberglass (carbon fabric) glued in a checkerboard pattern to the outer and side surfaces of the frames, which are the primary skin. At the bottom of the figure, pieces of fiberglass (carbon fiber) are shown without their connection to the set and before giving their sides a bent shape.

Fig.6 Shows an isometric view of the primary skin elements after curing. One element is glued only to the frames, the other only to stringers and to the central parts of elements glued only to frames.

Fig.7 The power set of the ship's side is shown with a piece of fiberglass (carbon fabric) glued to the outer and side surfaces of the frames and stringers, which is the primary skin. In this case, the segment is made with grooves and protrusions along the edges.

Fig.8 Shows an isometric view of a primary cladding element with grooved edges after curing. The bent protrusions of the element are glued to the frames and to the stringers.

Fig.9 Isometric projection of the load-bearing set of the ship's side with a piece of fiberglass (carbon fabric) glued to the outer and side surfaces of the frames and stringers, which is the primary skin, is shown. In this case, the segment is made with grooves and protrusions along the edges and closes several holes (windows) at once, formed by the intersection of stringers with frames. Also shown is such a cured piece of fiberglass (carbon fiber) without connection to the set.

Best Modes for Carrying Out the Invention

Fig.l shows the power set of a part of the hull of the vessel, consisting of connections of frames (1), stringers (2) and a keel set. Also shown is a part of the elements of the primary skin (3), one of which is glued to the set, and another one is shown separately. Elements of the primary skin (3) contain a central part (4), bent sides (5) for connection with the side surfaces of the frames (1) and bent sides (6) for connection with the side surfaces of the stringers (2). Reference symbol (3) means an already cured element of the primary skin. As can be seen from the figure, the elements of the primary skin are glued to the ship's frame in a checkerboard pattern, since it is impossible to glue adjacent "windows" with the same element (with a curved side surface) and in the same way (along the outer and inner sides of the frames and stringers).

Many known methods can be used for impregnation. Fig.2 shows the step of the process of vacuum impregnation of fiberglass with resin. For example, a piece of fiberglass (7) of the desired shape is placed in a vacuum bag and impregnated resin using the well-known vacuum infusion process. To do this, you will need a film, adhesive tape, layers of sacrificial tissue, hoses, a pump, etc. Also, instead of all these devices, you can apply physical pressure. For example, put it in a film (8) and fill it with resin, but solder it (stick it with tape, etc.) while not completely, not from all sides. Further, with the pressure of the roller on the film, the resin will impregnate the fiberglass, and its excess, together with air, will be squeezed out through the non-sealed side of the bag.

The most productive and high-quality method of impregnation is probably electromagnetic pressing. This will significantly improve the productivity and quality of products. With this method, the fiberglass in the vacuum bag must be placed on an iron table to attract the electromagnet.

Further, after impregnating the fiberglass with resin, the not yet cured (plastic) fiberglass is combined with a set to give it the desired shape. If physical pressure was applied, then the non-sealed side of the film bag is also sealed and the fiberglass in the bag (through the film) is connected to the set. Possible connection options are shown in Fig.3. To understand this image, imagine that the fiberglass is in a vacuum bag. This is easy to imagine, although in this figure the film (bag) is not indicated so as not to complicate the drawing. As can be seen from the figure, one bent side (5) of the primary skin element is pressed against the side surface of the frame (1) by clamps (9) through spacers (10), distributing pressure over a large area. In the same way, the other two bent sides (6) (upper and lower) are pressed against the side surfaces of the stringers (2). In the side closest to the viewer (5), pressed against the frame (1), and in the frame itself, through holes (11) are made, through which bolts (12) will pass, tightening the linings (13), in which holes are also made.

After the resin has cured, the clamps and bolts are unscrewed, the element of the primary skin is removed from the set and removed from the film (vacuum bag). Next, the element is glued to the same place, to the same surfaces of the frames (and stringers), according to which its shape was set. The bonding process is also shown in Fig.3. It should be understood that the film (vacuum bag) is missing in the process. The surfaces are lubricated with an adhesive (resin, etc.) and pressed down (pulled together with clamps, etc.).

Fig.4 shows a set of a ship's side with primary skin elements glued in a checkerboard pattern (3). Each element is glued to both frames and stringers. Also shown is a piece of glass fabric (7), which is a blank, from which, after curing, an element (3) is obtained. The places of the bends in the piece (7) are indicated by lines. After gluing the elements (3), it is necessary to glue the open areas (14) located between the elements. Areas (14) can be sealed with pre-cured fiberglass (fiberglass) (15).

Fig.5 shows another version of the skin. Shown here is a set of a ship's side with elements of the primary plating glued in a checkerboard pattern (16). Each element is glued only to the frames. Also shown is a piece of glass fabric (17), which is a blank, from which, after curing, an element (16) is obtained. The places of the bends in the piece (17) are indicated by lines. After gluing the elements (16), it is necessary to glue the open areas (14) located between the elements. Sections (14), as in the previous case, can be sealed with pre-cured fiberglass (fiberglass) (15). Or elements can be used that are glued to the outer and side surfaces of the stringers, and to areas of previously glued elements (16). Under the reference designation (18) shows a piece of fiberglass (carbon fiber) with the upper and lower ledges for bending and gluing to the outer and side surface of the stringer. After curing, it becomes an element (19). It is more convenient to make elements (19) before gluing the elements (16) to the set, since in this case it is more convenient to bend the glass cloth (18) in a vacuum bag onto the stringers. If elements (18) are used, a special impregnation technique can be used. For example, it is first possible to impregnate with resin only those parts of the piece of fiberglass (18) that are folded onto the stringers, and also impregnate the central part. In the process of shaping the segment (18), this will allow the segment (18) to be screwed not only to the stringers, but also to the frames (as shown in Fig.3). But at the same time, the fiberglass, bent on the frames, does not cure, since it is not impregnated with resin. The purpose of this is only to stretch the piece of fiberglass (18) and secure it to the ship's framing. After curing the central part and the sides of the segment (18) folded onto the stringers (2), it is removed from the set, the uncured sides that were bent onto the frames are straightened and the flat surface is impregnated with resin, and cured.

It is obvious that element (15) can close not only one unglued window, but also glue several at once. Fig.7 and 8 show another variant of the skin, in which instead of sealing the "windows" in a checkerboard pattern, all the holes are glued at once. In this case, the elements of the primary skin (19) are made with grooves and protrusions along the edges. In this case, unlike the previous versions of the "chessboard", all non-closing (non-glued) "windows" between the frames are closed by these elements. Grooves can be cut into an uncured piece of fiberglass (carbon cloth) before it is impregnated with resin or after it has been cured. In addition to individual elements, each of which closes one "window", elements (20) can be made that close several adjacent "windows" at once (Fig.9), vertically or (and) horizontally. With any cladding option, gaps will remain between the elements or elements and the set. Slots are glued from the inside or outside with other layers of fiberglass (carbon fiber) or in small segments. After gluing all the layers, the body is puttied and painted. In the manufacture of hulls with a double side (tankers, etc.), primary skin elements are glued not only from the outside, but also from the inside.

Industrial Applicability

Given the disclosure of essential technical features, additional distinguishing features become apparent to a person skilled in the art. The prospects of the claimed method and industrial applicability are clear from the description.

Claims

Formula

Clause 1. A method for manufacturing a ship hull, containing the manufacture of a power set of the hull, characterized in that it contains:

- a process for the manufacture of primary skin elements, in which pieces of fiberglass or other applicable material of a rectangular or cruciform shape are impregnated with resin and their sides are folded onto the side surfaces of the frames, and can be folded onto the side surfaces of the stringers, while the fiberglass is separated from the set by a polymer film in order to be able to further removing the cured element from the set;

- the process of gluing the primary skin elements made in this way to the same surfaces of the load-bearing set, according to which their shape was specified at the previous stage;

- the process of gluing the remaining not closed "windows" in the set with sheets of fiberglass or other applicable material and the process of pasting the resulting matrix with other layers of fiberglass.

Item 2. A method for manufacturing a ship's hull, containing the manufacture of a power set of the hull, characterized in that it contains:

- the process of manufacturing primary skin elements, in which pieces of fiberglass or other applicable material are impregnated with resin and their sides are bent onto the side surfaces of the frames, and can be bent onto the side surfaces of the stringers, while the fiberglass is separated from the set by a polymer film in order to be able to further remove the cured element from set;

- the process of cutting grooves, which will include the protrusions of adjacent elements that go around the frames (and which can also go around stringers), while the grooves are cut on uncured pieces of fiberglass or on cured ones;

- the process of pasting the resulting matrix with other layers of fiberglass. Clause 3. A method for manufacturing a ship's hull, containing the manufacture of a power set of the hull, characterized in that it contains:

- a primary skin manufacturing process in which the resin-impregnated sides of pieces of fiberglass or other applicable material of rectangular or cruciform shape (prepregs) are folded onto the side surfaces of the frames, and may be folded onto the side surfaces of the stringers, and cured;

Clause 4. A method for manufacturing a ship's hull, containing the manufacture of a power set of the hull, characterized in that it contains:

- the process of cutting grooves on the sides of pieces of fiberglass or other applicable material impregnated with resin (prepregs), which will include the protrusions of adjacent elements;

- the process of connecting the obtained blanks with the side surfaces of the frames (and the connection with the side surfaces of the stringers can be used), and curing; - the process of pasting the resulting matrix with other layers of fiberglass.

Item 5. The ship's hull, characterized in that it contains composite elements of the primary plating with curved edges for connection with the side surfaces of the frames and / or frames and stringers, while along the edges of the elements, grooves can be made into which, during installation, protrusions of adjacent elements enter, enveloping frames (and which can also go around stringers).