Method of manufacturing foam core boat collars

• US 20040250402A1
• Filed: 06/13/2003
• Published: 12/16/2004
• Est. Priority Date: 06/13/2003
• Status: Active Grant

• Current Assignee: Safe Boats International LLC
• Original Assignee: Safe Boats International LLC
• Inventors: Hansen, William M.
• Granted Patent: US 7,070,730 B2
• Time in Patent Office: Days
• US Class Current: 29/446
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/3496 The foam being compressed and later released to expand B29C44/3465 takes precedence
• CPC Class Codes: Y10T 29/49863 with prestressing of part

Abstract

A method for fabricating foam cored items in which the foam core is tightly encased by an outer shell. The method is particularly suited for fabricating foam collars that are located above the chine of a boat and extend longitudinally along the sides of the boat to provide stabilization for the boat during high performance maneuvering and/or provide a fendering system.

Claims

1. A method of fabricating an item of manufacture of a type in which a sleeve encompasses and firmly surrounds polymeric foam material, said method comprising the steps of:

(a) forming a sleeve having a shape and size that corresponds to the item of manufacture, said sleeve having an interior for receiving said polymeric foam material and having an opening that allows placement of said polymeric foam in said interior of said sleeve;

(b) fabricating one or more inserts for placement in said sealable interior of said sleeve, said one or more inserts being formed of compressible polymeric foam, having a shape that corresponds to the shape defined by said interior of said membrane and being oversized relative to said interior of said membrane;

(c) compressing said one or more foam inserts to a size less than the size of said interior of said membrane;

(d) placing the compressed foam inserts in said interior of said sleeve;

(e) closing said opening of said sleeve; and

(f) expanding the compressed polymeric foam inserts so that the expanded foam inserts bear firmly against said sleeve to cause the sleeve to fully encompass and firmly surround the polymeric foam.

2. The method of claim 1 wherein said inserts are formed from a compressible polypropylene foam.

3. The method of claim 2 wherein the density of said polypropylene is within a range of approximately 0.05 pounds per cubic foot to approximately 5.0 pounds per cubic foot.

4. The method of claim 3 wherein said step of forming the sleeve includes the step of installing a zipper for allowing access to and sealing off of said interior of said sleeve.

5. The method of claim 1 wherein said inserts are formed from compressible polyethylene foam.

6. The method of claim 5 wherein the density of said polypropylene is within a range of approximately 0.05 pounds per cubic foot to approximately 5.0 pounds per cubic foot.

7. The method of claim 6 wherein said step of forming the sleeve includes the step of installing a zipper for allowing access to and sealing off said interior of said sleeve.

8. The method of claim 1 wherein said step of compressing said one or more foam inserts includes the steps of inserting said inserts in a hyperbaric chamber and increasing the atmospheric pressure in the hyperbaric chamber until the size of said one or more inserts is less than the size of said interior of said sleeve and are small enough to allow placement in said interior of said sleeve.

9. The method of claim 8 wherein said inserts are formed from a compressible polypropylene foam.

10. The method of claim 9 wherein the density of said polypropylene is within a range of approximately 0.05 pounds per cubic foot to approximately 5.0 pounds per cubic foot.

11. The method of claim 1 wherein said step of compressing said one or more foam inserts includes the steps of surrounding peripheral regions of said inserts with tensioning belts and tightening the tensioning belts to compress said polymeric foam to a size less than the size of said interior of said sleeve.

12. The method of claim 11 wherein said inserts are formed from compressible polyethylene foam.

13. The method of claim 12 wherein the density of said polypropylene is within a range of approximately 0.05 pounds per cubic foot to approximately 5.0 pounds per cubic foot.