The invention relates to a marine fender for protecting an object against impact, in particular against impact from naval activity.

Marine fenders are known and used for marine applications to prevent objects like vessels, such as ships, barges and the like, from getting damaged due to impact or contact while mooring to wharfs, docks or shores or ship-to-ship interaction. Marine fenders may also be used to protect stationary marine objects, such as bridge piers and/or pile caps, quays, docks or mooring landings from getting damaged due to contact or impact with movable marine objects, such as vessels and the like.

Fenders can have different forms or shapes, and may be fixedly attached to a fixed and/or floating marine structure. Fenders can also be suspended along the fixed and/or floating marine structures with for example cables.

The main task of a fender, however, is to protect two marine structures from severe damage due to impact when contacting each other by placing such a fender in between the two marine structures. Known fenders are made of rubber, either solid or with an air chamber in the center. The size of the fender may depend on the size, weight, use and/or operations of the vessel. Heavy ships or vessel will be difficult to stop once in movement due to a great momentum force. Therefore the fender needs to be able to absorb the momentum forces and slow down the ship without severely damaging the hull, for example by the hull getting in direct contact to the quay or wharf. Due to high forces, especially friction, between the fender and wall of the wharf or dock or between the fender and the hull of the ship, the rubber material of the fender may roll up and will wear rapidly, such that costly replacements and/or repairs are necessary at regular intervals.

Some known fenders are fixed to the hull of a ship at certain locations. This is especially important for vessels such as pilot boats which may be in direct contact with other ships, such that time consuming placement of loose suspending fenders are not an option. The mooring between the pilot boat and ship to be piloted is usually performed while both are moving, such that friction between the fender of the pilot boat and the hull of the ship to be piloted may be high, resulting in fast wear, ripping, tearing or rolling up of the rubber existing fender. Maintenance intervals may have to be regularly scheduled, during which possibly time-consuming maintenance intervals the pilot boats cannot be used, thus further increasing maintenance costs.

Moreover, known fenders, especially the type mounted to hulls of ships, are fixed by means of plates, clamping and holding the rubber fender in place. The plates are mounted to the hull with heavy bolts. Heavy bolts are needed due to the high forces acting on the fender during use. The bolts are mounted in holes that are drilled through or in the structure like the hull of the ship, enhancing possible leakage in, for example, rough sea with high waves and/or bad weather. Replacement of such fenders is time consuming and may result therefore in high maintenance cost, as mostly the fender needs to be disassembled for repair or replacement, which often has to be done in a dock or other special repair environment.

Existing rubber fenders are heavy, negatively effecting fuel efficiency and lowering maximum speed possible for, in particular, such fast ships like pilot boats or other fast marine vessels. The weight comes especially from the solid rubber and the mounting with heavy materials, hke the above mentioned bolts and plates.

Especially when using known fenders in, for example, a lock of a harbour, replacing or repairing damaged fenders can be costly. Not only maintenance costs are relatively high, but also valuable time during repair in which the lock can not be used.

Another known type of fender comprises a core of at least a closed cell foam part, an intermediate layer fully enclosing the core comprising at least a fiber reinforced cloth and a coating that at least partly covers the intermediate layer. This type of fender is relatively hght weight and strong and has a good performance and resistance against impact. However, for large and/or heavy and/or fast vessels and, consequently, relatively large possible impact loads such a fender becomes rather bulky and/or rather heavy. Also, such a high-resistance fender may become relatively complex to manufacture and, thus, rather expensive.

An object for the invention is to provide a marine fender that obviates at least one of the above mentioned drawbacks while maintaining the advantages. Preferably, a relatively hghtweight and/or compact high- resistance fender is provided.

Thereto, the invention provides a marine fender for impact protection comprising a core of closed cell foam, wherein said core comprises at least one chamber substantially entirely surrounded by said closed cell foam and enclosing an elastically deformable closed object.

In this way, a relatively light-weight, still relatively strong, fender can be provided of which the elasticity is high enough to also absorb heavy impact loads without damaging the fender. By providing such an elastically deformable closed object, the spring characteristics of the fender highly improve with respect to the known coil springs used. In fact, upon high impact loads, it is observed that the coil springs break, while the elastically deformable closed object returns back to its original shape after such a high impact, as well as the foam surrounding it. This significantly improves the protection of the vessel, reduces repair costs, and improves safety of the vessel and its load. Moreover, the features of the closed cell foam, as well as the chamber being substantially entirely surrounded by said closed cell foam, as well as the elastically deformable object being a closed object, all lead to a fender that is relatively well protected against water absorption in case of damage. Also, the fender according to the invention can have a smaller size for the same or similar energy absorbing capacity as compared to a prior art fender. This allows a more compact and/or more slender- shaped fender.

Preferably, the elastically deform able closed object may tightly fit in said at least one chamber, which can further enhance the resiliency of the fender, when there is no air pocket in between the closed cell foam and the elastically deformable closed object. Load can be transferred directly from the closed cell foam to the elastically deformable closed object, thereby improving the overall elastic characteristics of the fender. For example, the external dimensions of the elastically deformable closed object may be the same as the internal dimensions of the corresponding chamber as to obtain a tight fit. Alternatively or additionally, the elastically deformable closed object may clampingly fit in the chamber. For example, the external dimensions of the elastically deformable closed object may be slightly larger than the internal dimensions of the corresponding chamber as to obtain a clamping fit. Further, the elastically deformable closed object may be inserted in the chamber and the connection to the chamber may be provided by the tight fitting or clamping fitting. Alternatively and/or additionally, the elastically deformable closed object may be connected to the chamber by means of an adhesive such as a glue.

More preferably, said core can comprise a plurality of said chambers, each chamber comprising an elastically deformable closed object. The more chambers enclosing an elastically deformable closed object, the higher the resiliency of the fender, further improving load absorption of heavy shocks. The plurality of chambers can be equally distributed over the fender, or can be concentrated on places where more heavy shocks may be expected. The size of the chambers and/or of the enclosed elastically deformable closed object can be equal over the fender or vary as well according to where heavy load is to be expected. The size and/or distribution of the chambers and/or of the enclosed elastically deformable closed object can be optimized depending on the use of the vessel and/or where heavy impact is most hkely.

Advantageously, the core comprises at least two blocks of closed cell foam, wherein said at least one chamber extends into two adjacent blocks of closed cell foam. Closed cell foam is typically provided in solid premanufactured blocks of more or less regular dimensions. From such solid premanufactured blocks, a predetermined form can be cut or sawn out or milled or otherwise extracted by abrasive means, to produce a desired core form, such that every desired form of the fender can be obtained, which gives the designer a large design freedom, but also allows obtaining a form suitable for optimal protection of the object. Preferably, the at least one closed cell foam part of the core is manufactured from such a solid

premanufactured foam block. To obtain the desired thickness of the fender, such blocks can be piled up, preferably with the longest and largest sides facing each other. By providing said at least one chamber "between" two adjacent blocks, i.e. extending into said adjacent blocks of closed cell foam, the manufacturing process of said chambers, as well as insertion of the elastically deformable closed object can be simplified.

It may be preferred that said at least two blocks of closed cell foam have a mutually different density. By providing blocks of closed cell foam with mutually different densities, the elasticity of the fender's core can be made variable over a fender's length and/or thickness. The elasticity can for example be linearly variable or variable in a progressive way, for example in a fender's core with inwardly increasing density. The density can also be varied over the fender's length according to where heavier impacts may be expected.

Advantageously, said elastically deformable closed object can be a substantially spherical object. Aa a spherical object does not have any edges or corners, a spherical object has relatively better spring characteristics. However, any other closed form, such as a cylindrical or pyramidal shape, is also possible. In this context, a closed object is to be understood as a three- dimensional object, preferably a convex object, which fully encloses a volume, which volume can be sohd or not. A coil spring or spiral spring is not considered a closed object, as it does not fully enclose a volume.

Said elastically cleformable closed object can preferably comprise rubber, as rubber is known for its elastic properties. At the same time, rubber can be rather insensitive to damage, even under relatively heavy load. Said elastically deformable closed object can for example substantially entirely be made of a plastic material, such as for example polymer or polyurethane, alternatively rubber may be used. The elastically deformable closed object can also comprise only a shell, e.g. made from polymer or polyurethane. Alternatively, the elastically deformable closed object may comprise closed cell foam having a density that is different from the surrounding closed cell foam density. In all of these cases, the choice of material for the elastically deformable closed object may be determined by the desired elastic properties of the material.

It is preferred that said elastically deformable closed object is a hollow object. The hollow object can typically be filled with air, which air can have the same pressure as the surrounding pressure, or which air can be pressurized, such that the air inside the hollow closed object has a higher pressure than the surrounding air. A hollow object typically filled with air can produce a good bouncing effect when exposed to an impact. Instead of air, the hollow closed object may be filled with another gas such as nitrogen or similar. Such a bouncing effect is advantageous for returning to its original size after an impact. As such, the elastic properties for resisting to an impact of the fender greatly improve when using elastically deformable hollow closed pockets.

Advantageously, said elastically deformable closed object can be a ball-like or ball-shaped object comprising a substantially spherical closed shell, for example a shell made of a material comprising rubber and/or polymer and/or polyurethane, or of any other material with similar elastic properties or a combination thereof, or for example of leather. The shell can be filled with air, which air can be pressurized or pressureless, as for example in balls used in sports, e.g. tennis ball. Such a tennis ball may e.g. be used with or without skin. Of course, any other ball may be used instead. Alternatively, the substantially spherical closed shell can also be filled with another elastically deformable material. Preferably, the material of the shell has sufficient elastic characteristics from its own, such that it provides for the "bouncing" -effect of the closed pocket.

More preferably, said elastically deformable closed object can be a pressureless ball. In this context, pressureless is to be understood as not being pressurized, such that air pressure within the ball is the same as outside the ball. The advantage of a pressureless ball is that the ball can be relatively long-lasting, as the air does not risk to escape out of the ball. At the same time, a pressureless ball has relatively good spring characteristics and/or is relatively insensitive for fatigue and/or wear and/or ageing. Also, by providing a pressureless elastically deformable object, heat dissipation due to elastic deformation can be relatively limited, which is advantageous during use, in particular for the surrounding material.

Further, the invention provides for a method for manufacturing such a marine fender. The method comprises providing at least one block of closed cell foam, providing in the at least one block of closed cell foam at least one hollow chamber entirely surrounded by said closed cell foam, inserting an elastically deformable closed object into the chamber. The method can provide a marine fender presenting one or more of the above- mentioned advantages.

The hollow chamber can preferably be carved out of the at least one block of closed cell foam, which is a relatively easy, cheap and flexible method to obtain said chamber. Contrary to common fenders, for which liquid foam is poured in a mandrel, starting from a premanufactured block of foam and carving out the required chambers, provides for an enormous flexibility, customization and/or optimization. In fact, every fender can thus be made different, depending on the required characteristics, such as the vessel's hull, the expected impact and loads etc.

In an advantageous way, the method can comprise the steps of providing at least two blocks of closed cell foam, further providing a first chamber part of the at least one chamber in a first block and a second chamber part of said at least one chamber in a second block, inserting the elastically deformable closed object in one of the first or second chamber part of the first, respectively second, block, and closing the chamber by placing the other of the first or second chamber part in the first or second block over the closed object. As closed cell foam is typically provided in solid premanufactured blocks, which blocks can be piled up to obtain a desired thickness of a fender, it is easier to first provide a first block of closed cell foam with at least one, or preferably a plurality of, first chamber parts, for example by carving them out on one of the sides of the first block, then provide a second block with corresponding second chamber parts, such that, when the two blocks are piled up, the chamber extends into the two adjacent blocks. Creating, for example by carving out, the chamber is easier on a block's surface than in a block's inside, albeit possible as well. Also the insertion of the elastically deformable closed object can be done more easily and more quickly when a first chamber part is located on a block's surface, than when the object needs to be inserted into the inside of a block of closed cell foam.

The present invention will be further elucidated with reference to a drawing comprising figures. In the drawing shows Figure 1 a schematic cross-section of a preferred embodiment of a marine fender according to a first aspect of the invention; Figure 2a a schematic side view of blocks of closed cell foam usable for manufacturing a fender according to a first aspect of the invention;

Figure 2b a schematic side view of the opened-up blocks of closed cell foam of Figure 2a along the line A- A;

Figure 2c a schematic perspective view on the blocks of closed cell foam of Figure 2b;

Figures 3a and 3b schematic perspective views on two alternative opened-up blocks of closed cell foam;

Figure 4 a schematic perspective view on a preferred step of a method for manufacturing a marine fender according to a second aspect of the invention;

Figure 5 a schematic side view on a preferred step of a method for manufacturing a marine fender according to a second aspect of the

invention.

It is understood that the figures are given by way of exemplary embodiments only. Corresponding elements are designated with

corresponding reference signs.

Figure 1 shows a schematic cross-section of a preferred

embodiment of a marine fender 1 according to a first aspect of the invention. The marine fender can be attached to a marine structure 2, for example a vessel or a mooring platform, to protect that structure against impact, for example due to unwanted collisions between vessels and/or marine structures. Marine fenders are particularly useful for vessels which often moor close to other ships and risk coming into contact with them, such as tender, patrol or pilot vessels. The fender 1 can be attached to the marine structure 2 by known attachment means such as screws, bolts, adhesives, such as for example Sikaflex®, or other attachment means known to the person skilled in the art. Advantageously, adhesives can be used such that the fender can become an inextricable part of the structure, e.g. of a vessel hull. By providing the fender as an inextricable part of e.g. the vessel hull, the marine fender can be taken into account in the vessel's design, and/or the buoyancy of the marine fender can be taken into account for stability calculations of the vessel. The marine fender 1 comprises a core of closed cell foam 3, an intermediate layer 4 at least partly enclosing the core 3 and a coating 5 at least partly covering the intermediate layer 4.

In this preferred embodiment, the intermediate layer 4 encloses the core on three sides, in particular three sides which are most exposed to possible impacts, i.e. the surfaces of the fender 1 which will be external once the fender is mounted to a marine structure 2. On the fourth side, which adheres to the marine structure 2, the intermediate layer 4 encloses the corners, providing an extra protection, but does not necessarily enclose the core. The intermediate layer 4 is preferably a fiber reinforced cloth, to reinforce the strength and durability of the fender 1 and to improve the core's protection against impact, as the cloth can provide resistance against tearing. The fibre reinforced cloth may for example be a PVC-cloth or a neoprene cloth reinforced with known fibres such as canvas fibres, glass fibres or other known fibres. The cloth can for instance comprise Hypalon®. The cloth can for example be glued to the core to obtain a firm connection, for which typically a two-component adhesive can be used. The glueing of the cloth may form an airtight layer around the core, at least there where the core is covered by the intermediate layer, supporting the closed cell foam core during compression and reacting as a pneumatic fender.

The intermediate layer 4 can be covered by a coating 5, which can cover the entire intermediate layer 4, and which may also cover the core 3, where the core is not covered by the intermediate layer 4. Preferably, the coating 5 fully encloses the entire external surface of the fender 1, also the side of the fender 1 that will be attached to the marine structure 2. The coating can provide the fender with additional protection and resistance, for example against tearing, wear, or against UV radiation, and can provide the fender 1 with a water-tight layer. The coating 5 can for example be sprayed onto the intermediate layer 4, wherein the thickness of the coating can vary along the fender, adapting said thickness in zones of the fender which are more or less prone to wear. The thickness of the coating 5 may for example vary between 3 - 20 mm. The coating 5 can for example comprise

PolyUrea™ or any other material with similar characteristics. In this embodiment, there is provided an intermediate layer 4 and a coating 5. Of course, many variants, with or without intermediate layer and/or with or without coating are possible.

In the fender 1 according to the invention, the core 3 comprises at least one chamber 6 substantially entirely surrounded by said closed cell foam 3 and enclosing an elastically deformable closed object 7. In the preferred embodiment represented in Figure 1, said core comprises a plurality of said chambers 6, each chamber 6 comprising an elastically deformable closed object 7. The core 3 comprises at least two blocks of closed cell foam, in this case four blocks 3a, 3b, 3c, 3d of closed cell foam. Every chamber 6 extends into two adjacent blocks of closed cell foam. Compared to a prior art fender, the marine fender comprising a core 3 of closed cell foam with chambers 6 therein and elastically deformable objects 7 therein, can be lighter and or smaller and/or more compact to obtain the same or similar energy absorbing capacity as the prior art fender. Should a vessel nevertheless require a relatively large area of the hull to be covered by the fender and/or a relatively large thickness of the fender, a layer of relatively high density foam may be provided additionally, which still may result in a lighter fender than using a prior art fender.

Figure 2 a shows a schematic side view of blocks of closed cell foam which are usable for manufacturing a fender according to a first aspect of the invention. Figure 2b shows a schematic side view of the opened-up blocks of closed cell foam of Figure 2a along the line A- A, and Figure 2c shows a schematic perspective view on the blocks of closed cell foam of Figure 2b. As closed cell foam is typically provided in solid premanufactured blocks, the blocks can be piled up to obtain a desired thickness of a fender. In case of substantially cuboid blocks, the sides with the largest surface area of two adjacent blocks can face each other to form two different layers. In Figures 2a, 2b and 2c, there are three layers 8a, 8b, 8c of such cuboid blocks of closed cell foam. Said different blocks and/or layers 8a, 8b, 8c of closed cell foam preferably have a mutually different density. As can be seen in Figures 2b and 2c, the core 3 comprises a plurality of chambers 6 substantially entirely surrounded by said closed cell foam 3. Each chamber 6 extends into two adjacent blocks 8a, 8b or 8b, 8c of closed cell foam. Each chamber 6 encloses an elastically deformable closed object 7. Said elastically

deformable closed object 7 preferably tightly fits in said chamber 6. In the embodiment of Figures 2b and 2c, the elastically deformable closed object 7 is a substantially spherical object. Figures 3a and 3b show schematic perspective views on two alternative opened-up blocks of closed cell foam, where the elastically deformable objects 7 have a different shape, i.e. a cylindrical shape with spherical ends. In this alternative embodiment, a longitudinal axis of said elongated elastically deformable closed objects 7 can extend along three different axes, of which two examples are shown in Figures 3a and 3b. The position of these objects 7 can vary along the fender, and can for example be adapted to where the highest impact loads may be expected. The elastically deformable closed objects 7 can have other shapes, but in order to enhance their resiliency, it is preferred to avoid shapes comprising ribs and/or corners. In an advantageous embodiment, as represented in Figures 2b and 2c, said elastically deformable closed object may be a ball-like object comprising a substantially spherical closed shell, which shell can for example comprise rubber. Said shell may be typically filled with air, for example pressureless air, i.e. with a pressure equal to the surrounding air pressure, such that the ball-like object can produce a bouncing effect similar to a bouncing ball when experiencing a high impact load. A rubber-like shell comprising air inside can absorb relatively high impacts without tearing or breaking due to the high restoring capacities of such a ball-like object. This is contrary to other classical springs, for example metal spiral springs, which can easily break once an impact is higher than a given limit. Alternatively, said elastically deformable closed object 7 could also be filled with rubber, or with a closed cell foam having a different density than the density of the surrounding closed cell foam. The elastically deformable closed objects 7 could also be a hollow object different from a ball -like object, such as for example shown in Figures 3a and 3b.

Figure 4 shows a schematic perspective view on a preferred step of a method for manufacturing a marine fender according to a second aspect of the invention. In order to advantageously prepare blocks of closed cell foam, as represented in Figures 2a, 2b and 2c, for the manufacturing of a fender 1 according to a first aspect of the invention, the invention also provides an very advantageous method for manufacturing such a fender 1. According to said method, at least one block of closed cell foam is provided, in which at least one hollow chamber is made, for example carved out. It is however preferred to provide at least two blocks of closed cell foam, or for example three blocks 8a, 8b and 8c. Then a first chamber part 6a can be provided, for example carved out, in a first block, for example in block 8c, more

specifically on one of the two large and wide sides 9, 10 of the cuboid block 8c. Preferably, a plurality of first chamber parts 6a is carved out in said side 9, which parts 6a are for example halves of a sphere. Corresponding second chamber parts 6b can then be provided in a second block, for example in a side 10 of block 8b, such that said first chamber parts 6a and second chamber parts 6b can together form a chamber extending over two adjacent blocks of closed cell foam. In a same block 8b, two sides 9 and 10 can both be provided with first and second chamber parts 6a, 6b. In a next step, an elastically deformable closed object 7 is inserted into the chamber 6, preferably, into a first chamber part 6a, preferably one elastic deformable closed object 7 in each first chamber part 6a. Advantageously, the balls are glued in the chambers, by means of an adhesive material well known the skilled person, e.g. glue or any other suitable adhesive material. The balls can alternatively be connected mechanically to the chamber e.g. by hooks or bayonet-connection. Many variants are possible.

As is illustrated in Figure 5, showing a schematic side view on a preferred step of a method for manufacturing a marine fender, the chambers 6 can then be closed by placing the other of the first or second chamber part, e.g. the second chamber parts 6b, in the first or second block, for example in block 8b, over the closed objects 7. The first and second chamber parts 6a, 6b are such that the closed objects 7 preferably tightly fit into the chamber 6 formed by said two chamber parts, and such that the closed cell foam of one block is in contact with the closed cell foam of an adjacent block in between said closed objects, as can be seen in Figure 2a. Once the desired thickness for the fender 1 has been reached and the core structure 3 of the fender 1 is ready, an intermediate layer 4 can be provided, which at least partly encloses the at last one block of closed cell foam, for example as shown in Figure 1. Then a coating 5 can be provided which at least partly, preferably fully, covers the intermediate layer 4. The coating 5 can also cover part of the core 3 which is not covered by an intermediate layer 4, as is for example the case in the embodiment of Figure 1, where the side of the fender 1 that is attached to a marine structure 2 is not entirely covered by the

intermediate layer 4, but is covered by the coating 5. For the purpose of clarity and a concise description, features are described herein as part of the same or separate embodiments, however, it will be appreciated that the scope of the invention may include

embodiments having combinations of all or some of the features described. It may be understood that the embodiments shown have the same or similar components, apart from where they are described as being different. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word 'comprising' does not exclude the presence of other features or steps than those listed in a claim. Furthermore, the words 'a' and 'an' shall not be construed as limited to 'only one', but instead are used to mean 'at least one', and do not exclude a plurality. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to an advantage. Many variants will be apparent to the person skilled in the art. All variants are understood to be comprised within the scope of the invention defined in the following claims.