Surfboard and method of manufacturing
A surfboard includes a core covered with a laminate and having perforations where the user places his feet, in order to prevent air blisters from forming between the core and laminate. The core is formed from an extruded closed-cell polystyrene foam block which has been shaped by restraining it against a shaped form using shaped restraining tools and straps, and heating it; and by cutting using a hot wire. The core is laminated with FIBERGLAS® and epoxy resin, and the perforations are formed using a perforating tool that has a planar or curved working surface and one or more heated needles extending perpendicularly from the working surface.
This application is a divisional of U.S. patent application Ser. No. 10/403627, filed Mar. 28, 2003, and currently co-pending.
FIELD OF THE INVENTIONThe present invention relates generally to water sports equipment. The present invention relates more particularly, though not exclusively, to a water sports board made of laminated closed-cell foam with perforation vents in the laminate for preventing deformations of the surface of the board. The present invention is useful for surfboards, sailboards, wave skis and other applications requiring buoyant, rigid, and durable boards.
BACKGROUND OF THE INVENTIONMany water sports boards and craft (e.g., surfboards, sailboards, wave skis, etc.) are made of expanded open-cell rigid polymer foam. Where the discussion herein refers to a surfboard or “board”, it applies to surfboards, sailboards, body boards, wave skis, and other types of water sports boards and craft as well. To make a board of open-cell foam, a “molded method” is often used. Specifically, in using the molded method, a mold of the board is filled with liquid foam, which expands to fill the mold. The foam is then allowed to harden in the mold until it is rigid. The rigid foam is made of air cells that are open to each other. The cells at the surface of the rigid foam are also open to the atmosphere. Another method of board formation is the traditional hand-shaping method wherein the board is cut, or shaped, from a block of expanded foam.
A problem with open-cell foam is that it absorbs water. To minimize this absorption of water, the open-cell foam is often coated with a water-proofing material, such as FIBERGLAS® and epoxy resin, to seal the board and make the board more durable.
Unfortunately, even though covered with a water-proofing material, in the event the board is bumped or the water-proofing materials are breached, the board absorbs water through that breach. When the open-cell foam has absorbed water, the open-cell foam is much heavier than when it is dry. A board made with open-cell foam that has absorbed water is significantly more difficult to use because of its increased weight and decreased buoyancy. Furthermore, a board that has absorbed water must be dried out before it is stored, in order to avoid deterioration of the board.
In light of the above, it would be advantageous to make a board having similar buoyancy, rigidity, and durability characteristics of a board made from open-cell foam, yet does not absorb water into the foam material if the water-proofing material is breached.
SUMMARY OF THE INVENTIONThe advantages of open-cell foam can be obtained, and its disadvantages avoided, by using a closed-cell foam in its place. Closed-cell foam is extruded, and then formed into the shape of a board by hand shaping by a professional board shaper, or by using CNC machining into the desired board shape, instead of expansion into a mold as is the process used with open-cell foam. In a preferred embodiment, closed-cell foam may be made of polystyrene. An advantage of closed-cell foam is that it does not substantially absorb water. A board made of closed-cell foam does not become substantially heavier due to water absorption, and retains its physical properties, including buoyancy and ease of use for water sports and other purposes. Closed-cell foam also dries out much more quickly than open-cell foam, without yellowing or damage areas.
The present invention includes a surfboard made of laminated closed-cell foam. The laminate is perforated at places where pressure is likely to be applied to the surface of the board (e.g., where a user is likely to stand), such that air, or gas, can escape from between the laminate and foam. This avoids the formation of air blisters, thus overcoming a disadvantage to the use of laminated closed-cell foam.
Closed-cell foam extruded into a rough board shape may be referred to as a “blank” or “block”. The blank may be heated, pressed and cut into a desired shape. The shaped blank may be laminated with water-proofing materials, such as FIBERGLAS® and epoxy resins, to make the board more durable.
To make a board of the present invention, a blank is treated with heat and pressure to shape it, if desired, and to anneal the surface (close any open cells). The board is shaped by placing the blank against a shaped form, pressing the blank against the form by use of tension devices (e.g., restraining tools and straps), heating the blank using heated water vapor, then cooling it until it holds its new shape. The heated and pressed blank may be further shaped by cutting it with a hot wire. The cut and shaped blank or “core” is laminated with FIBERGLAS® and epoxy resin. Once laminated, the laminate is perforated in multiple locations using a tool that has a substantially planar or curved surface with multiple perforation needles extending therefrom. The perforations are formed by pressing or rolling the needled surface of the tool against the laminate thereby penetrating the laminate. The board may have one or more optional fins.
BRIEF DESCRIPTION OF THE DRAWINGSThe novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
A preferred embodiment of the Improved Surfboard And Method Of Manufacturing of the present invention is shown in
Board 100 may have one or more optional fins 160. Board 100 shown in
Referring to
Blank 210 may be shaped in the following manner. Blank 210 is initially placed in initial position 230 (shown in dashed lines) upon shaped form surface 254 of form 250. Restraining tool surface 264 of each restraining tool 260 is placed upon blank 210. Straps 270 are attached to restraining tools 260 and to form 250. Tension is applied to straps 270 such that each restraining tool surface 264 is pressed against blank 210, and blank 210 is pulled toward and pressed against shaped form surface 254 of tool 250. At the same time, heat may be applied to blank 210 from heat source 272.
The application of heat and tension to blank 210 causes blank 210 to be conformed to shaped form surface 254 of form 250 and to restraining tool surfaces 264. In a preferred embodiment, the heat provided by heat source 272 may not exceed 180 degrees Fahrenheit, and for an exposure period of less than 30 minutes. Outside temperature variations and humidity may affect the heat levels and duration applied to form the blank 210. Other heating periods and temperatures may be used, however, without departing from the present invention. Rather, the specific temperature and time periods are merely exemplary of a preferred embodiment, and no limitation is intended.
Once heated, blank 210 is then allowed to cool until it holds the shape of shaped form surface 254 of form 250 and restraining tool surfaces 264 in shaped position 240 without being pressed against shaped form surface 254 or restraining tool surfaces 264. Restraining tools 260 and straps 270 are then removed from blank 210, and blank 210 is removed from form 250. Form 250 and restraining tools 260 are made of one or more materials that can withstand pressure and heat required to shape blank 210. In a preferred embodiment, form 250 may be made from wood or metal, and restraining tools 260 may be made from wood or metal, however, other materials having suitable strength and resistance to moisture may be used.
While two tools 260 have been shown in
Referring now to
Once in position, restraining straps 270 are attached to tools 260 and the straps 270 are tightened such that the stack of blanks 210 and sheets 274 are brought tightly against form 250. As the straps 270 are tightened, the blanks 210 and sheets 274 are deformed to match the curvature of tools surfaces 264 and form 250. When the blanks 210 are in the proper form against form 250, heat is supplied by heat source 272 for a predetermined period of time. At the end of that heating time period, the heat source is removed, and the straps are removed, yielding several blanks 210 having the curvature of curved surface 254 of form 250.
Flexible metal heat-conducting sheet 274, in a preferred embodiment, is made from aluminum, however, it is to be appreciated that other materials having similar flexibility and heat transfer characteristics may be used. The sheet 274 provides for separation between blanks 210 as well as conducts heat from heat source 272. The conduction of heat between blanks 210 is important because blanks 210, by their nature, are good heat insulators. By providing a heat conduction path between blanks 210 in the stacked configuration, each blank is exposed to sufficient heat across its entire surface during the heating period to provide for the formation of blank 210 into the curved form 240 (shown in
Referring now to
Referring now to
Referring to
Air blisters 410 may form where the user places his feet on board 100, however, blisters 410 can also be caused by other sources of pressure upon board 100 at other places on board 100. Each air blister 410 causes a deformation of laminate 120, which can damage laminate 120 and decrease the strength of board 100 and make it more difficult to use. Additionally, exposure of the board 100 to heat sources, such as the sun, may cause the formation of air blisters 410 between the core 110 and the laminate 120 when the board is not properly vented.
In a preferred embodiment, perforations 130 are formed through laminate 120 of board 100 at the time of manufacturing and prior to use, and thus, prior to the formation of any bubbles or blisters 420. As a result, there is little or no chance for a blister to form, because any air or gas that develops between laminate 120 and core 110 escapes through perforation 130 before it can develop into a blister 410.
As used herein, it is to be understood that “little water” comprises the meanings of “no water” and “substantially no water” as well as the meaning of “a very small amount of water more than no water.” No measurable or significant weight change is caused by any moisture absorption into the surfboard or surf craft.
Each perforation vent 130 is formed by a perforating tool 610 which has a perforating tool body 620 having a working surface 624, and at least one perforation needle 630 extending from working surface 624. Each perforation vent 130 is formed as follows. Working surface 624 is placed adjacent laminate 120 and perforating tool 610 is manipulated such that at least one needle 630 is translated in the direction 640 toward board 100 until needle 630 penetrates (or perforates) laminate 120 to form an airway, or vent 130, through the laminate 120.
Perforating tool 610 is then manipulated such that each at least one needle 630 is then translated in the direction 650 opposite the direction 640 in which needle 630 points, and needle 630 is withdrawn from laminate 120, leaving a perforation, or vent, 130 formed in laminate 120 by each needle 630 that penetrates laminate 120. In a preferred embodiment of the present invention, each needle 630 does not penetrate core 110. In an alternative embodiment of the present invention, at least one needle 630 at least partially penetrates core 110.
Needles 630 may be made of stainless steel. Needles 630 may alternatively be made of any other material having sufficient strength to perforate laminate 120. In a preferred embodiment of the present invention, at least one needle 630 is heated to facilitate penetration of laminate 120. If needles 630 are heated, they may be heated to a range of 200 to 250 degrees F. Alternatively, needles 630 may be heated to a temperature in the range from zero degrees Kelvin to the melting point temperature of the material of which the needles 360 are made. In an alternative embodiment of the present invention, each needle 630 is not heated.
In an alternative embodiment, needles 630 may be formed with grooves or threads 635 like a traditional drill bit having a small diameter. In such an embodiment, perforating tool 610 may be capable of rotating needle 630 in direction 633 to bore a perforation vent 130 through laminate 120.
Referring now to
Referring now to
As shown in
The diameter 636 of perforation needle 630 may vary between 0.005 inches and 0.05 inches, and in a preferred embodiment, is 0.008 inches. It is to be appreciated that although perforation needle 630 has been depicted in the Figures as a cylindrical needle, no limitation as to the cross-sectional shape is intended. To the contrary, the cross-sectional shape of the perforation needle 630 may vary, including but not limited to, oval, rectangular, square, or other shapes. Regardless of the cross-sectional shape of perforation needle 630, the cross-sectional area of vent 130 remains small enough to allow the exit of gasses collecting between material 120 and core 110.
Alternatively, curved perforating tool 1010 can be manipulated such that curved working surface 1024 does not actually contact laminate 120 thereby avoiding any damage to laminate 120 from perforating tool 1010. For instance, as curved perforating tool 1010 is rolled clockwise above laminate 120, each needle 630 rotates as the tool 1010 is translated, such that each needle 630 remains substantially perpendicular to laminate 120 as it forms perforation vent 130. This is particularly useful when tool 1010 is heated, and contact between tool 1010 and laminate 120 may cause marks or blemishes to form.
In
Referring now to
The assembly of tools, blanks separated by sheets, and secured to the form, is then exposed to heat from a heat source for a predetermined time period in step 1210. At the expiration of that time period, the assembly is cooled for a second predetermined time period in step 1212.
Once cooled, the tools and straps are removed, and the blanks are removed from the form and separated from the conductive sheets in step 1214.
Once thoroughly cooled, the now-formed blanks are shaped to form a core and covered with sealing material in step 1216. Once the sealing material is dry, a number of vents are formed through the sealing material in final step 1218 to yield an Improved Surfboard of the present invention.
While the particular Improved Surfboard And Method Of Manufacturing as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
Claims
1. A method of manufacturing a surfboard, comprising the steps of:
- providing a core covered by a laminate; and
- forming at least one perforation in said laminate.
2. A method of manufacturing as in claim 1, wherein:
- said step of forming at least one perforation in said laminate, comprises the steps of providing a perforating tool having a working surface and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface; manipulating said perforating tool such that said at least one needle is translated substantially in the direction that said at least one needle points, such that said at least one needle penetrates said laminate; and manipulating said perforating tool such that said at least one needle is translated substantially opposite the direction that said at least one needle points, such that said at least one needle is withdrawn from said laminate.
3. A method of manufacturing as in claim 2, wherein:
- said at least one needle is heated.
4. A method of manufacturing as in claim 2, wherein:
- said working surface is substantially planar.
5. A method of manufacturing as in claim 1, wherein:
- said step of forming at least one perforation in said laminate, comprises the steps of providing a perforating tool having a working surface curved in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface; rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.
6. A method of manufacturing as in claim 5, wherein:
- said at least one needle is heated.
7. A method of manufacturing as in claim 1, wherein:
- said step of forming at least one perforation in said laminate, comprises the steps of providing a perforating tool having a working surface having substantially the shape of an arc of a circle in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface; rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.
8. A method of manufacturing as in claim 7, wherein:
- said at least one needle is heated.
9. A method of manufacturing as in claim 1, wherein:
- said step of providing a core covered by a laminate, comprises the steps of: extruding closed-cell foam into a blank; shaping said blank into a core; and covering said core with a laminate.
10. A method of manufacturing as in claim 9, wherein:
- said step of covering said core with a laminate, comprises the steps of covering said core with FIBERGLAS®; and covering said core with epoxy resin.
11. A method of perforating a laminate, comprising the steps of:
- providing a laminate;
- providing a perforating tool having at least one needle; and
- manipulating said perforating tool such that said at least one needle perforates said laminate.
12. A method as in claim 11, wherein:
- said at least one needle is heated.
13. A method as in claim 11, wherein:
- said step of providing a perforating tool having at least one needle, comprises the step of providing a perforating tool having a working surface and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface.
14. A method as in claim 11, wherein:
- said step of manipulating said perforating tool such that said at least one needle perforates said laminate, comprises the steps of manipulating said perforating tool such that said at least one needle is translated in the direction that said at least one needle points, such that said at least one needle perforates said laminate; and manipulating said perforating tool such that said at least one needle is translated opposite the direction that said at least one needle points, such that said at least one needle is withdrawn from said laminate.
15. A method as in claim 11, wherein:
- said step of forming at least one perforation in said laminate, comprises the steps of: providing a perforating tool having a working surface having substantially the shape of an arc of a circle in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface; rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.
16. A perforating tool, comprising:
- a perforating tool body having a working surface; and
- at least one needle extending from said working surface.
17. A perforating tool as in claim 16, wherein:
- said working surface is substantially planar.
18. A perforating tool as in claim 16, wherein:
- said working surface is substantially curved in at least one dimension of said working surface.
19. A perforating tool as in claim 16, wherein:
- said working surface substantially has the shape of an arc of a circle in at least one dimension of said working surface.
20. A perforating tool as in claim 16, wherein:
- each said at least one needle is substantially parallel to each other said at least one needle.
21. A perforating tool as in claim 16, wherein:
- each said at least one needle is substantially at an angle to each other said at least one needle.
22. A perforating tool as in claim 16, wherein:
- said at least one needle is substantially perpendicular to said working surface at the point where said at least one needle extends from said working surface.
23. A perforating tool as in claim 16, wherein:
- said at least one needle can be heated.
Type: Application
Filed: Oct 21, 2004
Publication Date: Mar 24, 2005
Inventor: Javier Huarcaya-Pro (Carlsbad, CA)
Application Number: 10/970,777