Construction of gliding board and method of production

Abstract

A gilding board, which means of the kinds of sporting or leisure boards for sliding on waters, snow and land, was constructed by polyethylene foam material, in three-ply or above layers of constant density or different densities as its multi-layer of bard core, agglutinate with a layer of plastic polymer graphic film on one side of the board core and bonded with high tenacity of plastic protective board on the other side. The essence of the gliding board is its particular methodology of production by mechanically adhibiting instant injection of high temperature of compound thermoplastic substance on the surface of the first layer of the board core while bonding with a layer of plastic graphic film. Thereafter, cleaving a plastic protective board or polyethylene foaming skin with the third layer of board core, by adopting heat lamination method to viscose the second layer of board core with both graphic film layer plus plastic protective board layer, in which an outer core of media foam layer is being exempted between the graphic film layer and board core, and the plastic polymer protective board to board core, as a result of simplify the production process in making the board, less resources and material to be consumed during the production that leads environmental-friendly, reducing cost to be involved in production, but provides a great performance and substantially deep-set of the structure of the board. Three-ply board core enhances the greater crash-worthiness from water surfing, snow or land gliding, with provision of better comfort and a function of high security for users by smooth surface of board on both ends.

Description

FIELD OF THE INVENTION

This invention is related to gliding board, particularly means of all kinds of gliding devices for sporting and leisure purposes. The devices can be identified as surfboards, bodyboards, wakeboards, swimboards, kickboards, snow sleds, skimboards, grass-gliders, sand-gliders, etc. The unique production methods and multi-layers of board core give the advantages of simplification the manufacturing process, minimise the consumption of resources and material in production, reducing manufacturing cost, provides a better architecture of the board itself together with enhancing its steadfast of the board core for providing better safety and comfort performance for end-users.

BACKGROUND OF THE INVENTION

Generally, a gliding board is applied as a surfing board on waters which is formed by a single layer of polymer foam material with opened cell and low density or double layers with different densities, laminated together for performance of an inner board core, in which the board itself wrapped by crosslinked or non-crosslinked polyethylene by heat lamination, in between an outer board core of single layer of high density, closed-cell foam material performed as an essential media layer to bond to both sides of board core by heat lamination, to forming the surf boards.

Similar as surfing boards, another type of sports boards which normally used as a snow slider, usually composed of dual-layer with low density of polymer foam material as board core and essentially having a higher density, closed-cell foam material as media layer for better bonding, by heat laminating between the top and bottom sides of board core and top and bottom skin of the boards. Normally, the boards have hand rails apparatus and shaped the board as upward curve for speed acceleration.

Typically the bonding of plastic graphic film, in general the thickness would be between 1 mil to 5 mils, with one or above layers of plastic polymer film for covering the graphic artwork inside, should have laminated to no less than one layer of media backing foam or backing sheet, with thickness around 2 mils to 6 mils, and with higher density around 6 pounds PCI, for adherence to the polyethylene foam board core of sports boards by heat lamination and to protect the graphic imprint, in which augment the complexity and difficulty of production process and much resources to be expended and being not cost efficiency and effectiveness.

The impulsion of the cleave lamination between plastic protective board and the board core was the mezzanine plastic backing foam layer with higher density, normally this layer was in range of 2 mils to 6 mils in thickness and 6 pounds PCI in density. Being the resistance of polyethylene foam material involved the limitation of boding method, thereof, such sport boards were usually being made by this method.

SUMMARY OF THE INVENTION

The concernment of the invention to the gliding boards is the architecture of the three-ply board core in which omitted the two layers of outer core. The structure of the polyethylene board core is configured by four different ways of combination of triplex polyethylene foam material. First, the three-ply board core is configured by three layers of same density and thickness, preferably in range of 3 to 6 pounds PCI with thickness between 2 mils and 18 mils, or at the same density with different thickness. Further, it is applicable by adopting a different density with the same thickness or different thickness either; preferably the top two layers of the board core would be having the same higher density than the bottom layer. Density of both top two layers will be in a range of 3 to 6 pounds PCI with thickness at around 2 mils to 15 mils, to comparison with the bottom layer of board core, which have lower density at a range of 1 to 4 pounds PCI with thickness around 10 mils to 20 mils. The remarkable improvement over the existing congeneric sports boards was the structure of the polyethylene board core enabled for directly agglutinating, without the aid of outer core of backing foam or backing sheet, to the top plastic polymer graphic. film and the bottom plastic polymer protective board mechanically. By applying of this methodology, both two layers of backing foam or backing sheet on both ends of board core will be omitted as a result of cost saving on resources consumption and production cost would be minimized, and to be more environmental-friendly.

The improved methodology of bonding the plastic polymer graphic film to the polyethylene board core was made by adopting a layer of compound thermoplastic substance, a newly refined material for supersede the traditional bonding method of heat lamination. The compound substance consists of low density polyethylene, tackifying resin and ethylene vinyl acetate copolymer, to be furnaced with high temperature of 180 to 200 degree, thereafter, to be mechanically injected on the surface of the first layer of polyethylene board core. Generally, the thickness of the thin plastic polymer graphic film is under the range of 0.01 mil to 0.5 mil and the side with reverse graphic artwork imprinted will be adhesively cleaving, by the compound thermoplastic substance, approximately 0.1 to 0.8 mil in thickness, to the side of board core. Furthermore, in which the surface with graphic imprinted will be well protected against the frictions from extrinsic impacts. Being the air-cell from the board core have been filled up by the compound thermoplastic substance thereby the integration of the plastic polymer graphic film with the polyethylene board core will be adhesively agglutinated. To ensue a better performance of tenacity of the both layers, a pair or rollers will be applied while the injection mode has been performed in between the surface of the polyethylene board core and the plastic polymer graphic film, in which a top roller consists of pattern on its surface and the plain roller at the bottom will be pressurized on the graphic film to board core for a better interlock for the prevention of the graphic film to be tear-off from the board core, and with the provision of a greater smooth graphic skin of the gilding boards.

The other invention to the gliding boards is the production process of the adhesion of plastic polymer protective board to polyethylene board core. Traditionally, from prior generic bonding method of the protective board to board core, there would be a media layer, a mezzanine closed-cell, high density of polyethylene backing foam or backing sheet, which thickness was approximately 2 mils to 6 mils, would be adhered by heat lamination method to the board core for further easier bonding with the protective board. The present invention is to omit the function of the mezzanine polyethylene backing foam as media, but to directly agglutinate the board core with the plastic polymer protective board by adopting the new methodology of dual-layer of thermoplastic polymer substance as the way for replacement of heat lamination of board core with backing foam to plastic protective board. It is a new invented method that separately applying two furnaces with high temperature around 180 to 200 degree for melting the polymer substance. These two adhesive elements are either low density polyethylene or high density polyethylene. These two layers of thermoplastic polymer substance will be injected simultaneously with same pace, on one side of the third board core. Thickness of the first layer of polymer substance will be in range of 0.1 mil to 0.5 mil and the second layer will be in range of 2 mils to 5 mils. The function of the first layer is to fill in the air cells on the surface of polyethylene board core by the polymer substance to enhance the stiff of the board core. Thereafter, the second layer of polymer substance is to agglutinate both board core with plastic polymer protective board, in which the thickness is around 0.2 mil to 0.8 mil, to perform a better bonding for the gliding boards. This method is to viscose the board core with plastic polymer protective board in a better condition that not easily for tearing from frictions and conclusion, and bonding without the aid of backing foam or backing sheet, but to be directly agglutinated, not by generic hot lamination, as a result of less production process will be made, cost saving on resources consumption and much eco-friendly to the earth.

Another invention on the polyethylene board core is applying three layers of polyethylene foam as the core of the gliding board. This improved core design is to provide a better function of board core as a cushion itself, to alleviate the impacts and hurtle from gliding in speed and to perform a better protection for users. Generally, from prior art boards, the structure of the boards were made of one layer or two layers of polyethylene foam, with lower density, approximately at two pounds PCI with 10 mils to 15 mils foam board as board's inner core, thereafter laminated with one layer of closed-cell but high density of polyethylene foam sheet, approximately at six pounds PCI with 2 mils to 6 mils thickness, by heat lamination method to bonding the outer core on both sides of the inner core, to form as an outer core for the function of protection of the inner core and further heat lamination with plastic polymer protective board and plastic polymer skin at the top. However, by means of one or two layers of inner board core was not effective for alleviation of impulse from waters and snow while gliding. Therefore, the present invention is to enhance the structure of the board core into three layers, in which the first two layers will have the same higher density than the bottom layers, to intensity the cushiony function of the polyethylene foam core. Normally the density will be around 3 to 6 pounds PCI with 2 mils to 15 mils in thickness. The bottom layer is to alleviate the impulse of the friction while gliding on land, waters or snow and to sustain the pressure from the users when lying or sitting on the top of the board gliding. Normally this layer of foam core will be lower density but in same thickness as in second layer of board core, approximately at round 1 to 4 pounds PCI with thickness at around 10 mils to 20 mils.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view of a prior art sports board structure.

FIG. 2 is a cross-sectional view of new invention gliding board structure with same density on the first two layers of board core.

FIG. 3 is a cross-sectional view of new invention gliding board structure with different density on the first two layers of board core.

FIG. 4 is a perspective view of nineth embodiment of the gliding board.

FIG. 5 is a partially schematic view of the new methodology of bonding of plastic polymer graphic film to polyethylene board core of the invention.

FIG. 6 is a partially schematic view of the new methodology of viscose of polyethylene board core of the invention.

FIG. 7 is a partially schematic view of the method of manufacturing of gliding board of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 shows that a structure of a prior art sports board 13, the inner board core is formed by heat lamination of 13 and 14, a lower density, closed-cell polyethylene foam material, thereon, 12 the outer core of backing foam board sheet, with higher density and closed-cell foam, heat laminated to 13 for further heat lamination of the surfaces to 11, the plastic polymer graphic film 15, a layer of backing foam sheet, by heat lamination to 15 as a media laminate with 16, the plastic polymer protective board

FIG. 2 shows a cross-sectional view of the structure of the invention in which three layers of polyethylene board core are in same thickness or in same density. Adopting the compound thermoplastic substance 18 for agglutination with 17 the plastic polymer graphic film to 19 first layer board core with high density with closed-cell polyethylene foam material, thereafter, 22 a dual-layer of thermoplastic polymer substance agglutinated with 23 the plastic polymer protective board to 21 third layer of polyethylene board core, a lower density with closed-cell polyethylene foam material, therewith, by heat lamination method for bonding 20 a same density, closed-celled polyethylene foam material as 19 to 21, pre-shaped thereafter by heat lamination with 19, 17 the plastic polymer graphic film extending from the top portion to the plastic protective board at the bottom and formed the gliding board.

FIG. 3 shows a similar cross-sectional view of the structure of the invention as at FIG. 2, but in which three layers of polyethylene board core are in different thickness or density. Adopting the compound thermoplastic substance 25 for agglutination with 24 the plastic polymer graphic film to 26 first layer board core with high density with closed-cell polyethylene foam material, thereafter, 29 a dual-layer of thermoplastic polymer substance agglutinated with 30 the plastic polymer protective board to 28 third layer of polyethylene board core, a lower density with closed-cell polyethylene foam material, therewith, by heat lamination method for bonding 27 a same density, closed-celled polyethylene foam material as 26 to 28, pre-shaped thereafter by heat laminating with 26, 24 the plastic polymer graphic film extending from the top portion to the plastic protective board at the bottom and formed the gliding board.

FIG. 4 shows a perspective view of nineth embodiment of the present invention of a gliding board consists of a plastic polymer graphic film 32 at the top with graphic imprint inside 34 and pattern on the surface 31, by agglutination of compound thermoplastic substance 33 to the first layer of polyethylene board core 35 and by heat lamination to the second layer of polyethylene board core 36 and third layer of polyethylene board core 37. Thereto, with aid of a dual-layer of thermoplastic polymer substance 38 for cleave agglutinate with 39 the plastic polymer protective board. Finally, the top plastic polymer graphic film extending from the top portion to the plastic protective board at the bottom and formed the gliding board.

FIG. 5 shows a schematic view of the new methodology of bonding of plastic polymer graphic film to polyethylene board core of the invention. By shoving the compound thermoplastic substance which contains low density polyethylene, tackifying resin and ethylene vinyl acetate copolymer in the 40 furnace with high temperature of 180 to 200 degree, thereafter, going through the T-die for injection a layer of compound thermoplastic substance in between of 41 plastic graphic film and 44 first layer of polyethylene board core which are both in roll format and to be bonded and pressurized by 42 the upper pattern roller and 43 a lower plain roller for reinforcement of the stiffness of the graphic film to board core.

FIG. 6 shows a schematic view of the new methodology of viscose of the polyethylene board core of the invention. By shoving either low density polyethylene or high density polyethylene into both 45 and 46 furnace with high temperature of 180 to 200 degree, thereafter, going through the T-die for injection a dual-layer of thermoplastic substance on the surface of 49 third layer of polyethylene board core which is exported from roll format and to be bonded and pressurized by 47 the upper roller and 48 a lower roller for reinforcement of the stiffness of the board core for replacement of the backing foam sheet laminated to the board core for further heat lamination of plastic polymer protective board.

FIG. 7 is a schematic view of the method of manufacturing of gliding board of the invention. By applying heat lamination method through 51 the febrifacient and pushing through the pair of roller for pressurizing, to bonding either 50 the plastic polymer protective board and 53 third layer of polyethylene board core, or 50 the second layer of polyethylene board core to 53 the third layer of polyethylene board core with plastic polymer protective board, or 50 the first layer polyethylene board core bonded with plastic polymer graphic film to 53 the pre-shaped second plus third polyethylene board core bonded with plastic polymer protective board. Thereafter, behind the rollers, press the materials for having a curve shape at the front of the board, and 52 is the semi-product of the gliding board and will be processed afterwards by further heat lamination to extending the graphic film from top to the bottom of plastic polymer protective board to form the gliding board.

The foregoing description should be considered as illustrative only of the principles of the invention. Since numerous modifications and changes will be readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and, accordingly, all suitable modifications and equivalents, including the composition by means of the number of layers, the densities of the materials and the thickness of each layers, may be resorted to, falling within the scope of the invention.

Claims

1. A gliding board comprising

a top plastic polymer graphic film,

a bottom plastic polymer protective board, and

a three-ply polyethylene board core located between the top plastic polymer graphic film and the bottom plastic polymer protective board, the three-ply polyethylene board core including closed-cell, polymer foam material.

2. The gliding board as claimed in claim 1, wherein the top plastic polymer graphic film has a thickness of between 0.01 mil to 0.5 mil, with a reverse graphic imprint on one side.

3. The gliding board as claimed in claim 1, wherein a lamination between the top plastic polymer graphic film and a first layer of the three-ply polyethylene board core is agglutinated by a compound thermoplastic substance, the compound thermoplastic substance includes a mixture of low density polyethylene, tackifying resin and ethylene vinyl acetate copolymer having a thickness of approximately 0.1 to 0.8 mil.

4. The gliding board as claimed in claim 1, wherein a first layer of the three-ply polyethylene board core includes closed-cell foam material having a density in a range of 3 to 6 pounds PCI with a thickness of 2 mils to 15 mils.

5. The gliding board as claimed in claim 4, wherein a second layer of the three-ply polyethylene board core includes closed-cell foam material having a density in a range of 3 to 6 pounds PCI with a thickness of approximately 2 mils to 15 mils.

6. The gliding board as claimed in claim 5, wherein a third layer of the three-ply polyethylene board core includes closed-cell foam material having a density in a range of 1 to 6 pounds PCI with a thickness of approximately 10 mils to 20 mils.

7. The gliding board as claimed in claim 1, wherein a thickness of the three-ply polyethylene board core is approximately 2 mils to 20 mils.

8. The gliding board as claimed in claim 1, wherein a density of the three-ply polyethylene board core is approximately 1 to 6 pounds PCI.

9. The gliding board as claimed in claim 1, wherein the bottom plastic polymer protective board has a thickness of approximately 0.2 mils to 0.8 mils.

10. The gliding board as claimed in claim 1, wherein a lamination between the bottom plastic polymer protective board with a third layer of the three-ply polyethylene board core is achieved by a dual-layer of thermoplastic substance for cleave agglutination.

11. The gliding board as claimed in claim 10, wherein a thickness of a bottom layer of the dual-layer of thermoplastic substance is 0.1 mil to 0.5 mil and a top layer of the dual-layer of thermoplastic substance is in a range of 2 mils to 5 mils.

12. The gliding board as claimed in claim 11, wherein the dual-layer thermoplastic substance consists of one of high density polyethylene and low density polyethylene.

13. The gliding board as claimed in claim 1, wherein the top plastic polymer graphic film extends to attach to the bottom plastic polymer protective board.

14-20. (canceled)