SURFBOARD PROTECTOR

Abstract

An adjustable surfboard transporter that protects the most fragile parts of a surfboard whether in transit or for storage. The surfboard protector or transporter can be adjusted in size to accommodate several different surfboard lengths. The transporter may focus on the most vulnerable parts of the surfboard protecting the nose, tail, and rails. In particular, an adjustable protective cover for the fragile outer perimeter of a surfboard is described. The light and durable form of protection cushions the surfboard to prevent damage from impacts. The system may be easy to use, quick to assemble, and may be broken down to an easily-transportable or storable size.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/870,679, filed Aug. 27, 2010, entitled “Surfboard Protector”, which claims benefit of priority of the following U.S. Provisional Patent Applications: Ser. No. 61/275,378, filed Aug. 28, 2009, entitled “Adjustable Surfboard Transporter”; Ser. No. 61/278,937, filed Oct. 14, 2009, entitled “Adjustable Surfboard Transporter”; and Ser. No. 61/334,038, filed May 12, 2010, entitled “Attachment Device for Segmented Surfboard”. In addition, this application claims benefit of priority of U.S. Provisional Patent Application Ser. No. 61/456,949, filed Nov. 15, 2010, entitled “Single Layer Concept”. These applications are all owned by the owner of the current application and each is incorporated by reference in its entirety.

BACKGROUND

The fiberglass construction of modern surfboards is necessary for weight and maneuverability. However, given the harsh surf environment, modern surfboards are prone to accumulating dings, which are dents or other damage due to collision with rocks, etc. Dings also occur as the result of travel, especially as it is becoming more common for surfers to bring their surfboards to experience surfing at locations around the world. In fact, surf travel is a sizable niche in the travel industry.

Several products exist to address the problem of surfboard damage during travel. These products each have various drawbacks, which in many cases can be categorized as follows. First, the product's performance does not warrant the price. Second, many products have difficulty achieving a custom fit, as necessary for varying sizes of surfboards. For example, some products include bags in which a surfboard may be inserted, where the bag is equipped with foam for ding protection. Unfortunately, these products are not adjustable and further lack protection against sudden sharp impacts. Other products work to focus protection on the nose or tail of the surfboard. However, these lack protection of surfboard rails. Still other products protect the nose, tail, and rails, but not to a sufficient degree, and not in a way that is adjustable to fit varying sizes of surfboards. Additional attempts at protecting surfboards include large hard suitcases in which a surfboard may be stored during travel. However, such solutions are generally very heavy and expensive.

In more detail, surfboard protection devices have been disclosed in, e.g., the Geronimo (U.S. Pat. No. 4, 719,952), Mori (U.S. Pat. No. 4,586,451), and Joyce (U.S. Pat. No. 3,374,495) patents. All three designs describe a molded, wrap-around protector. None of these designs, however, provide both comprehensive protection of key areas such as the nose, tail, and rails, nor are they especially versatile to use. Joyce (U.S. Pat. No. 3,374,495) discloses a nose bumper that affixes to the tip of a surfboard by means of an adhesive. Triangular-shaped cut outs are made along its upper and lower walls to increase its flexibility. Although form-fitting, the design lacks protection in the tail and rails and is a permanent fixture. Mori (U.S. Pat. No. 4,586,451) utilizes a system of partial covers to protect the surfboard. These are forced on non-adhesively and fastened by belts. The coverage provided is limited, and it may be unwieldy to transport the numerous parts and awkward belts. Geronimo (U.S. Pat. No. 4,719,952) employs a design that provides protection of the areas most susceptible to damage. His design, however, is non-adjustable and would fit the form of just a single surfboard. A user would be required to purchase a custom cover for each surfboard owned.

SUMMARY

An adjustable and protective cover for the fragile outer perimeter of a surfboard is described. Intended in one embodiment for preparing a surfboard before travel, the light and durable form of protection cushions the surfboard to prevent damage from impact sustained en route. One embodiment employs a nose protector, a tail protector, and railguards that protect the rails of the surfboard. The railguards may be attached to each other and to the nose or tail protector in an adjustable fashion, such as by an adaptor that can attach to the railguards in a number of positions.

In one implementation, the invention is directed towards an adjustable assembly for protecting a surfboard during transit and/or in storage. The invention includes a nose protector, the nose protector structured and configured to receive at least a portion of a nose of a surfboard. The invention also includes a tail protector, the tail protector structured and configured to receive at least a portion of a tail of a surfboard. First and second left railguards are included that are structured and configured to receive at least a portion of a left rail of a surfboard, where the first left railguard is configured to be attached to a left side of the nose protector and where the second left railguard is configured to be attached to a left side of the tail protector. First and second right railguards are included that are structured and configured to receive at least a portion of a right rail of a surfboard, where the first right railguard is configured to be attached to a right side of the nose protector and where the second right railguard is configured to be attached to a right side of the tail protector. A left adaptor and a right adaptor are included, the left and right adaptor structured to connect the first and second left railguards and the first and second right railguards, respectively, such that the first and second left railguards and the first and second right railguards may be separated by one of a variety of distances while being held securely by the left and right adaptor, respectively.

Implementations of the invention may include one or more of the following. At least one of the nose protector, the tail protector, and one of the railguards may be constructed of a bilayer, a first layer constructed of a foam, and a second layer constructed of a hard shell material. The first layer may be made of polyethylene foam or a biofoam, and the second layer may be made of a material selected from the group consisting of Surlyn®, a biodegradable material such as cardboard, ABS plastic, and combinations thereof The assembly may further include a third layer coating the second layer on the face of the second layer opposite the first layer, and the third layer may be made of rubber. A portion of the railguards may define a slot and a portion of the nose or tail protector may have formed thereon a protrusion, such that engagement of the protrusion and the slot causes the railguard to be attached to the nose protector or tail protector a portion of the railguards defines a groove and a portion of the nose protector has formed thereon a tongue, such that engagement of the tongue and the groove causes the railguard to be attached to the nose protector. A portion of the railguards may define a groove and a portion of the tail protector may have formed thereon a tongue, such that engagement of the tongue and the groove causes the railguard to be attached to the tail protector. At least a portion of the railguards may have corrugations formed therein. The adaptor may snap-fit to a pair of railguards. The adaptor may have formed thereon, on one or both edge(s), a nub for engagement with an edge of a railguard. At least a portion of the railguards may have corrugations formed therein, and a height of the corrugations may be substantially equal to a height of the protrusion.

In another aspect, the invention may be directed to an adjustable assembly for protecting a surfboard during storage, including a nose protector configured to receive a nose of a surfboard, a tail protector configured to receive a tail of a surfboard, and means to adjust a distance between the nose protector and the tail protector, the adjustment means including one or more railguards configured to receive at least a portion of a rail of a surfboard.

Implementations of the invention may include one or more of the following. The two railguards may span a length of each surfboard rail. The nose protector and the tail protector may be each composed of a bilayer structure, the bilayer structure including a hard exterior and a soft form interior. Each of the nose protector, the tail protector, and the railguards may be structured and configured to attach to a surfboard by a friction fit. An adaptor may be included that is configured to attach two railguards together, the adaptor attaching to each railguard by a friction fit. At least one railguard may be attached to the nose protector using an attachment mechanism, and moreover at least one railguard may be attached to the tail protector using an attachment mechanism.

Another embodied system or assembly employs three basic elements. One piece fits closely to the outer perimeter of the upper half of the surfboard. A second piece does the same for the lower half of the surfboard. A third piece fits over a series of channels that line the sides of each arm creating a union. When necessary, the halves can be spaced apart in order to accommodate a different length of surfboard. The third piece may bridge the divide between the two halves, align with the channels, and help secure the cover to the surfboard. This feature makes the design adjustable and thus effective for multiple surfboards.

Additional advantages of the invention may include one or more of the following. The system may be adjusted to fit multiple sizes and can be used interchangeably between surfboards of a similar shape. Further, certain elements of the assembly can be made universal to fit surfboards of a different shape, e.g., railguards may protect the rails of a modern thruster and a modern fish. The system is reusable. The system may be easy-to-use, quick to assemble, versatile, adjustable, effective against damage, durable, practical to store, and may provide a comprehensive solution to the problem of surfboard damage during travel. Other advantages will be apparent from the description that follows, including the figures and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective exploded view of the components of a surfboard protector according to an embodiment of the invention, surrounding a surfboard.

FIG. 2 illustrates various views of a nose protector according to an embodiment of the invention, as well as views of the nose protector attached to railguards.

FIG. 3 illustrates various views of a tail protector according to an embodiment of the invention, as well as views of the tail protector attached to railguards.

FIG. 4 illustrates various views of a railguard and adaptor structure according to an embodiment of the invention.

FIG. 5 illustrates an alternative device that may be employed to connect a railguard to the nose or tail protectors.

FIG. 6 illustrates an alternative adaptor configuration.

FIG. 7 illustrates a perspective view of the embodiment of the surfboard protector in use.

FIG. 8(A) and (B) illustrate perspective views of a nose protector employing molded pulp.

FIG. 9(A) and (B) illustrate perspective views of a tail protector employing molded pulp.

FIG. 10(A)-(D) illustrate perspective views of a nose protector employing molded pulp made in a clam shell design.

FIG. 11(A)-(D) illustrate perspective views of a tail protector employing molded pulp made in a clam shell design.

FIG. 12(A) and (B) illustrate perspective views of a rail guard employing molded pulp.

FIG. 13(A) and (B) illustrate perspective views of an adaptor employing molded pulp.

FIG. 14 illustrates a surfboard protector in an exploded view.

FIG. 15 illustrates use of a system according to the principles disclosed here, in use for protecting a centerboard for a sailboat.

FIG. 16 illustrates use of a system according to the principles disclosed here in connection with protecting any product or object with an extended perimeter, including a tabletop, a laptop computer, a mirror, or the like.

FIG. 17(A)-(D) illustrate various embodiments of corner protectors and edge protectors that may be employed according to the principles disclosed here.

FIG. 18(A)-(E) illustrate an alternative set of embodiments of corner protectors and edge protectors that may be employed according to the principles disclosed here.

FIG. 19(A)-(C) illustrates a corner protector in an unfolded configuration, as well as a rectangular sheet of such unfolded corner protectors, indicating a manufacturing process for the same.

FIG. 20(A)-(E) illustrate perspective and detail views of a system according to the principles disclosed here, in connection with protecting a tabletop. With appropriate sizing, such a system may also be employed for protecting laptops, mirrors, sheets of glass, or the like.

FIG. 21(A)-(B) illustrate embodiments of the system according to the principles disclosed here in both an exploded configuration and an in-use configuration, respectively.

FIG. 22(A)-(C) illustrate views of a device which may accept an object having a nose or tail protector as described, the device allowing the object to be placed into a shipping container and shipped with a minimum of movement.

FIG. 23(A)-(C) illustrate views of a prior art shipping method (23(A)) as well as the device of FIG. 22(A)-(C) in use shipping five protected objects together.

DETAILED DESCRIPTION

Referring to FIG. 1, a perspective view is illustrated of a system or assembly 100 of an embodiment of the invention surrounding a surfboard 10. The system or assembly 100 includes a nose protector 200, a tail protector 500, a left railguard assembly, which in this embodiment has been split into two left railguards 300a and 300b, and a right railguard assembly, which in this embodiment has been split into two right railguards 302a and 302b. An attachment mechanism such as an adaptor 400a serves to join the two left railguard portions in a secure fashion and in the same way an attachment mechanism such as an adaptor 400b serves to join the two right railguard portions. Additional details about the nose and tail protectors and the railguards and attachment mechanisms are described below.

Referring to FIG. 2(A)-(E), additional details about the nose protector 200 are seen. In particular, the nose protector 200 includes nubs, protrusions, or ramps 202 and 204, hereinafter termed “protrusions”. These protrusions 202 and 204 engage slots 208 on the railguards 300a and 302a to hold the railguards securely to the nose protector. As is described in greater detail below, the railguards 300a and 302a may be equipped with ribs or corrugations, and the railguards may slide onto the protrusion of the nose protector in a fashion substantially parallel to the corrugations.

The protrusions may be slightly sloped and have substantially the same height as a rib or corrugated portion of the railguard. The female part may be a slit near the terminus of the railguard. In constructing the protector around the surfboard, first the nose protector and tail protector would be mounted on to their respective surfboard sections. The raised protrusions would be exposed and ready for insertion. Next, the railguard would be fitted over the rail. The terminus end with the slit or hole defined may be slid over the raised protrusion until the protrusion is fitted into this slit or hole. Next, the adaptor slides over the corrugations of each railguard, connecting both and bridging the gap of exposed surfboard. This procedure is then repeated for the railguards on the other side of the surfboard.

As may be seen in particular in FIG. 2(B), the nose protector 200 may have formed thereon an invagination 201 and a groove 203. These elements may allow the systems 100 to be conveniently stacked. Invagination 201 and groove 203 are also reference points for the insertion of the tip of the surfboard and a means of releasing the protrusions from their slots by squeezing the edges of these grooves.

Referring to FIG. 2(E), the system 100 may employ a bilayer construction, and this is also true of the nose protector 200 and tail protector 500. That is, the nose protector 200 may employ a hard shell exterior 205 and the softer foam interior 212. In the area of the nose protector 200, a hole 214 may be defined into which a surfboard nose may be inserted.

Referring to FIGS. 3(A) and 3(B), the tail protector 500 is in some ways similar to the nose protector 200. As with the nose protector 200, the tail protector 500 may be equipped with protrusions 502 and 504 which matingly engage corresponding holes 304b and 306b defined in railguards 300b and 302b, respectively. The tail protector may have the same sort of bilayer construction discussed above in connection with the nose protector.

Referring to FIG. 4(A)-(G), embodiments of the railguards and adaptors are illustrated. Besides various views, it is noted that FIG. 4(B) depicts an exterior view of an adaptor and FIG. 4(C) depicts an interior view. For example, a railguard 302a is illustrated adjacent a railguard 302b. An adaptor 400b is shown spanning the same. The adaptor 400b includes a number of corrugations 404, and at the base of one or more corrugations is disposed a nub 402. The adaptor 400b slides over and fits onto the corrugations in the railguards, and the nub 402 helps hold the adaptor onto the railguards. The corrugations generally allow secure positioning of the railguards at a given distance apart, and thus allow the system or assembly to be rendered adjustable—accommodating various sizes of surfboards. While in FIG. 4(A)-(G) corrugations are illustrated on both the adaptor and on the railguards, it will be understood that in some embodiments corrugations need only be on the adaptor or on the railguard. So long as the adaptor can be held securely onto the railguard in such a way as to prevent significant longitudinal movement (i.e., movement along the direction of the axis of the surfboard), any adaptor/railguard configuration will work. For example, in FIG. 4(E), no corrugations are illustrated on the adaptor. However, a foam section 406 is provided in the center, and the same may be contacted by each railguard in the case that the shortest system or assembly is constructed. The foam section 406 protects the rail of a surfboard in the general case where the railguards are separated by a gap and where the surfboard and protector receive a blow in the midsection. That is, where the adaptor would otherwise strike the rail without any foam protection.

FIG. 4(G) illustrates how an adaptor may fit over a snap onto a railguard, and in this case is disposed between two corrugations. In this figure, the nub is not illustrated for clarity. In addition, it will be understood that the adaptor nubs may also snap onto the corrugations themselves. FIG. 4(F) further illustrates the connection of a railguard to the nose protector.

FIG. 5 illustrates an alternative attachment mechanism between a nose protector 200′ and a railguard 300′. In particular, a tongue 202′ formed on the nose protector 200′ may be rotatably inserted into a corresponding hole formed in or defined by the railguard 300′. Besides these techniques, one of ordinary skill in the art will recognize other attachment mechanisms given these teachings. In any of these cases, a left railguard will attach at one point to the left side of a nose protector, and a right railguard will attach at one point to the right side of a nose protector. Analogous attachments will be seen for the left and right railguards and the left and right portions of the tail protector.

In an alternative embodiment, disclosed in an application (61/278,937) incorporated by reference above and further described with reference to FIG. 6(A)-(F) as noted below, the system may be made from polyethylene foam reinforced by Surlyn®, a plastic resin. The system overlaps the outer perimeter of the surfboard on its edges. Extended coverage is placed on the nose and tail. Polyethylene foam creates a light, flexible, and shock absorbing core that is reinforced by a strong and durable Surlyn® shell. Together they provide considerable protection against impact. The system may be installed first on the nose protector and tail protector of the surfboard. At this point, the railguards have not been secured to the rails of the surfboard. Once the nose protector and tail protector fit snuggly onto their respective positions, the railguards are then slid onto the rails of the surfboard. Next, the adaptor attaches to the railguard and secures the system to the surfboard. The nose protector may attach to the railguard by the Surlyn® along the edge, i.e., the nose protector has a horizontal slit where the nose of the surfboard inserts. (Other methods may be employed as well.) The joints between the tail protector and railguards act as hinges that swing open allowing the system to easily accommodate the tail and rails. These joints exist in the upper half as well. In cuts are made along the arms of both the upper and lower halves of the design to decrease rigidity. A series of channels may be employed along the edge where the two halves of the system meet. These channels serve as anchorage points for the adaptor. Cast from a plastic resin, the adaptor is shaped in a complimentary form to the pattern of the channels and arms. This piece connects the two halves, further secures the system in position, and protects the rails of the surfboard from damage.

FIGS. 6(A)-(F) illustrate this alternative adaptor assembly in which an adaptor attaches to a railguard permanently and is capable of moving both forward and back. This system may be difficult to form via the vacuum forming techniques that are one way of creating the prior embodiments, but the system of FIG. 6 may still be formed by other methods. The adaptor may lock on to an opposing railguard and secure both railguards into place by various different methods including, but not limited to, clamps, cinches, ratchets, tongue and groove systems, and/or elastic bands. One method may function in the following way. An adaptor 602 defines a pattern 614 in its side. This pattern serves as a track for an anchor 612. The anchor 612 is embedded into the side of a railguard 300b′. FIG. 6(B) illustrates how the adaptor 602 may be situated in a rest position on the railguard 300b′ when not in use. When the length needs to be adjusted, the adaptor 602 slides along the railguard until the desired position is obtained, then one or more teeth 604 hook into one or more channels 610 of the opposing railguard 300a′. Taking the “anchored end” of the adaptor 602, the grooves 603 are pulled over the anchor 612 creating a locked-in position.

In other words, the teeth 604 fit into grooves 610. The anchor 612 can be moved within the channel 614 when the teeth 604 are not positioned inside the groove 610. When the teeth 604 fit inside the groove 610, the anchor engages one of several slots 603 along channel 614 causing the adaptor 602 to lock on the railguards, disallowing movement. In order to adjust the adaptor 602 according to board length, the teeth 604 lift up out of the groove 610, disengaging the anchor from its slot 603, allowing it to move freely along the track of channel 614. By connecting the adaptor to the arms, the likelihood of losing a part is reduced.

FIG. 7 illustrates a system or assembly 100 in use protecting a surfboard 10.

Certain details of the embodiments are discussed below.

The corrugations may be, e.g., spaced apart by a range of distances from 0.25 inches to more than 1 inch, e.g., 0.75 inches or 1 inch. The corrugations may have a depth that varies between about 0.12 inches and 0.5 inches, e.g., 1/4 inch. An optional flanged section on the railguard, adjacent the portion forming the slot, may provide a face at an angle to ease attachment/detachment of the railguard to the nose protector or tail protector. In other words, the flange may allow the railguard to be more easily and conveniently mounted to/dismounted from the nose or tail protectors by lifting the same to slide over the protrusion smoothly. The face of the flange may at an angle of, e.g., 30°. The thickness of the hard shell exterior, e.g., the Surlyn®, may be, e.g., ⅛″ to ¼″, e.g., 3/16″. The thickness of the softer foam material may be, e.g., ¼″ to ½″. These thicknesses may vary, however, not only from surfboard protector to surfboard protector, but also within a given surfboard protector.

The system or assembly may be made to fit surfboards of varying designs including hybrids, fish, longboards, SUPs, and so forth. In addition, the system or assembly may be employed to protect other fragile products, especially those whose length may vary but whose overall shape remains constant, e.g., snowboards, artwork, laptops, airplane wings, foils, or the like. The system or assembly may be made stackable by pressing a groove into the top of each assembly and an invagination into the bottom of each assembly. It will be understood that variations of this design may also be employed to provide a stackable feature. Such channel and groove features allow stackability regardless of the dimension of the surfboard—in this aspect, the surfboards and protectors may not be centered one atop the other, but so long as an invagination is engaging a groove somewhere on the railguards or nose or tail protectors, the surfboards may be securely stacked.

While the above description has described the invention in terms of specific exemplary embodiments, it will be understood that the same are purely for illustration, and that many variations of the above will be seen by one of ordinary skill in the art given this teaching. For example, instead of a segmented design where nose and tail protectors mate with railguards, a large enough tool could allow just two segments to be manufactured, e.g., a nose protector and tail protector with integral railguards that are coupled together with an adaptor. In a related embodiment, the railguards may be non-integral but hingedly attached to the nose or tail protectors.

In another variation, the system may be supplemented by being removably encased in a surfboard bag, the bag serving to further protect the surfboard as well as the nose and tail protectors and railguards. In a related embodiment, the railguards and nose and tail protectors may be equipped with attachment mechanisms, e.g., buttons or snaps, by which flat bags may be spanned and attached. These flat bags may be opened by zippers or other known techniques. By inserting clothing, blankets, towels, wetsuits, or the like into the flat bags, additional storage may be gained for travel, and additional protection is afforded to the top and bottom of the surfboard. To create the flat bags, two layers of threaded mesh may be sewn together around their perimeter. In another embodiment, instead of the flat bags, flexible foam sheets may be attached in the same way. The flexible foam sheets provide protection against damage, and may be employed during a trip as a yoga mat, pillow, or as an extra cushion. Additional pockets may be sewn into the mesh or foam to provide storage for small items.

In another variation, large bands, e.g., similar to large rubber bands or bungee cords, may further be employed to retain the protective pieces by circling the same in a rail-to-rail fashion around the board and protector. The disclosed adaptors may be replaced with various other designs. For example, to connect together two railguards in an adjustable fashion, elastic bands may be employed. Alternatively, one railguard may have mounted thereon a mechanism that can matingly engage with another railguard in a variety of positions. For example, one mechanism may be an invagination, formed on a piece hingedly mounted to one railguard, that is rotated into one of a set of grooves on another, the insertion allowing a friction-fit, the groove chosen to allow a suitable length of the combined railguards to be achieved. Other mechanisms may be Velcro® straps, clamps, bindings such as those found on ski boots, or the like.

In an alternative implementation, instead of a bilayer construction as disclosed above, one or more (or all) components may be constructed from a single layer of a variety of materials, including but not limited to: postconsumer recycled paper (molded pulp), a plant—based material such as molded roots, molded fungus, cardboard, wheat, reed, bamboo, or rubber. In this way, while being environmentally friendly, the systems may still be made reusable. A coating or slurry additive may further be employed to provide an even greater layer of reusability. Such coatings and/or additives may include water-based glues or vapor inhibitors or the like to prevent surface corrosion.

FIGS. 8-14 illustrate such an implementation involving molded pulp. While not required, this implementation employs corrugated molded pulp for additional durability and reusability.

Referring to FIG. 8, a nose protector is illustrated made of molded pulp. In this embodiment, as shown in FIGS. 8-9 a “deep-draw” method of fabrication may be employed. The “deep-draw” method may be employed where the depth (the height of the triangle formed by the product, in the distance along the corrugations) of the product required is less than about 5″. Where additional depth is required, as is commonly the case for surfboards or other action sports boards, a clamshell system is employed which is disclosed in FIGS. 10-11.

In FIG. 8(A)-(B), the nose protector 701 is made of corrugated molded pulp. The corrugations are made by valleys 705 and peaks 706. A central invagination 702 is formed on one side of the nose protector, and a corresponding protrusion 703 is formed on an opposite side. The invagination and protrusion generally run in the center of the product, and provide for convenient stacking. Tabs 704 are provided on each side of the product as well as on the top and bottom, for a total of four. One of ordinary skill in the art will recognize that more or less may be provided according to the requirements of a particular implementation. The tabs 704 are employed to cooperate with the rail guards (see FIG. 12) to attach one to the other.

FIG. 9(A)-(B) is generally similar to FIG. 8. The tail protector 711 is made of corrugated molded pulp. The corrugations are made by valleys 715 and peaks 716. A central invagination 712 is formed on one side of the tail protector, and a corresponding protrusion 713 is formed on an opposite side. The invagination and protrusion generally run in the center of the product, and provide for convenient stacking. Tabs 714 are provided on each side of the product as well as on the top and bottom, for a total of four. One of ordinary skill in the art will recognize that more or less may be provided according to the requirements of a particular implementation. The tabs 714 are employed to cooperate with the rail guards (see FIG. 12) to attach one to the other. A primary difference of the tail protector is that the same may have a slightly different shape to accommodate the shape of the typical surfboard tail.

FIG. 10(A)-(C) illustrate various views of a molded pulp nose protector 727 in a clamshell design. The same is shown in use protecting a nose of a surfboard 728. In this case, the corrugations are illustrated by valleys 725 and peaks 726. Tabs 724 are provided to interlock in the rail guards in the same way tabs 704/714 did in FIGS. 8 and 9. In FIG. 10, to keep the clamshell together until this function is performed by the rail guards, an indentation 724′may be employed on opposite sides of the product to allow a rubber band to be held securely around the product, keeping the clamshell together. The rubber band would run perpendicular to the longitudinal axis of the surfboard.

Similarly to FIG. 10, FIG. 11(A)-(D) illustrate various views of a molded pulp tail protector 738 in a clamshell design. The same is shown in use protecting a tail of a surfboard 739. In this case, the corrugations are illustrated by valleys 735 and peaks 736. Tabs 734 are provided to interlock in the rail guards in the same way tabs 704/714 did in FIGS. 8 and 9. In FIG. 11, to keep the clamshell together until this function is performed by the rail guards, an indentation 734′may be employed on opposite sides of the product to allow a rubber band to be held securely around the product, keeping the clamshell together. The rubber band would run perpendicular to the longitudinal axis of the surfboard. In both FIG. 10 and FIG. 11, other ways of keeping the clamshell together may also be employed, such as by interlocking tabs and protrusions on the product itself.

FIG. 12(A)-(B) illustrates an exemplary rail guard 740 made of, e.g., molded pulp. The rail guard 740 includes a plurality of ribs 742 which in themselves serve to strengthen the rail guard. The ribs 742 engage with inter-cooperating ribs and the valleys in an adapter (see FIG. 13). Pilot holes 741 are provided on the rail guard 740 through which the tabs on the nose and tail protectors enter and engage in a secure fashion to hold the rail guards to the nose and tail protectors. In the case of the clamshell design, the pilot holes 741 and rail guards 740 also can serve to hold the clamshell closed. It will be understood that variations of this design may be seen. For example, holes may be provided on the nose and tail protectors which engage tabs on the rail guards. Other closure and fixation devices may also be employed, such as clips, and the like.

Referring to FIG. 13, an adapter 750 is illustrated made of, e.g., molded pulp. A number of ribs 751 are illustrated, which are placed between the ribs 742 of the rail guard 740. Because of the number of parallel ribs 751 and ribs 742, the adapter 750 may be employed to securely hold two rail guards 740 in a variety of distances apart from each other in a friction fit.

FIG. 14 illustrates a system 760 in an exploded configuration, showing how the various components may be located in use.

FIG. 15 illustrates a system analogous to system 760 that may be employed to protect a centerboard 713 of a sailboat. Referring to FIG. 15(A), a centerboard 713 is illustrated with a top area 774 requiring protection, a bottom area 776 requiring protection, and rail areas 775 requiring protection. In the system 781, a top protector 777 is provided, and on the opposite end of the centerboard 713 a bottom protector 779 is disposed. Rail guards 778 are provided which engage the top protector and bottom protector by tabs or the like. The adapters 780 allow a variety of lengths of centerboards to be accommodated without requiring changing the size of the components. The only change needed is where the adapter attaches to the rail guards.

In addition, besides surfboards and centerboards, the implementations of the principles disclosed here may be employed to protect other fragile objects, such as other items related to action sports, e.g., skis, wake boards, snowboards, and other action sports boards.

Implementations may also be employed in packaging and/or protecting objects wherever a fragile edge or object having a perimeter needs protection, e.g., mirrors, tabletops, sheets of glass, table legs, and the like. In particular, referring to FIGS. 16-21, a system is provided for protecting virtually any object which has a perimeter on which a rail guard may be placed. For objects with corners, corner protectors are also disclosed below. As will be seen, corner protectors may be constructed and employed that protect a corner that extends laterally beyond the extent of an underpiece such as molding or, e.g., table legs. Such protectors are shown by corner protectors 829, and generally protect a, e.g., table corner, on both a top and a bottom as well as on two sides, i.e., four total planar surfaces. Corner protectors may also be constructed and employed that protect just on three planar surfaces (see corner protectors 828), and the same may be particularly appropriate for, e.g., table corners that are flush with table legs. Corner protectors 829 generally engage with rail guards 824 and 834, and corner protectors 828 generally engage with rail guards or edge protectors 831.

It will be seen that edge protectors 831 and rail guards 824 are provided with a number of holes spanning their entire length. The same may span two corner protectors, and be affixed securely thereto, even in the absence of an adapter. Thus in such a system, illustrated by the rail guard 824 of FIG. 20(A), no adapters are required. It is noted that such rail guards may also be employed in the action sports board protectors described in FIGS. 1-15, thus providing an adjustable assembly for protecting at least a portion of a perimeter of an object during transit and/or storage including corner (or nose/tail) and rail/edge protection without the use of an adapter. The perforations between the holes may allow a convenient way to cut the edge protectors 831 and rail guards 824 to a desired size.

In FIG. 16, protection of an object 800 is illustrated with rail guards 834 connected by adapters 835. For a rectangular object of arbitrary size, rail guards and adapters are provided along each of the edges. The rail guards 834 and adapters 835 act basically similarly to those discussed above in connection with surfboard protection. For corner protection, corner protectors or end caps 829 are provided. The rail guards are provided with pilot holes to attach to the end caps 829, the latter having been provided with tabs which engage the pilot holes.

Referring to the more detailed drawing of FIG. 17(A)-(D), an end cap 829 is illustrated having tabs 830 cooperating with pilot holes in a rail guard. The end cap 829 is of the type that would be appropriate for a tabletop, where the tabletop extends beyond the extent of the legs.

Referring to FIG. 18, appropriate rail protectors 824 for use with end caps 829 are illustrated as provided with pilot holes 823 and perforations 822, for the same reasons as the corresponding elements in FIG. 17. The rail protectors 824 have a shape to conform around the edge of a table (around three surfaces) or around three surfaces of a leg.

FIGS. 17(C)-(D) illustrate alternative rail guards or edge protectors 831, the same serving to protect two sides of a rail or leg instead of three. The edge protector 831 further includes a number of pilot holes 832. Between the pilot holes are perforations 833 which may be employed to allow a user to conveniently cut the edge protector to any desired length. The rail guards or edge protectors 831 cooperate with corner protectors 828 (see FIG. 18(D)-(E)) to protect, e.g., table corners having flush legs. That is, the corner protectors 828 are provided which when folded protect corners of objects and further provide tabs for connection to edge protectors 831. In the figure, the corner protectors 828 include pilot holes 825 and tabs 826. In FIG. 18(E), the corner protector is shown in an unfolded configuration 827. The flat unfolded corner protector is shown in FIG. 19(A)-(C) as well, and FIG. 19(C) in particular illustrates how a number of such corner protectors may be formed from a single sheet, e.g., of molded pulp.

Such corner protectors have the advantage that they ship flat, and allow for maximum yield during processing. The same engage the edge protectors (rail guards) without the use of adhesive. Such provide a benefit over current corner protectors because current corner protectors are shipped in the same form as when they are used, e.g., in a triangular or pyramidal shape. A disadvantage to this is that transporting a stack of such pyramidal protectors is limited by its size. In the current system, a flat design capable of being assembled by the end-user as a pyramid has significant advantages when shipping, and further has significant functionality when used.

Moreover, the manufacturing of molded pulp corners is limited by the number of parts that can be constructed in one cycle. In other words, their size and dimensions allow a certain number to be produced at one time. Using systems and methods according to the principles disclosed here, an assembly line of parts may be provided for manufacturing at one time, while limiting the amount of molded pulp waste. The square shape of each part allows for a high yield and minimal waste because the same can be arranged side-by-side. It is noted that corner protectors 829 may also be constructed in this manner.

As noted above, the tabs of the corner protectors engage pilot holes in the edge protectors. This interface creates a union that does not require adhesive. The simple connection can be made very rapidly, e.g., while preparation is made to shrink wrap products. It further reduces the need for tape and other expensive adhesives.

FIG. 20(A)-(E) illustrates use of corner protectors 829 in combination with edge protectors or rail guards 834, the rail guards 834 being secured together using adapters 835. It will be seen that an alternative embodiment of a rail guard, a rail guard 824 may further be employed to engage tabs on the corner protector 829 instead of the use of rail guards 834 and the adapter 835. Such a system may be conveniently employed when the perimeter of the tabletop extends beyond (is not flush with) the extent of the legs.

FIG. 21(A)-(B) illustrate the use of edge protectors 831 connected to corner protector 828. In FIG. 21(A), an exploded configuration is illustrated. In FIG. 21(B), the parts are shown in use. Such a system may be conveniently employed when the perimeter of the tabletop does not extend beyond (i.e., is flush with) the extent of the legs.

It is noted that in any of the embodiments, typically a first corner protector is connected to a second corner protector using first and second edge protectors or rail guards and adapters according to the principles disclosed above. In many cases, full perimeter protection will be provided having such edge protectors or rail guards and corner protectors surrounding the entire perimeter.

It is noted that in implementations where molded pulp or the like is employed, marketing materials such as trademarks, instructions for folding or for use in packaging, advertising, and the like may be conveniently molded or printed thereon. Codes, which may be unique, may be imprinted on the product to enable giveaways in known manner, as well as to enable products to be tracked wherever the product travels. Such can provide a highly useful online or (e.g., for actions sports usage or other consumer uses) social networking aspect, depending on implementation.

Referring to FIG. 23(A), an end cap 901 is illustrated for engaging the nose and tail protectors of the surfboard. Normally when surfboards are shipped, they are packaged and placed inside boxes, with void spaces being filled with foam, bubble wrap, etc. FIG. 23(A) illustrates such a prior art situation, in which a surfboard 913 is placed in a box 918 having only foam pieces 917. The problem is that such objects shift around inside the box, causing damage.

The end caps shown in FIG. 22(A)-(C) solve this problem. The nose and tail protectors slide inside the end caps 901 and are held in place by friction fit protrusions 910 of various heights and depths that engage the nose and tail protector, holding the board firmly in place. A cap on the nose and tail protector may then interlock with one or more pilot holes 907, further securing its position. Grooves 904 and tongues 905 allow for stacking. Wings 902 extend outward and abut the inside walls of the box, preventing shifting. Depending on the width of the box, the wing's length can be adjusted by cutting along perforations 908.

FIG. 22(B) depicts the inside of the end cap 901. Protrusions 910-912 vary in height and spacing so as to accommodate nose and tail protectors of different widths and thicknesses.

FIG. 22(C) demonstrates end cap 901 adjacent to three different surfboard noses. Viewing the end cap 901 from the top looking down, the varying depths of protrusions 910-912 can be seen. For example, longboard 915 is the widest. Therefore, it would generally engage end cap 901 being held in place by protrusions 910 and stopping at protrusions 911. Hybrid board 914 engages end cap 901 being held in place by protrusions 911 and stopping at protrusions 912. Short board 913, the narrowest, engages end cap 901 being held in place by protrusions 912 and stopping at the abutting wall.

In use, the end caps 901 situate objects that are protected by a nose or tail protector or the like within a shipping box. Of course, it will be understood that such may also situate, within boxes in a secure fashion, objects that are protected by other embodiments of the invention, including those described with respect to furniture. The end caps 901 generally define a pocket having a top wall and a bottom wall. The pocket is open in one section and in the remainder is sealed together in a seam. Protrusions are in the interior of the pocket, and an object encased in a protector may bypass some protrusions and abut others, when the object is slid into the end cap in a longitudinal direction. The width of the object and nose protector determine which protrusions are slid the past, which are abutted against, and which touch, if any, the top and bottom exterior portions of the nose or tail or other protector. Wings may extend from the pocket which abut the interior sides of a box to limit movement of the object situated within the box. The wings may have perforations formed thereon to allow different sizes or widths to be conveniently accommodated.

FIG. 23(B) is a top view of a surfboard packaged with a nose and tail protector and end caps inside a box according the principles described here. The protector 919 provides full rail protection to the short board 913 in the manner described above. End cap 901 engages the nose protector 920 and tail protector 921 and protects the same when the object is placed inside a shipping or storage container.

FIG. 23(C) is a profile view of several actions sports boards 913 packaged with protection 919 according to principles described here with end caps 901 and stacked on top of one another inside a box.

Variations of the above systems and methods for protecting actions sports boards such as surfboards and furniture will be understood. For example, the end caps 901 may be employed for shipping stacked objects such as tabletops, laptops, mirrors, sheets of glass, or the like.

Therefore, the scope of the invention is to be determined solely by the scope of the claims appended hereto, and equivalents thereof.

Claims

1. An adjustable assembly for protecting the full perimeter of an action sports board during transit and/or in storage, comprising:

a nose protector, the nose protector structured and configured to receive at least a portion of a nose of an action sports board;

a tail protector, the tail protector structured and configured to receive at least a portion of a tail of the action sports board;

first and second left railguards, the first and second left railguards structured and configured to receive at least a portion of a left rail of the action sports board, wherein the first left railguard is configured to be attached to a left side of the nose protector and wherein the second left railguard is configured to be attached to a left side of the tail protector;

first and second right railguards, the first and second right railguards structured and configured to receive at least a portion of a right rail of the action sports board, wherein the first right railguard is configured to be attached to a right side of the nose protector and wherein the second right railguard is configured to be attached to a right side of the tail protector;

a left adaptor and a right adaptor, the left and right adaptor structured to connect the first and second left railguards and the first and second right railguards, respectively, such that the first and second left railguards and the first and second right railguards may be separated by one of a variety of distances while being held securely by the left and right adaptor, respectively, such that the full perimeter of the action sports board is collectively protected by the nose protector, tail protector, railguards, and adaptors.

2. The assembly of claim 1, wherein the nose protector, the tail protector, and the railguards are constructed of a material selected from the group consisting of: postconsumer recycled paper (molded pulp), a plant-based material such as molded roots, molded fungus, cardboard, wheat, reed, bamboo, or rubber.

3. The assembly of claim 2, wherein the material is molded pulp.

4. The assembly of claim 3, wherein the molded pulp is constructed with a message disposed thereon.

5. The assembly of claim 4, wherein the message is related to advertising or marketing.

6. The assembly of claim 4, wherein the message is a unique code.

7. The assembly of claim 1, wherein a portion of the first left and first right railguards defines a slot and a portion of the nose protector has formed thereon a protrusion, such that engagement of the protrusion and the slot causes the first left and first right railguards to be attached to the nose protector.

8. The assembly of claim 1, wherein a portion of the second left and second right railguards defines a slot and a portion of the tail protector has formed thereon a protrusion, such that engagement of the protrusion and the slot causes the second left and second right railguards to be attached to the tail protector.

9. The assembly of claim 1, wherein a portion of the first left and first right railguards defines a groove and a portion of the nose protector has formed thereon a tongue, such that engagement of the tongue and the groove causes the first left and first right railguards to be attached to the nose protector.

10. The assembly of claim 1, wherein a portion of the second left and second right railguards defines a groove and a portion of the tail protector has formed thereon a tongue, such that engagement of the tongue and the groove causes the second left and second right railguards to be attached to the tail protector.

11. The assembly of claim 1, wherein at least a portion of the first or second left railguards and first or second right railguards have corrugations formed therein.

12. The assembly of claim 1, wherein the left adaptor snap-fits to the first and second left railguards and the right adapter snap-fits to the first and second right railguards.

13. The assembly of claim 12, wherein each adaptor has formed on one or both edge(s) a nub for engagement with an edge of a railguard.

14. The assembly of claim 7, wherein at least a portion of the first or second left railguards and first or second right railguards have corrugations formed therein, and wherein a height of the corrugations is substantially equal to a height of the protrusion.

15. An adjustable assembly for protecting the full perimeter of an action sports board during transit and/or in storage, comprising:

a nose protector, the nose protector structured and configured to receive at least a portion of a nose of an action sports board;

a tail protector, the tail protector structured and configured to receive at least a portion of a tail of the action sports board;

a right railguard and a left railguard, the right and left railguards having a number of holes defined therein, the holes configured to engage corresponding protrusions on the nose and tail protector, the railguards structured and configured to receive at least a portion of a right and left rail of the action sports board, respectively, wherein the left railguard is configured to be attached at one end to a left side of the nose protector and at another end to a left side of the tail protector and wherein the right railguard is configured to be attached at one end to a right side of the nose protector and at another end to a right side of the tail protector,

such that the full perimeter of the action sports board is collectively protected by the nose protector, tail protector, and railguards.

16. An adjustable assembly for protecting at least a portion of a perimeter of an object during transit and/or in storage, comprising:

a first corner protector, the first corner protector structured and configured to receive at least a portion of a first corner of an object having a perimeter;

a second corner protector, the second corner protector structured and configured to receive at least a portion of a second corner of the object having a perimeter;

first and second edge protectors, the first and second edge protectors structured and configured to receive at least a portion of an edge of the object between the first and second corners, wherein the first edge protector is configured to be attached to the first corner protector and wherein the second edge protector is configured to be attached to the second corner protector; and

an adaptor, the adaptor structured to connect the first and second edge protectors, such that the first and second edge protectors may be separated by one of a variety of distances while being held securely by the adaptor, such that the at least a portion of the perimeter of the object is collectively protected by the first and second corner protectors, the first and second edge protectors, and the adapter.

17. The assembly of claim 16, wherein the corner protectors protect three surfaces that meet at the corner.

18. The assembly of claim 16, wherein the corner protectors protect four surfaces that constitute the corner.

19. The assembly of claim 16, wherein the first and second corner protectors, first and second edge protectors, and the adapter are made of molded pulp.

20. The assembly of claim 16, wherein the edge protectors protect two surfaces that meet at the edge.

21. The assembly of claim 16, wherein the edge protectors protect three surfaces that constitute the edge.

22. The assembly of claim 16, wherein the corner protectors and edge protectors are configured to protect an object selected from the group consisting of: a tabletop, a laptop computer, a mirror, an artwork, or a sheet of glass.

23. An end cap for situating an object within a shipping box, the object protected within a nose or tail protector or both, the nose or tail protector having a protrusion or pole located or defined thereon, respectively, the end cap comprising:

a pocket having a number of protrusions formed therein, the protrusions disposed on an interior of the pocket such that varying widths of nose or tail protectors may be inserted into the end cap pocket varying amounts of longitudinal distances, the width of the nose or tail protector at least partially determining which protrusions the nose or tail protector does not engage in a friction fit when the nose or tail protector is inserted in a longitudinal direction and which protrusions the nose or tail protector abuts against, engages, and is thus prohibited from further movement in a longitudinal direction; and

at least one wing extending from the pocket in a direction perpendicular to the longitudinal direction.

24. The end cap of claim 23, further comprising two wings, each wing extending from the pocket in a direction perpendicular to the longitudinal direction.

25. The end cap of claim 24, wherein each wing includes perforations, the perforations running the length of the wing and in a direction parallel to the longitudinal direction.

26. The end cap of claim 23, wherein for protrusions are provided for each width, and wherein three widths are provided for, two of the four protrusions on a top interior of the pocket and two of the protrusions on a bottom interior of the pocket, each of the sets of two protrusions disposed such that one of each set is on each side of a center axis defined by the longitudinal direction.