SPORTS BOARD

Abstract

A sports board includes a foam core, a non-foamed plastic plate, and a foam skin. The bottom surface of the foam core has a lower exposed area that is not covered by the non-foamed plastic plate. The top surface of the foam core has an upper exposed area that is not covered by the foam skin. The foam core also has an exposed peripheral area, which is located between the lower exposed area and the upper exposed area.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a sports board associated with sports, recreational, or lifesaving activities, particularly a board with a core having an exposed periphery.

2. Description of the Related Art

Over the years, boards for sports, recreational, or lifesaving purposes, such as a snowboard or a surfboard, have been developed with a basic structure comprising a foam core, a skin, and a plate. The foam core is made of plastic foam material and serves as the primary provider of buoyancy. The skin is also usually made of plastic foam material, but it has a smoother surface compared to the foam core, and its soft texture t provides a pleasant touch for the user. The skin can be a single piece or comprised of a wide upper skin and a plurality of narrow peripheral skins. As for the plate, it is typically a non-foamed plastic plate with a smooth outer surface, enabling the snowboard or surfboard to glide effortlessly on snow or water.

The foam cores of modern sports boards are typically fully wrapped by the skins and the plates to prevent the ingress of water, sand, or other particles. However, fully wrapping the foam core requires considerable manpower and time to securely bond the skins and the plates to the top, bottom, and peripheral surfaces of the foam core, and to ensure the sealing of the seams between them. This task becomes even more laborious and time-consuming when the skin is not a single piece. Therefore, there is a strong industry demand for a new sports board structure that can address the aforementioned issues.

SUMMARY OF THE INVENTION

This invention disclosed a sports board comprising a foam core, a non-foamed plastic plate and a foam skin. The foam core has a bottom surface, a top surface and an exposed periphery. The bottom surface of the foam core has a lower foundation and a lower exposed area surrounding the lower foundation. The top surface of the foam core has an upper foundation and an upper exposed area surrounding the upper foundation. The peripheral surface of the foam core is disposed between the lower exposed area and the upper exposed area.

The non-foamed plastic plate is disposed on the lower foundation of the bottom surface of the foam core and covers only the lower foundation. The foam skin is disposed on the upper foundation of the top surface of the foam core and covers only the upper foundation.

In a preferred embodiment, the area of the lower foundation on the bottom surface of the foam core of the invention is greater than the area of the lower exposed area on the bottom surface of the foam core.

In one embodiment, the area of the upper foundation on the top surface of the foam core is greater than the area of the upper exposed area on the top surface of the foam core.

In one embodiment, the invention includes a connecting foam layer. The connecting foam layer is boned to the bottom surface of the foam core and covers only the lower foundation. The non-foamed plastic plate is boned to the connecting foam layer and covers only the connecting foam layer.

In one embodiment, the bottom surface of the foam core is flat.

In another embodiment, the upper foundation on the top surface of the foam skin is concaved.

In one embodiment, the top surface of the foam skin is higher than the upper exposed area on the top surface of the foam core.

In one embodiment, the foam core is a colored EPP core.

In another embodiment, the non-foamed plastic plate, the connecting foam layer, and the foam skin are all made of EPP.

As described above, the non-foamed plastic plate does not completely cover the entire bottom surface of the foam core, and the foam skin does not completely cover the top surface of the foam core. Furthermore, both the non-foamed plastic plate and the foam skin do not completely cover the peripheral surface of the foam core. Thus, in the manufacturing process of the present invention, there is no need to spend time and labor applying any skin to the peripheral surface of the foam core, nor is there a requirement to perform the sealing operations typically associated with conventional sports boards. As a result, the present invention saves manpower and time, while also shortening the production process. Furthermore, in one embodiment of the present invention, the sports board is entirely made from the same material (such as EPP), which not only facilitates recycling but also exhibits characteristics of impact resistance, abrasion resistance, and scratch resistance.

In one embodiment, the foam skin may be deleted while the foam core and the non-foamed plastic plate remain. In another embodiment, the non-foamed plastic plate may be deleted while the foam core and the foam skin remain.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom view of a sports board in accordance with the first embodiment of the present invention;

FIG. 2 is a top view of a sports board shown in FIG. 1;

FIG. 3 is a cross-sectional view and a partially enlarged view of the sports board shown in FIG. 1;

FIG. 4 is a bottom view of a sports board in accordance with a second embodiment of the present invention;

FIG. 5 is a top view of a sports board shown in FIG. 4.

DETAILED DESCRIPTION OF EMBODIMENTS

The present invention relates to a sport, recreational, or rescue board, such as various types of surfboards, paddleboards, snowboards, grass boards, sandboards, kickboards, rescue float boards, and the like. Referring to FIGS. 1 to 3, there is shown a first embodiment of the sports board, which is a surfboard. FIGS. 4 and 5 show a second embodiment of the sports board, which is a snowboard. However, the specific embodiments of the present invention are not limited to the aforementioned examples.

As shown in FIGS. 1 and 3, the sports board comprises a foam core 1, a non-foamed plastic plate 2 disposed in the bottom surface 10a of the foam core 1, and a foam skin 3 disposed in the top surface 10b of the foam core. The foam core 1 has a thickness greater than the non-foamed plastic plate 2 and the foam skin 3. The foam skin 3 has a thickness greater than or equal to the non-foamed plastic plate 2. The area of the bottom surface 10a of the foam core 1 is greater than the non-foamed plastic plate 2, the area of the top surface 10b of the foam core 1 is greater than the foam skin 3. The area of the foam skin 3 can be greater than, less than or equal to the non-foamed plastic plate 2. Preferably, the area of the non-foamed plastic plate 2 is typically greater than that of the foam skin 3. Furthermore, the density of foam core 1 is less than that of foam skin 3.

The foam core can be made of plastic materials such as EPE, EPP, EPO, and the like. Its thickness is approximately between 20 mm and 90 mm, which may vary depending on its application. For example, when the foam core 1 is used for manufacturing surfboards or paddleboards, a greater thickness is typically selected. On the other hand, when it is utilized for making snowboards, sandboards, or grass boards, a smaller thickness is usually selected. The expansion ratio of the foam core 1 ranges from approximately 15 to 65, and can vary depending on its application. Regardless of the selection, the foam core 1 should have good structural strength to prevent easy breakage or damage from collisions. Moreover, it is preferable for the foam core 1 to be made from a single foam plastic material. In the first embodiment, the foam core 1 is made of EPP, which exhibits strong structural strength, impact resistance, scratch resistance, and wear resistance.

The bottom surface 10a of the foam core 1 has a lower foundation covered by the non-foamed plastic plate 2 and a lower exposed area 11 not covered by the non-foamed plastic plate 2, wherein the lower exposed area 11 surrounds the non-foamed plastic plate 2. The non-foamed plastic plate 2 occupies the majority of the area of the bottom surface 10a of the foam core 1, while the lower exposed area 11 occupies a minor portion. In other words, the lower foundation is greater than the lower exposed area 11.

The top surface 10b of the foam core 1 comprises an upper foundation covered by the foam skin 3 and an upper exposed area 12 not covered by the foam skin 3. The upper exposed area 12 surrounds the upper foundation and the foam skin 3. The foam skin 3 occupies the majority of the area of the top surface 10b of the foam core 1, while the upper exposed area occupies a smaller portion. In other words, the area of the upper foundation is greater than the upper exposed area. Additionally, the exposed periphery 13 of the foam core 1 is disposed between the lower exposed area 11 and the upper exposed area 12, and it surrounds the non-foamed plastic plate 2 and the foam skin 3. The exposed periphery 13, the lower exposed area 11 and the upper exposed area 12 together form an exposed area without any cover, meaning that the entire surface of this exposed area is exposed to surrounding environments. This exposed area allows a user's hand to hold it.

The foam skin 3 can be made of plastic materials such as EPE, EPP, EPO, and the like. Its thickness is approximately between 1.5 mm and 7 mm, and its expansion ratio varies between approximately 7 to 30, depending on the intended application. Moreover, it is preferable for the foam skin 3 to be made from a single foam plastic material. In this embodiment, the foam skin 3 is made of EPP with color.

The non-foamed plastic plate 2 can be made of low-density, medium-density, or high-density non-foamed plastic materials, such as PR or PP. The thickness of the non-foamed plastic plate 2 is approximately between 0.2 mm and 0.8 mm, depending on its intended use. Additionally, it is preferable for the non-foamed plastic plate 2 to be made of a single non-foamed plastic material. In this embodiment, the non-foamed plastic plate 2 is a non-foamed EPP plate.

Typically, the non-foamed plastic plate 2 is in one piece, and the foam skin 3 is also in one piece.

In summary, in the first preferred embodiment, the sports board of the present invention is entirely made of PP, thereby possessing the advantages of strong structural strength, impact resistance, abrasion resistance, scratch resistance, and ease of recycling.

Preferably, the foam core 1 and the foam skin 3 both can be made of foam plastic material with added colorants to give it a specific color, such as black. But the color of the foam skin 3 is generally different from the color of the foam core 1. As for the non-foamed plastic plate 2, it can be made from non-foamed plastic materials with added colorants to give it a specific color. Typically, the color of the non-foamed plastic plate 2 is generally different from the color of the foam core 1. Additionally, the color of the non-foamed plastic plate 2 can be the same as or different from the color of the foam skin 3.

Preferably, the sports board can also include an upper plastic film (not shown in the figures), which is directly heat laminated to the foam skin 3, covering the entire top surface of the foam skin 3. Printed patterns on the upper plastic film are visible from the outside and their color can be black and white or in color. Additionally, one or multiple layers of the upper plastic film can be made of non-foamed plastic films, such as low-density, medium-density, or high-density PE or PP. The thickness of the upper plastic film is approximately between 0.05 mm and 1.2 mm.

It should be noted that the non-foamed plastic plate 2 can be directly bonded to the foam core 1, for example, by heat laminating the non-foamed plastic plate 2 onto the foam core 1. The non-foamed plastic plate 2 can also be bonded to the foam core through the connecting foam layer 5, as illustrated in FIG. 3. Specifically, the non-foamed plastic plate 2 is fully bonded to the bottom surface of the connecting foam layer 5 by lamination. Subsequently, the non-foamed plastic plate 2 with the connecting foam layer 5 is directly heat laminated onto the bottom surface 10a of the foam core 1, allowing the top surface of the connecting foam layer 5 to be directly bonded to the bottom surface 10a of the foam core 1. Whether it is the non-foamed plastic plate 2 or the non-foamed plastic plate 2 with the connecting foam layer 5, neither of them had sunk into the foam core 1, so that the corresponding area of the non-foamed plastic plate corresponding to the foam core 1 is on the same plane as the other areas.

Furthermore, the sports board can further include a lower plastic film (not shown), which can be attached to the inner or outer surface of the non-foamed plastic plate 2, and the printed patterns on the lower plastic film are visible from the outside. The printed patterns can be black and white or in color. Additionally, one or multiple layers of the lower plastic film can be made of non-foamed plastic films, such as low-density, medium-density, or high-density PE or PP. The thickness of the lower plastic film is approximately between 0.07 mm and 1.2 mm.

In the first preferred embodiment, the connecting foam layer 5 is directly bonded to the non-foamed plastic plate 2 without any additional material layer between them, the thickness of the connecting foam layer 5 is smaller than the thickness of the non-foamed plastic plate 2. Similarly, the connecting foam layer 5 is directly bonded to the foam core 1 without any additional material layer between them. Additionally, the foam skin 3 is directly bonded to the foam core 1 without any additional material layer between them.

The connecting foam layer 5 can be made of foam plastic materials such as EPE, EPP, EPO, etc. The thickness of the connecting foam layer 5 is approximately between 0.5 mm and 3 mm, and its expansion ratio is approximately between 7 and 30, depending on the application. Furthermore, it is preferable for the connecting foam layer 5 to be made of a single foam plastic material. In this embodiment, the connecting foam layer 5 is made of EPP. Typically, the density of the connecting foam layer 5 is the same as the foam skin 3, but the connecting foam layer 5 is usually thinner than the foam skin 3.

The thickness of the connecting foam layer that is bonded to the foam core 1 is smaller than the thickness of the foam skin 3. Additionally, as shown in FIG. 3, the thickness of the foam connecting skin 5 that is bonded to the foam core 1 is smaller near the peripheral region compared to other regions. This is because during the aforementioned heat-laminating process, the foam connecting skin 5 undergoes higher pressure in its peripheral region compared to the middle region surrounded by the peripheral region, resulting in the thinner peripheral region of the compressed foam connecting skin 5. Similarly, the thickness of the non-foamed plastic plate 2 that is bonded to the foam core 1 is smaller in the peripheral region compared to other regions.

In this embodiment, as shown in FIG. 3, the foam skin 3 is recessed into the foam core 1, creating a shallow groove 13 corresponding to the foam skin 3. Ideally, the foam skin 3 slightly protrudes from the shallow groove 13, meaning that the top surface of the foam skin 3 is slightly higher than the top surface 10b of the foam core 1. The height difference H between them is preferably between 0.5 mm and 2 mm, although it can also be adjusted to make the top surface of the foam skin 3 flushes with or slightly lower than the top surface 10b.

Furthermore, in this embodiment, the sports board includes one or more downward projecting fins 6, indicated by dashed rectangular frames in FIGS. 1 and 2 to indicate their approximate positions.

FIGS. 4 and 5 show the second preferred embodiment of the sports board, wherein the sports board is a snowboard. The sports board also has the aforementioned foam core 1, the non-foamed plastic plate 2, and the foam skin 3, the only difference between these three elements and the sports board shown in FIGS. 1 to 3 is the shape, which will not be described in detail.

Preferably, the sports board shown in FIGS. 4 and 5 can selectively includes the aforementioned connecting foam layer 5, the upper plastic film, and the lower plastic film.

Furthermore, in FIG. 4, the lower exposed area 11 between the front side of the non-foamed plastic plate 2 and the front side of the foam core 1 is noticeably wider than the lower exposed area 11 between the rear side of the non-foamed plastic plate 2 and the rear side of the foam core 1. In other words, the non-foamed plastic plate 2 on the bottom surface of the foam core 1 is positioned towards the rear.

Similarly, in FIG. 5, the upper exposed area 12 between the front side of the foam skin 3 and the front side of the foam core 1 is noticeably wider than the upper exposed area 12 between the rear side of the foam skin 3 and the rear side of the foam core 1. In other words, the position of the foam skin 3 on the bottom surface of the foam core board 1 is towards the rear.

Claims

1. A sports board comprising:

a foam core having a bottom surface, a top surface, and an exposed periphery, wherein the bottom surface of the foam core has a lower foundation and a lower exposed area surrounding the lower foundation while the top surface of the foam core has an upper foundation and an upper exposed area surrounding the upper foundation, wherein the exposed periphery of the foam core is located between the lower exposed area and the upper exposed area; and

a non-foamed plastic plate disposed on the lower foundation of the bottom surface of the foam core and covering only the lower foundation.

2. The sports board as recited in claim 1, further comprising a foam skin disposed on the upper foundation of the top surface of the foam core and covering only the upper foundation.

3. The sports board as recited in claim 1, wherein an area of the lower foundation of the bottom surface of the foam core is greater than that of the lower exposed area of the bottom surface of the foam core.

4. The sports board as recited in claim 2, wherein an area of the upper foundation of the top surface of the foam core is greater than that of the upper exposed area of the top surface of the foam core.

5. The sports board as recited in claim 1 further comprising a connecting foam layer bonded to the bottom surface of the foam core and covering only the lower foundation, wherein the non-foamed plastic plate is bonded to the connecting foam layer and covers only the connecting foam layer.

6. The sports board as recited in claim 5, wherein the bottom surface of the foam core is flat.

7. The sports board as recited in claim 4 wherein the upper foundation of the top surface of the foam core is concaved.

8. The sports board as recited in claim 7, wherein a top surface of the foam skin is higher than the upper exposed area of the top surface of the foam core.

9. The sports board as recited in claim 7, wherein the bottom surface of the foam core is flat.

10. The sports board as recited in claim 5, wherein the foam core is made of expanded polypropylene with color.

11. The sports board as recited in claim 10, wherein the non-foamed plastic plate is made of polypropylene while both of the connecting foam layer and the foam skin are made of expanded polypropylene.

12. A sports board comprising:

a foam core having a bottom surface, a top surface, and an exposed periphery, wherein the bottom surface of the foam core has a lower foundation and a lower exposed area surrounding the lower foundation while the top surface of the foam core has an upper foundation and an upper exposed area surrounding the upper foundation, wherein the exposed periphery of the foam core is located between the lower exposed area and the upper exposed area;

a connecting foam layer bonded to the bottom surface of the foam core and covering only the lower foundation;

a non-foamed plastic plate bonded to the connecting foam layer and covers only the connecting foam layer; and

a foam skin disposed on the upper foundation of the top surface of the foam core and covering only the upper foundation.

13. The sports board as recited in claim 12, wherein the upper foundation of the top surface of the foam core is concaved.

14. The sports board as recited in claim 13, wherein a top surface of the foam skin is higher than the upper exposed area of the top surface of the foam core.

15. The sports board as recited in claim 14, wherein the bottom surface of the foam core is flat.

16. The sports board as recited in claim 15, wherein the non-foamed plastic plate is made of polypropylene while both of the connecting foam layer and the foam skin are made of expanded polypropylene.

17. The sports board as recited in claim 16, wherein the foam core is made of expanded polypropylene with color.