U.S. patent application number 10/403627 was filed with the patent office on 2004-09-30 for surfboard and method of manufacturing.
Invention is credited to Huarcaya-Pro, Javier.
Application Number | 20040192127 10/403627 |
Document ID | / |
Family ID | 32989986 |
Filed Date | 2004-09-30 |
United States Patent
Application |
20040192127 |
Kind Code |
A1 |
Huarcaya-Pro, Javier |
September 30, 2004 |
Surfboard and method of manufacturing
Abstract
A surfboard includes a core covered with a laminate and having
perforations where the user places his feet, in order to prevent
air blisters from forming between the core and laminate. The core
is formed from an extruded closed-cell polystyrene foam block which
has been shaped by restraining it against a shaped form using
shaped restraining tools and straps, and heating it; and by cutting
using a hot wire. The core is laminated with FIBERGLAS.RTM. and
epoxy resin, and the perforations are formed using a perforating
tool that has a planar or curved working surface and one or more
heated needles extending perpendicularly from the working
surface.
Inventors: |
Huarcaya-Pro, Javier;
(Carlsbad, CA) |
Correspondence
Address: |
Eastman & Associates
Suite 1800
707 Broadway Street
San Diego
CA
92101
US
|
Family ID: |
32989986 |
Appl. No.: |
10/403627 |
Filed: |
March 28, 2003 |
Current U.S.
Class: |
441/74 |
Current CPC
Class: |
B29C 63/0047 20130101;
B32B 2266/08 20130101; B32B 27/04 20130101; B29C 70/545 20130101;
B29C 2793/0045 20130101; B32B 27/38 20130101; B32B 2307/726
20130101; B29L 2031/5272 20130101; B32B 5/28 20130101; B32B 27/065
20130101; B32B 5/18 20130101; B32B 5/245 20130101; B29C 53/84
20130101; B26F 1/32 20130101; B32B 2266/0228 20130101; B63B 2231/50
20130101; B32B 17/04 20130101; B32B 38/04 20130101; B26F 1/24
20130101; B29C 53/04 20130101; B29K 2105/046 20130101; B32B 3/266
20130101; B32B 2038/047 20130101; B32B 2307/724 20130101; B63B
32/57 20200201 |
Class at
Publication: |
441/074 |
International
Class: |
B63B 035/79 |
Claims
I claim:
1. A surfboard, comprising: a core; a laminate covering said core;
and at least one perforation in said laminate.
2. A surfboard as in claim 1, wherein: said laminate comprises
FIBERGLAS.RTM. and epoxy resin.
3. A surfboard as in claim 1, wherein: said at least one
perforation allows air to pass through it, and said at least one
perforation allows little water to pass through it.
4. A surfboard as in claim 1, wherein: said core comprises
closed-cell foam.
5. A surfboard as in claim 4, wherein: said foam is extruded.
6. A surfboard as in claim 4, wherein: said foam comprises
polystyrene.
7. A method of manufacturing a surfboard, comprising the steps of:
providing a core covered by a laminate; and forming at least one
perforation in said laminate.
8. A method of manufacturing as in claim 7, wherein: said step of
forming at least one perforation in said laminate, comprises the
steps of providing a perforating tool having a working surface and
at least one needle extending from said working surface at an angle
substantially perpendicular to said working surface at the point
where said at least one needle intersects said working surface;
manipulating said perforating tool such that said at least one
needle is translated substantially in the direction that said at
least one needle points, such that said at least one needle
penetrates said laminate; and manipulating said perforating tool
such that said at least one needle is translated substantially
opposite the direction that said at least one needle points, such
that said at least one needle is withdrawn from said laminate.
9. A method of manufacturing as in claim 8, wherein: said at least
one needle is heated.
10. A method of manufacturing as in claim 8, wherein: said working
surface is substantially planar.
11. A method of manufacturing as in claim 7, wherein: said step of
forming at least one perforation in said laminate, comprises the
steps of providing a perforating tool having a working surface
curved in at least one dimension, and at least one needle extending
from said working surface at an angle substantially perpendicular
to said working surface at the point where said at least one needle
intersects said working surface; rolling said working surface along
said laminate such that each said at least one needle successively
penetrates and is then withdrawn from said laminate.
12. A method of manufacturing as in claim 11, wherein: said at
least one needle is heated.
13. A method of manufacturing as in claim 7, wherein: said step of
forming at least one perforation in said laminate, comprises the
steps of providing a perforating tool having a working surface
having substantially the shape of an arc of a circle in at least
one dimension, and at least one needle extending from said working
surface at an angle substantially perpendicular to said working
surface at the point where said at least one needle intersects said
working surface; rolling said working surface along said laminate
such that each said at least one needle successively penetrates and
is then withdrawn from said laminate.
14. A method of manufacturing as in claim 13, wherein: said at
least one needle is heated.
15. A method of manufacturing as in claim 7, wherein: said step of
providing a core covered by a laminate, comprises the steps of
extruding closed-cell foam into a blank; shaping said blank into a
core; and covering said core with a laminate.
16. A method of manufacturing as in claim 1 5, wherein: said step
of covering said core with a laminate, comprises the steps of
covering said core with FIBERGLAS.RTM.; and covering said core with
epoxy resin.
17. A method of shaping a closed-cell foam blank, comprising the
steps of: providing a closed-cell foam blank; providing a form
having a shaped form surface; providing one or more restraining
tools, each said one or more restraining tools having a restraining
tool surface; placing said blank upon said shaped form surface;
placing each said restraining tool surface of said one or more
restraining tools upon said blank; pressing said one or more
restraining tools against said blank, wherein said blank is pressed
against said shaped form surface; heating said blank until said
blank is conformed to said shaped form surface and to each said
restraining tool surface; and allowing said blank to cool until
said blank remains so conformed without pressing said blank against
said shaped form surface or each said restraining tool surface.
18. The method of claim 17, wherein: said step of pressing said one
or more restraining tools against said blank, comprises the steps
of providing one or more straps; attaching each of said one or more
straps to at least one of said one or more restraining tools and to
said form; and applying tension to said one or more straps, wherein
said blank is pressed against said shaped form surface.
19. A method of perforating a laminate, comprising the steps of:
providing a laminate; providing a perforating tool having at least
one needle; and manipulating said perforating tool such that said
at least one needle perforates said laminate.
20. A method as in claim 19, wherein: said at least one needle is
heated.
21. A method as in claim 19, wherein: said step of providing a
perforating tool having at least one needle, comprises the step of
providing a perforating tool having a working surface and at least
one needle extending from said working surface at an angle
substantially perpendicular to said working surface at the point
where said at least one needle intersects said working surface.
22. A method as in claim 19, wherein: said step of manipulating
said perforating tool such that said at least one needle perforates
said laminate, comprises the steps of manipulating said perforating
tool such that said at least one needle is translated in the
direction that said at least one needle points, such that said at
least one needle perforates said laminate; and manipulating said
perforating tool such that said at least one needle is translated
opposite the direction that said at least one needle points, such
that said at least one needle is withdrawn from said laminate.
23. A method as in claim 19, wherein: said step of forming at least
one perforation in said laminate, comprises the steps of providing
a perforating tool having a working surface having substantially
the shape of an arc of a circle in at least one dimension, and at
least one needle extending from said working surface at an angle
substantially perpendicular to said working surface at the point
where said at least one needle intersects said working surface;
rolling said working surface along said laminate such that each
said at least one needle successively penetrates and is then
withdrawn from said laminate.
24. A perforating tool, comprising: a perforating tool body having
a working surface; and at least one needle extending from said
working surface.
25. A perforating tool as in claim 24, wherein: said working
surface is substantially planar.
26. A perforating tool as in claim 24, wherein: said working
surface is substantially curved in at least one dimension of said
working surface.
27. A perforating tool as in claim 24, wherein: said working
surface substantially has the shape of an arc of a circle in at
least one dimension of said working surface.
28. A perforating tool as in claim 24, wherein: each said at least
one needle is substantially parallel to each other said at least
one needle.
29. A perforating tool as in claim 24, wherein: each said at least
one needle is substantially at an angle to each other said at least
one needle.
30. A perforating tool as in claim 24, wherein: said at least one
needle is substantially perpendicular to said working surface at
the point where said at least one needle extends from said working
surface.
31. A perforating tool as in claim 24, wherein: said at least one
needle can be heated.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to water sports
equipment. The present invention relates more particularly, though
not exclusively, to a water sports board made of laminated
closed-cell foam with perforation vents in the laminate for
preventing deformations of the surface of the board. The present
invention is useful for surfboards, sailboards, wave skis and other
applications requiring buoyant, rigid, and durable boards.
BACKGROUND OF THE INVENTION
[0002] Many water sports boards and craft (e.g., surfboards,
sailboards, wave skis, etc.) are made of expanded open-cell rigid
polymer foam. Where the discussion herein refers to a surfboard or
"board", it applies to surfboards, sailboards, body boards, wave
skis, and other types of water sports boards and craft as well. To
make a board of open-cell foam, a "molded method" is often used.
Specifically, in using the molded method, a mold of the board is
filled with liquid foam, which expands to fill the mold. The foam
is then allowed to harden in the mold until it is rigid. The rigid
foam is made of air cells that are open to each other. The cells at
the surface of the rigid foam are also open to the atmosphere.
Another method of board formation is the traditional hand-shaping
method wherein the board is cut, or shaped, from a block of
expanded foam.
[0003] A problem with open-cell foam is that it absorbs water. To
minimize this absorption of water, the open-cell foam is often
coated with a water-proofing material, such as FIBERGLAS.RTM. and
epoxy resin, to seal the board and make the board more durable.
[0004] Unfortunately, even though covered with a water-proofing
material, in the event the board is bumped or the water-proofing
materials are breached, the board absorbs water through that
breach. When the open-cell foam has absorbed water, the open-cell
foam is much heavier than when it is dry. A board made with
open-cell foam that has absorbed water is significantly more
difficult to use because of its increased weight and decreased
buoyancy. Furthermore, a board that has absorbed water must be
dried out before it is stored, in order to avoid deterioration of
the board.
[0005] In light of the above, it would be advantageous to make a
board having similar buoyancy, rigidity, and durability
characteristics of a board made from open-cell foam, yet does not
absorb water into the foam material if the water-proofing material
is breached.
SUMMARY OF THE INVENTION
[0006] The advantages of open-cell foam can be obtained, and its
disadvantages avoided, by using a closed-cell foam in its place.
Closed-cell foam is extruded, and then formed into the shape of a
board by hand shaping by a professional board shaper, or by using
CNC machining into the desired board shape, instead of expansion
into a mold as is the process used with open-cell foam. In a
preferred embodiment, closed-cell foam may be made of polystyrene.
An advantage of closed-cell foam is that it does not substantially
absorb water. A board made of closed-cell foam does not become
substantially heavier due to water absorption, and retains its
physical properties, including buoyancy and ease of use for water
sports and other purposes. Closed-cell foam also dries out much
more quickly than open-cell foam, without yellowing or damage
areas.
[0007] The present invention includes a surfboard made of laminated
closed-cell foam. The laminate is perforated at places where
pressure is likely to be applied to the surface of the board (e.g.,
where a user is likely to stand), such that air, or gas, can escape
from between the laminate and foam. This avoids the formation of
air blisters, thus overcoming a disadvantage to the use of
laminated closed-cell foam.
[0008] Closed-cell foam extruded into a rough board shape may be
referred to as a "blank" or "block". The blank may be heated,
pressed and cut into a desired shape. The shaped blank may be
laminated with water-proofing materials, such as FIBERGLAS.RTM. and
epoxy resins, to make the board more durable.
[0009] To make a board of the present invention, a blank is treated
with heat and pressure to shape it, if desired, and to anneal the
surface (close any open cells). The board is shaped by placing the
blank against a shaped form, pressing the blank against the form by
use of tension devices (e.g., restraining tools and straps),
heating the blank using heated water vapor, then cooling it until
it holds its new shape. The heated and pressed blank may be further
shaped by cutting it with a hot wire. The cut and shaped blank or
"core" is laminated with FIBERGLAS.RTM. and epoxy resin. Once
laminated, the laminate is perforated in multiple locations using a
tool that has a substantially planar or curved surface with
multiple perforation needles extending therefrom. The perforations
are formed by pressing or rolling the needled surface of the tool
against the laminate thereby penetrating the laminate. The board
may have one or more optional fins.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features of this invention, as well as the
invention itself, both as to its structure and its operation, will
be best understood from the accompanying drawings, taken in
conjunction with the accompanying description, in which similar
reference characters refer to similar parts, and in which:
[0011] FIG. 1 is a perspective view of the Improved Surfboard And
Method Of Manufacturing of the present invention, showing a
finished board;
[0012] FIG. 2A is a side view of the Improved Surfboard And Method
Of Manufacturing of the present invention, showing how a blank is
curved by restraining it against a form with restraining tools and
straps, and subjected to a heat source;
[0013] FIG. 2B is an exploded side view of the Improved Surfboard
And Method Of Manufacturing of the present invention, showing how
multiple blanks are simultaneously curved by stacking them
vertically, separated by a flexible metal heat-conducting sheet,
and restraining the stack against a form with restraining tools and
straps, and subjecting the stack to a heat source;
[0014] FIG. 2C is a side view of the Improved Surfboard And Method
Of Manufacturing of the present invention, showing how multiple
blanks are simultaneously curved by stacking them vertically,
separated by a metal flexible heat-conducting sheet, and
restraining the stack against a form with restraining tools and
straps, and subjecting the stack to a heat source;
[0015] FIG. 3 is a top view of the Improved Surfboard And Method Of
Manufacturing of the present invention, showing how the blank is
cut into a surfboard shape using a hot wire;
[0016] FIG. 4 is a perspective view of the Improved Surfboard And
Method Of Manufacturing of the present invention, showing a
cut-away view of the interior of the board and showing how blisters
are formed in the surface of the board without perforations formed
in the laminate;
[0017] FIG. 5 is a cross-sectional view of the Improved Surfboard
And Method Of Manufacturing of the present invention, taken across
line 5-5 of FIG. 4, showing an air, or gas, blister;
[0018] FIG. 6 is a top view of the Improved Surfboard And Method Of
Manufacturing of the present invention, showing how perforations
formed in the laminate by a perforation tool, prevent formation of
blisters by allowing any air or gas to escape through the
perforation;
[0019] FIG. 7 is a top view of the Improved Surfboard And Method Of
Manufacturing of the present invention, showing a pattern of
perforations in the surface of a short board;
[0020] FIG. 8 is a top view of the Improved Surfboard And Method Of
Manufacturing of the present invention, showing a pattern of
perforations in the surface of a long board;
[0021] FIG. 9 is a side view of the Improved Surfboard And Method
Of Manufacturing of the present invention, showing a perforating
tool having a substantially planar working surface, and a number of
perforating needles extending perpendicularly from the planar
working surface;
[0022] FIG. 10 is a side view of the Improved Surfboard And Method
Of Manufacturing of the present invention, showing a perforating
tool having a curved working surface and a number of perforating
needles extending perpendicularly from the curved working
surface;
[0023] FIG. 11 is a side view of the Improved Surfboard And Method
Of Manufacturing of the present invention, showing a cross-section
of a board with a curved perforating tool perforating the laminate
of the board; and
[0024] FIG. 12 is a flow chart representing an exemplary process of
the present invention for manufacturing the Improved Surfboard of
the present invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0025] A preferred embodiment of the Improved Surfboard And Method
Of Manufacturing of the present invention is shown in FIG. 1 and is
generally designated 100. Board 100 has a foam core 1 10 (shown in
FIG. 4), a laminate 120 covering core 110 having a stringer 122,
and is formed with a number of perforations 130 in laminate 120.
Core 110 of board 100 is formed by shaping a "blank". A blank is a
substantially rectangular block of closed-cell foam.
[0026] Board 100 may have one or more optional fins 160. Board 100
shown in FIG. 1 is in the style of a short board. Perforations 130
are shown placed where a user would place his or her feet on board
100. Perforations 130 may alternatively be placed elsewhere on
board 100.
[0027] Referring to FIG. 2A, an apparatus for shaping a blank is
shown and generally designated 200. FIG. 2A shows a blank (or foam
body or block) 210. Blank 210 may be made of closed-cell extruded
polystyrene foam. Such a blank 210 is made by extruding closed-cell
polystyrene foam into a foam body of the desired shape. Blank 210
may alternatively be made of other materials having strength
similar to closed-cell foam.
[0028] FIG. 2 shows two positions for blank 210, an initial
position 230 (shown in dashed lines) and a shaped position 240.
FIG. 2 also shows a form (or form tool or mold) 250 having a shaped
form surface 254. Shaped form surface 254 has a shape in which
blank 210 is desired to be shaped. FIG. 2 also shows restraining
tools 260 each having a restraining tool surface 264 corresponding
to shaped form surface 254 in the manner in which blank 210 is
desired to be shaped. Straps 270 extend from form 250 to tools 260
and are tightened to bring tools 260 toward form 250 to capture
blank 210 between the tools 260 and the form 250.
[0029] Blank 210 may be shaped in the following manner. Blank 210
is initially placed in initial position 230 (shown in dashed lines)
upon shaped form surface 254 of form 250. Restraining tool surface
264 of each restraining tool 260 is placed upon blank 210. Straps
270 are attached to restraining tools 260 and to form 250. Tension
is applied to straps 270 such that each restraining tool surface
264 is pressed against blank 210, and blank 210 is pulled toward
and pressed against shaped form surface 254 of tool 250. At the
same time, heat may be applied to blank 210 from heat source
272.
[0030] The application of heat and tension to blank 210 causes
blank 210 to be conformed to shaped form surface 254 of form 250
and to restraining tool surfaces 264. In a preferred embodiment,
the heat provided by heat source 272 may not exceed 180 degrees
Fahrenheit, and for an exposure period of less than 30 minutes.
Outside temperature variations and humidity may affect the heat
levels and duration applied to form the blank 210. Other heating
periods and temperatures may be used, however, without departing
from the present invention. Rather, the specific temperature and
time periods are merely exemplary of a preferred embodiment, and no
limitation is intended.
[0031] Once heated, blank 210 is then allowed to cool until it
holds the shape of shaped form surface 254 of form 250 and
restraining tool surfaces 264 in shaped position 240 without being
pressed against shaped form surface 254 or restraining tool
surfaces 264. Restraining tools 260 and straps 270 are then removed
from blank 210, and blank 210 is removed from form 250. Form 250
and restraining tools 260 are made of one or more materials that
can withstand pressure and heat required to shape blank 210. In a
preferred embodiment, form 250 may be made from wood or metal, and
restraining tools 260 may be made from wood or metal, however,
other materials having suitable strength and resistance to moisture
may be used.
[0032] While two tools 260 have been shown in FIG. 2A, it is to be
appreciated that any number of tools may be used without departing
from the present invention. Additionally, tool 260 may extend the
length of form 250 such that a single tool 260 is used to capture
the entire blank 210.
[0033] Referring now to FIG. 2B, an exploded side view of the
Improved Surfboard And Method Of Manufacturing of the present
invention is shown and generally designated 280. In apparatus 280,
multiple blanks 210 that are substantially rectangular blocks, are
vertically stacked together, separated by a flexible metal
heat-conducting sheet 274. The stack of blanks 210 and sheets 274
are positioned over form 250.
[0034] Once in position, restraining straps 270 are attached to
tools 260 and the straps 270 are tightened such that the stack of
blanks 210 and sheets 274 are brought tightly against form 250. As
the straps 270 are tightened, the blanks 210 and sheets 274 are
deformed to match the curvature of tools surfaces 264 and form 250.
When the blanks 210 are in the proper form against form 250, heat
is supplied by heat source 272 for a predetermined period of time.
At the end of that heating time period, the heat source is removed,
and the straps are removed, yielding several blanks 210 having the
curvature of curved surface 254 of form 250.
[0035] Flexible metal heat-conducting sheet 274, in a preferred
embodiment, is made from aluminum, however, it is to be appreciated
that other materials having similar flexibility and heat transfer
characteristics may be used. The sheet 274 provides for separation
between blanks 210 as well as conducts heat from heat source 272.
The conduction of heat between blanks 210 is important because
blanks 210, by their nature, are good heat insulators. By providing
a heat conduction path between blanks 210 in the stacked
configuration, each blank is exposed to sufficient heat across its
entire surface during the heating period to provide for the
formation of blank 210 into the curved form 240 (shown in FIG.
2A).
[0036] Referring now to FIG. 2C, a side view of the Improved
Surfboard And Method Of Manufacturing of the present invention 280
is shown. This figure depicts the process by which multiple blanks
210 are simultaneously curved by stacking them vertically,
separated by a metal flexible heat-conducting sheet 274, and
restraining the stack against a form 250 with restraining tools 260
and straps 270. Once blanks 210 are in the proper position against
curve 254 of form 250, the entire stack of blanks 210 and sheets
274 is subjecting to a heat from heat source 272, such as
steam.
[0037] FIG. 3 shows a configuration for cutting blank 210 into a
desired shape, generally designated 300. More specifically, FIG. 3
shows blank 210 with portions 310 cut away from blank 210 to shape
a nose of a board of the present invention. In a preferred
embodiment, cut 310 is formed by a hot wire (not shown in FIG. 3)
that is known in the art. FIG. 3 shows cut 310 as being in a
surfboard shape. Blank 210 may also be shaped by various methods
including, without limitation, further heating, further pressing,
further cutting, sanding, grinding, smoothing, and other shaping
techniques known in the art. After blank 210 has been finally
shaped, it may be referred to as a core 110 as discussed in
conjunction with FIG. 1.
[0038] Referring now to FIG. 4, a cut-away view of board 100 is
shown and reveals core 110 having a stringer 122. Stringer 122 is
typically made of wood, extends the length of core 110 and provides
stiffening to the board 100. After core 110 has been formed, it is
covered with a sealing material, such as FIBERGLAS.RTM. and epoxy
resin, which form laminate 120. This sealing material makes board
100 more durable, and provides a water-proof covering. FIG. 4 also
shows bubbles, or blisters, 410 caused by air, or gas, pockets 420
that can form between core 110 and laminate 120 following use of
the board.
[0039] Referring to FIG. 5, a cross-sectional view of board 100
taken across line 5-5 of FIG. 4 is shown. Specifically, FIG. 5
shows air blister or bubble 410 caused by air pocket 420 between
core 110 and laminate 120. For instance, when a user stands on
board 100, the pressure of his feet upon board 100 can cause
localized deformation to the foam at that place. This deformation
causes air pockets 420 to form between core 110 and laminate 120 in
that location. Each air pocket 420 causes the area of laminate 120
adjacent to air pocket 420 to be raised away from core 110, causing
a raised area or "blister" 410 in laminate 120.
[0040] Air blisters 410 may form where the user places his feet on
board 100, however, blisters 410 can also be caused by other
sources of pressure upon board 100 at other places on board 100.
Each air blister 410 causes a deformation of laminate 120, which
can damage laminate 120 and decrease the strength of board 100 and
make it more difficult to use. Additionally, exposure of the board
100 to heat sources, such as the sun, may cause the formation of
air blisters 410 between the core 110 and the laminate 120 when the
board is not properly vented.
[0041] FIG. 6 shows another cross-sectional view of board 100
similar to FIG. 5, but with at least one perforation vent 130 now
formed in laminate 120 to allow air in air pocket 420 to escape,
thus reducing the size of air pocket 420 and in turn reducing or
eliminating blister 410. The perforation vents 130 help avoid
deformation and damage to laminate 120, and helps maintain the
utility of board 100. Each perforation vent 130 is large enough to
allow air to pass through it, and small enough to allow little
water or no water to pass through it. Thus, each perforation 130
allows air to get out from between laminate 120 and core 110, but
allows little water or no water to get in between laminate 120 and
core 110.
[0042] In a preferred embodiment, perforations 130 are formed
through laminate 120 of board 100 at the time of manufacturing and
prior to use, and thus, prior to the formation of any bubbles or
blisters 420. As a result, there is little or no chance for a
blister to form, because any air or gas that develops between
laminate 120 and core 110 escapes through perforation 130 before it
can develop into a blister 410.
[0043] As used herein, it is to be understood that "little water"
comprises the meanings of "no water" and "substantially no water"
as well as the meaning of "a very small amount of water more than
no water." No measurable or significant weight change is caused by
any moisture absorption into the surfboard or surf craft.
[0044] Each perforation vent 130 is formed by a perforating tool
610 which has a perforating tool body 620 having a working surface
624, and at least one perforation needle 630 extending from working
surface 624. Each perforation vent 130 is formed as follows.
Working surface 624 is placed adjacent laminate 120 and perforating
tool 610 is manipulated such that at least one needle 630 is
translated in the direction 640 toward board 100 until needle 630
penetrates (or perforates) laminate 120 to form an airway, or vent
130, through the laminate 120.
[0045] Perforating tool 610 is then manipulated such that each at
least one needle 630 is then translated in the direction 650
opposite the direction 640 in which needle 630 points, and needle
630 is withdrawn from laminate 120, leaving a perforation, or vent,
130 formed in laminate 120 by each needle 630 that penetrates
laminate 120. In a preferred embodiment of the present invention,
each needle 630 does not penetrate core 110. In an alternative
embodiment of the present invention, at least one needle 630 at
least partially penetrates core 110.
[0046] Needles 630 may be made of stainless steel. Needles 630 may
alternatively be made of any other material having sufficient
strength to perforate laminate 120. In a preferred embodiment of
the present invention, at least one needle 630 is heated to
facilitate penetration of laminate 120. If needles 630 are heated,
they may be heated to a range of 200 to 250 degrees F.
Alternatively, needles 630 may be heated to a temperature in the
range from zero degrees Kelvin to the melting point temperature of
the material of which the needles 360 are made. In an alternative
embodiment of the present invention, each needle 630 is not
heated.
[0047] In an alternative embodiment, needles 630 may be formed with
grooves or threads 635 like a traditional drill bit having a small
diameter. In such an embodiment, perforating tool 610 may be
capable of rotating needle 630 in direction 633 to bore a
perforation vent 130 through laminate 120.
[0048] FIG. 7 is a top view of board 100. Board 100 shown in FIG. 7
is a short board. An array of perforations 130 are placed where a
user would likely place his or her feet on board 100. Perforations
130 may alternatively be placed in any other location on board 100,
such as next to the rails of the surfboard.
[0049] Referring now to FIG. 8, a top view of another embodiment of
the Improved Surfboard And Method Of Manufacturing of the present
invention is shown and generally designated 800. This embodiment is
a typical long board and has perforations 130 in locations where a
user is likely to place his or her feet on this type of board 800.
Perforations 130 may alternatively be placed in any other location
on board 800.
[0050] FIG. 9 is a side view of another embodiment of a perforating
tool generally designated 910. Tool 910 includes a flat body 920
having a flat working surface 624 and multiple perforating needles
630. FIG. 9 shows needles 630 as substantially parallel to each
other, and extending from working surface 624 at an angle
substantially perpendicular to working surface 624 at the point
where needle 630 intersects working surface 624. In an alternative
embodiment, each needle 630 may extend from working surface 624 at
an angle other than perpendicular to working surface 624 at the
point where needle 630 intersects working surface 624.
[0051] Referring now to FIG. 10, a side view of another embodiment
of a perforating tool is shown and generally designated 1010. Tool
1010 includes a body 1020 having a curved working surface 1024 with
a radius 1012, and multiple perforation needles 630 extending
radially away from the curved working surface 1024.
[0052] FIG. 10 shows each perforation needle 630 as being at an
angle 632 to body 1020. In a preferred embodiment, this angle 632
is ninety degrees (90.degree.) as dictated by its radial placement
on the curved working surface 1024. FIG. 10 also shows each needle
630 as being substantially perpendicular to curved working surface
1024 at the point where needle 630 intersects curved working
surface 1024. In an alternative embodiment, each needle 630 may be
at an angle 632 other than perpendicular to curved working surface
1024 at the point where needle 630 intersects curved working
surface 1024.
[0053] As shown in FIG. 10, each perforation needle 630 has a
length 634 and a diameter 636. In a preferred embodiment, length
634 is slightly longer than the thickness 638 of laminate 120 (as
shown in FIG. 6). Also, in a preferred embodiment, thickness 638
may be 1/8 to {fraction (3/16)} inch or more, and length 634 may be
{fraction (3/16)} inch (0.1875") or more, so long as the length 634
is equal to or greater than thickness 638.
[0054] The diameter 636 of perforation needle 630 may vary between
0.005 inches and 0.05 inches, and in a preferred embodiment, is
0.008 inches. It is to be appreciated that although perforation
needle 630 has been depicted in the Figures as a cylindrical
needle, no limitation as to the cross-sectional shape is intended.
To the contrary, the cross-sectional shape of the perforation
needle 630 may vary, including but not limited to, oval,
rectangular, square, or other shapes. Regardless of the
cross-sectional shape of perforation needle 630, the
cross-sectional area of vent 130 remains small enough to allow the
exit of gasses collecting between material 120 and core 110.
[0055] FIG. 11 shows how curved perforating tool 1010 is used to
make a row of perforations 130. FIG. 11 shows a cross section of a
surfboard of the present invention, with curved perforating tool
1010 positioned adjacent board 100. In use, curved working surface
1024 is placed adjacent laminate 120 such that at least one needle
630 penetrates laminate 120. Curved working surface 1024 is then
"rolled" clockwise in direction 1030 across laminate 120 to a
second position (shown by 1020' in dashed lines) such that each
perforation needle 630 successively penetrates and is then
withdrawn from laminate 120, leaving a perforation vent where each
needle 630 has penetrated laminate 120. FIG. 11 shows curved
working surface 1024 as contacting laminate 120.
[0056] Alternatively, curved perforating tool 1010 can be
manipulated such that curved working surface 1024 does not actually
contact laminate 120 thereby avoiding any damage to laminate 120
from perforating tool 1010. For instance, as curved perforating
tool 1010 is rolled clockwise above laminate 120, each needle 630
rotates as the tool 1010 is translated, such that each needle 630
remains substantially perpendicular to laminate 120 as it forms
perforation vent 130. This is particularly useful when tool 1010 is
heated, and contact between tool 1010 and laminate 120 may cause
marks or blemishes to form.
[0057] In FIG. 11, curved working surface 1024 is curved in at
least one dimension of curved working surface 1024. FIG. 11 shows
curved working surface 1024 as substantially convex. Alternatively,
curved working surface 1024 can be at least partially concave
without departing from the present invention. In a preferred
embodiment, the curve of curved working surface 1024 is
substantially an arc of a circle that has a radius 1012, in at
least one dimension of curved working surface 1024. Alternatively,
curved working surface 1024 can have a curve that is other than
circular, including, without limitation, parabolic, hyperbolic, or
any combination thereof.
[0058] Referring now to FIG. 12, a flow chart representing a
preferred method of manufacturing an Improved Surfboard of the
present invention, and is generally designated 1200. Method 1200
includes a first step 1202 in which one or more closed-cell foam
blanks is obtained, and then placed on the form in step 1204. Once
on the form, conductive sheets are inserted between the blanks in
step 1206, and the blanks and conductive sheets are secured to the
form using tools and straps in step 1208.
[0059] The assembly of tools, blanks separated by sheets, and
secured to the form, is then exposed to heat from a heat source for
a predetermined time period in step 1210. At the expiration of that
time period, the assembly is cooled for a second predetermined time
period in step 1212.
[0060] Once cooled, the tools and straps are removed, and the
blanks are removed from the form and separated from the conductive
sheets in step 1214.
[0061] Once thoroughly cooled, the now-formed blanks are shaped to
form a core and covered with sealing material in step 1216. Once
the sealing material is dry, a number of vents are formed through
the sealing material in final step 1218 to yield an Improved
Surfboard of the present invention.
[0062] While the particular Improved Surfboard And Method Of
Manufacturing as herein shown and disclosed in detail is fully
capable of obtaining the objects and providing the advantages
herein before stated, it is to be understood that it is merely
illustrative of the presently preferred embodiments of the
invention and that no limitations are intended to the details of
construction or design herein shown other than as described in the
appended claims.
* * * * *