U.S. patent application number 16/583761 was filed with the patent office on 2020-01-16 for foam product.
The applicant listed for this patent is AGIT Global IP Holdings, LLC. Invention is credited to Tzong In Yeh.
Application Number | 20200016862 16/583761 |
Document ID | / |
Family ID | 61617924 |
Filed Date | 2020-01-16 |
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United States Patent
Application |
20200016862 |
Kind Code |
A1 |
Yeh; Tzong In |
January 16, 2020 |
FOAM PRODUCT
Abstract
A foam product includes a foam core, a soft skin covering the
foam core, and a base structure on which the foam core is disposed.
The foam core of expanded beads has an outer surface on which some
outermost beads of the expanded beads are exposed and bulging
outward with different heights to form a bubbly texture. The foam
skin has an inner surface attached to the outer surface of the foam
core, and has at its inner surface a plurality of concave cavities
each matedly surrounding a respective one of the bulging, outermost
beads on the outer surface of the foam core.
Inventors: |
Yeh; Tzong In; (Fremont,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AGIT Global IP Holdings, LLC |
Irvine |
CA |
US |
|
|
Family ID: |
61617924 |
Appl. No.: |
16/583761 |
Filed: |
September 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15819934 |
Nov 21, 2017 |
10464288 |
|
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16583761 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2266/0228 20130101;
B63B 32/57 20200201; B32B 27/32 20130101; B63B 32/80 20200201; B32B
3/30 20130101; A63C 5/03 20130101; B32B 2250/40 20130101; B32B 7/02
20130101; B32B 5/18 20130101; B32B 2266/025 20130101; B32B
2307/4026 20130101; B32B 3/266 20130101; B63B 34/20 20200201; B32B
2307/732 20130101; B32B 2307/554 20130101; B32B 2250/05 20130101;
B32B 2255/10 20130101; B32B 2307/75 20130101; A63C 5/003 20130101;
A63C 5/126 20130101; B32B 3/263 20130101; B32B 5/32 20130101; B32B
27/308 20130101; B63B 2035/009 20130101; B32B 2266/08 20130101;
B32B 27/065 20130101; B32B 7/12 20130101; B32B 3/04 20130101; B32B
7/022 20190101; B32B 27/08 20130101; B32B 5/142 20130101; B63B
2231/50 20130101 |
International
Class: |
B32B 5/32 20060101
B32B005/32; B32B 27/08 20060101 B32B027/08; B32B 27/30 20060101
B32B027/30; B32B 27/32 20060101 B32B027/32; B32B 27/06 20060101
B32B027/06; B32B 5/18 20060101 B32B005/18; A63C 5/00 20060101
A63C005/00; A63C 5/03 20060101 A63C005/03; B63B 35/71 20060101
B63B035/71; B63B 35/79 20060101 B63B035/79 |
Claims
1. A foam product comprising: a foam core including a tightly
packed cluster of expanded beads, wherein some outermost beads of
the expanded beads are exposed and protruded on an outer surface of
the foam core; and a foam skin having an inner surface bonded to
the outer surface of the foam core, and the inner surface of the
foam skin comprising a plurality of concave cavities sized and
shaped to respectively receive the protruded, outermost beads on
the outer surface of the foam core, wherein the foam core and the
foam skin are made of different foam materials.
2. The foam product as recited in claim 1, further comprising a
base structure on which the foam core is disposed, wherein the foam
product is directed to a bicycle saddle in which the foam core
serves as a padding of the bicycle saddle, the foam skin serves as
an overlying layer covering the padding, and the base structure
includes a saddle shell attached to the foam core, and a support
rail mounted underneath the saddle shell.
3. The foam product as recited in claim 1, wherein the expanded
beads of the foam core comprises expanded polypropylene or expanded
polystyrene.
4. The foam product as recited in claim 3, wherein the foam skin
comprises expanded polyethylene.
5. The foam product as recited in claim 4, further comprising a
non-foam plastic film bonded to an outer surface of the foam
skin.
6. The foam product as recited in claim 5, wherein the non-foam
plastic film having a printed pattern.
7. The foam product as recited in claim 1, wherein the foam product
is directed to one of a stand up paddle board, sit on top kayak,
small sail boat, windsurf board, a snow board, and a skiing
board.
8. A foam product comprising: a foam core including a tightly
packed cluster of expanded beads, wherein some outermost beads of
the expanded beads are exposed and protruded on a top surface of
the foam core; an upper foam skin having a bottom surface bonded to
the top surface of the foam core, and the bottom surface of the
upper foam skin comprising a plurality of concave cavities sized
and shaped to respectively receive the protruded, outermost beads
on the top surface of the foam core; a lower foam skin with a top
surface bonded to a bottom surface of the foam core; a non-foam
plastic film with a bottom surface bonded to a top surface of the
upper foam skin; and a non-foam plastic plate with a top surface
bonded to a bottom surface of the lower foam skin; wherein the foam
core and the upper foam skin are made of different foam materials;
the foam core and the lower foam skin are made of different foam
materials.
9. The foam product as recited in claim 8, wherein some outermost
beads of the expanded beads are exposed and protruded on the bottom
surface of the foam core; and the top surface of the lower foam
skin comprising a plurality of concave cavities sized and shaped to
respectively receive the protruded, outermost beads on the bottom
surface of the foam core.
10. The foam product as recited in claim 8, wherein the upper foam
skin and the lower foam skin are made of expanded polyethylene.
11. The foam product as recited in claim 8, wherein the non-foam
plastic film having a printed pattern.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of co-pending application Ser. No.
15/819,934, filed on Nov. 21, 2017.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a foam product, and more
particularly to a closed-cell foam product.
2. Description of the Related Art
[0003] Nowadays, if a foam product is too wide to be carried under
the arm, such as a standup paddle board, it may employ a recessed
grip handle structure so that a user may have the fingers of a hand
be inserted into the grip handle structure to carry the paddle
board under the arm.
[0004] One type of standup paddle board is illustrated in U.S. Pat.
No. 9,120,218. In this paddle board, the grip handle structure is
constructed from a rigid plastic material, such as Nylon.RTM. fiber
and installed flush into the deck of the paddle board at the center
of gravity of the board to provide the proper balance when the
board is carried using the grip handle. More specifically, the grip
handle structure is glued to the foam core of the paddle board
using an epoxy resin glue.
[0005] Another type of standup paddle board is illustrated in U.S.
Patent Pub. No. 2014/0315453. In this paddle board, a recess is
defined in a top surface of the foam core of the paddle board, and
an upper foam skin covers the top surface of the foam core. In
particular, a portion of the upper foam skin extends along the
profile of the recess in the foam core to form a grip handle
structure for carrying the paddle board.
SUMMARY OF THE INVENTION
[0006] This invention provides a new foam product with a different
structure as compared to the convention foam product.
[0007] Specifically, the foam product generally includes a foam
core, a foam skin, and a base structure. The foam core is disposed
on the base structure and is essentially made of expanded beads.
Moreover, the foam core has an outer surface on which some
outermost beads of the expanded beads are exposed and bulging
outward with different heights to form a bubbly texture. The foam
skin has an inner surface attached to the outer surface of the foam
core, and has at its inner surface a plurality of concave cavities
each matedly surrounding a respective one of the bulging, outermost
beads on the outer surface of the foam core.
[0008] In one embodiment, the foam product is directed to a bicycle
saddle in which the foam core serves as a padding, the foam skin
serves as an overlying covering, and the base structure includes a
saddle shell attached to the foam core and a support rail mounted
underneath the saddle shell.
[0009] In another embodiment, the foam product is directed to one
of a stand up paddle board, sit on top kayak, small sail boat,
windsurf board, a snow board, and a skiing board. The foam skin is
placed on top of the foam core. The base structure includes a
second, foam skin bonded to a bottom surface of the foam core, and
a non-foam plastic plate bonded to a bottom surface of the second
foam skin.
[0010] The foregoing and other objectives, features, and advantages
of the invention will be more readily understood upon consideration
of the following detailed description of the invention, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a foam product in accordance
with a first embodiment of the present invention;
[0012] FIG. 2 illustrates that the foam product shown in FIG. 1 is
carried by a user;
[0013] FIG. 3 is a partial cross-sectional view of the foam product
shown in FIG. 1, showing that fingers of a hand are inserted into a
recessed grip handle structure of the foam product;
[0014] FIG. 3A is an enlarged view of the foam product shown in
FIG. 3;
[0015] FIG. 4 is a cross-sectional view of the foam product shown
in FIG. 1 taken along the line IV-IV;
[0016] FIG. 5 is a perspective view of a foam core and a soft shell
of the foam product shown in FIG. 1;
[0017] FIG. 6 is an enlarged view of the foam product shown in FIG.
5;
[0018] FIG. 6A is an enlarged view of the foam product shown in
FIG. 6;
[0019] FIG. 7 is a perspective view of a foam product in accordance
with a second embodiment of the present invention;
[0020] FIG. 8 is a perspective view of a foam core and a soft shell
of the foam product shown in FIG. 7;
[0021] FIG. 9 is an enlarged view of the foam product shown in FIG.
8;
[0022] FIG. 9A is an enlarged view of the foam product shown in
FIG. 9;
[0023] FIG. 10 is a cross-sectional view of the foam product shown
in FIG. 7 taken along the line X-X;
[0024] FIG. 11 is a cross-sectional view of the foam product shown
in FIG. 7 taken along the line XI-XI;
[0025] FIG. 11A is an enlarged view of the foam product shown in
FIG. 11;
[0026] FIG. 12 is a cross-sectional view of a foam product in
accordance with a third embodiment of the present invention;
[0027] FIG. 12A is an enlarged view of the foam product shown in
FIG. 12;
[0028] FIG. 13 is another cross-sectional view of the foam product
shown in FIG. 12;
[0029] FIG. 13A is an enlarged view of the foam product shown in
FIG. 13;
[0030] FIG. 13B is another enlarged view of the foam product shown
in FIG. 13;
[0031] FIG. 14 is a cross-sectional view of a foam product in
accordance with a fourth embodiment of the present invention;
[0032] FIG. 14A is an enlarged view of the foam product shown in
FIG. 14;
[0033] FIG. 14B is another enlarged view of the foam product shown
in FIG. 14;
[0034] FIG. 15 is a cross-sectional view of a foam product in
accordance with a fifth embodiment of the present invention;
[0035] FIG. 15A is an enlarged view of the foam product shown in
FIG. 15;
[0036] FIG. 15B is another enlarged view of the foam product shown
in FIG. 15;
[0037] FIG. 16 is a perspective view of a foam core and a soft
shell of a foam product in accordance with a sixth embodiment of
the present invention;
[0038] FIG. 17 is a partial cross-sectional view of a foam product
in accordance with a seventh embodiment of the present
invention;
[0039] FIG. 18 is a perspective view of a foam core and a soft
shell of the foam product shown in FIG. 17.
[0040] FIG. 19 is a top perspective view of a foam product in
accordance with an eighth embodiment of the present invention;
[0041] FIG. 20 is a bottom perspective view of the foam product
shown in FIG. 19;
[0042] FIG. 21 is an exploded view of the foam product shown in
FIG. 19;
[0043] FIG. 22 is an exploded view of the foam product shown in
FIG. 20;
[0044] FIG. 23 is a cross-sectional view of the foam product shown
in FIG. 19 taken along the line XXIII-XXIII;
[0045] FIG. 23A is a partial enlarged view of the foam product
shown in FIG. 23.
[0046] FIG. 24 is a cross-sectional view of a foam product in
accordance with a ninth embodiment of the present invention;
and
[0047] FIG. 24A is a partial enlarged view of the foam product
shown in FIG. 24.
DETAILED DESCRIPTION OF EMBODIMENTS
[0048] Referring to FIGS. 1-6, there is shown a first embodiment of
the foam product 100 according to the invention. The foam product
100 is a standup paddle board with a grip handle structure 6. A
user can easily hold the foam product 100 using the grip handle
structure 6 under the arm for transporting the foam product 100 in
a comfortable and secure manner, as depicted in FIGS. 2 and 3.
[0049] As shown in FIG. 4, the foam product 100 further includes a
foam core 1, an upper foam skin 2 and a lower foam skin 3. In this
embodiment, the upper foam skin 2 is shaped like a half-shell and
has a bottom surface glued to a top surface as well as side
surfaces of the foam core 1. The lower foam skin 3 has a top
surface glued to a bottom surface of the foam core 1. The foam core
1 is made of expanded polystyrene (EPS). The upper foam skin 2 and
the lower foam skin 3 are both made of a relative softer material,
such as expanded polyethylene (EPE) and each has a thickness of
about 4 mm to 5 mm. The foam product 100 further includes a
non-foam plastic film 4 and a non-foam plastic plate 5 for
protection. The non-foam plastic film 4 has a bottom surface
directly heat-laminated to the top surface of the upper foam skin
2. The non-foam plastic film 4 may be colored or printed with a
pattern visible from the outside of the film 4. On the other hand,
the non-foam plastic plate 5 is directly heat-laminated to the
bottom surface of the lower foam skin 3. And, the non-foam plastic
plate 5 is made of a wear-resistant material, such as polyethylene
(PE), with a thickness of about 0.3 mm to 1.5 mm. Referring back to
FIG. 3, the grip handle structure 6 includes a soft shell 61 and an
opening 62 extending through the upper foam skin 2 and the non-foam
plastic film 4. The soft shell 61 is preferably made of an
irradiated cross-linked polyethylene foam, with a thickness of
about 2 mm to 3 mm.
[0050] FIG. 5 illustrates the foam core 1 with a recess 10 in which
the soft shell 61 is disposed. As shown in FIGS. 6 and 6A, the foam
core 1 includes a tightly packed cluster of expanded beads 11. Each
of the expanded beads 11 is made of a pre-expanded polystyrene
bead. The foam core 1 defines the recess 10 in its top surface. The
recess 10 has an upper space 101 and a lower, enlarged space 102.
The soft shell 61 is suited in the recess 10 of the foam core 1 and
has an upper space (not numbered) configured in size to receive
four fingers of a human hand, and a lower, enlarged space (not
numbered) to permit bending of the fingers, as shown in FIG. 3, as
well.
[0051] It is noted that, some outermost beads 11 of the expanded
beads 11 are exposed and bulging outward from the inner wall of the
recess 10 of the foam core 1 with different heights to form a
bubbly texture T. The soft shell 61 has its outer wall bonded to
the inner wall of the recess 10 of the foam core 1. More
specifically, as shown in FIGS. 3A and 6A, the soft shell 61 has a
plurality of concave cavities 610 at its outer wall. Each of the
concave cavities 610 of the soft shell 61 matedly surrounds a
respective one of the bulging, outermost beads 11 in the recess 10
of the foam core 1. In contrast, the inner wall of the soft shell
61 is relatively more flat than the outer wall of the soft shell
61. In other words, the concave cavities 610 are defined only in
the outer wall of the soft shell 61, not the inner wall of the soft
shell 61. The soft shell 61 and the foam core 1 are firmly bonded
together due to the inter-engaged convex and concave surfaces
between the soft shell 61 and the foam core 1. Besides, it should
be noted that the soft shell 61 and the foam core 1 may be directly
heat bonded to each other with similar materials. Alternatively, an
adhesive may be employed in between the soft shell 61 and the foam
core 1 to further enhance the bonding between the two.
[0052] Referring to FIGS. 7-11, there is shown a second embodiment
of the foam product 200 according to the invention. The foam
product 200 of the second embodiment is generally identical to the
foam product 100 of the first embodiment in appearance, and has a
grip handle structure 6 for being grasped. However, the foam
product 200 is slightly different from the foam product 100 in the
interior structure. For example, the foam core 1 of the foam
product 100 is made of a single foam body with the same material;
however, the foam product 200 is a combination of two foam bodies
with different materials and densities.
[0053] FIG. 8 illustrates a perspective view of the foam core 1 and
the soft shell 61 of the foam product 200. As shown, the foam core
1 includes a first foam body 1a and a second foam body 1b embedded
in the first foam body 1a. Specifically, the second foam body 1b is
more rigid than the first foam body 1a. The recess 10 is defined in
the second foam body 1b of the foam core 1. The first foam body 1a
is made of expanded polystyrene, and the second foam body 1b is
made of a copolymer of expanded polystyrene and expanded
polyethylene. As best seen in FIG. 9, the recess 10 has an upper
space 101 and a lower, enlarged space 102. The soft shell 61 is
suited in the recess 10 of the second foam body 1b of the foam core
1, and has an upper space (not numbered) configured in size to
receive four fingers of a human hand, and a lower, enlarged space
(not numbered) to permit bending of the fingers, as shown in FIG.
9.
[0054] As shown in FIG. 10, the foam product 200 further includes
an upper foam skin 2 and a lower foam skin 3. The upper foam skin 2
is shaped like a half-shell and has a bottom surface glued to a top
surface as well as side surfaces of the foam core 1. The lower foam
skin 3 has a top surface glued to a bottom surface of the foam core
1. The upper foam skin 2 and the lower foam skin 3 are both made of
a relative softer material, such as expanded polyethylene (EPE) and
each has a thickness of about 4 mm to 5 mm. The foam product 200
further includes a non-foam plastic film 4 and a non-foam plastic
plate 5 for protection. The non-foam plastic film 4 has a bottom
surface directly heat-laminated to the top surface of the upper
foam skin 2. And, the non-foam plastic film 4 may be colored or
printed with a pattern visible from the outside of the film 4. The
non-foam plastic plate 5 is directly heat-laminated to the bottom
surface of the lower foam skin 3. And, the non-foam plastic plate 5
is made of a wear-resistant material, such as polyethylene (PE),
with a thickness of about 0.3 mm to 1.5 mm. As shown in FIG. 11,
the grip handle structure 6 includes a soft shell 61 and an opening
62 extending through the upper foam skin 2 and the non-foam plastic
film 4. The soft shell 61 is preferably made of an irradiated
cross-linked polyethylene foam, with a thickness of about 2 mm to 3
mm.
[0055] Referring back to FIGS. 9 and 9A, the second foam body 1b of
the foam core 1 includes a tightly packed cluster of expanded beads
11. Each of the expanded beads 11 is made of a pre-expanded bead.
Similarly, the first foam body 1a of the foam core 1 is made of a
tightly packed cluster of expanded beads 11, not shown, but with a
different material. As shown in FIGS. 11 and 11A, some outermost
beads 11 of the expanded beads 11 are exposed and bulging outward
from the inner wall of the recess 10 of the second foam body 1b
with different heights to form a bubbly texture T. The soft shell
61 has its outer wall attached to the inner wall of the recess 10
of the foam core 1. More specifically, the soft shell 61 has a
plurality of concave cavities 610 at its outer wall. Each of the
concave cavities 610 of the soft shell 61 matedly surrounds a
respective one of the bulging, outermost beads 11 in the recess 10
of the second foam body 1b. In contrast, the inner wall of the soft
shell 61 is relatively more flat than the outer wall of the soft
shell 61. In this manner, the soft shell 61 and the second foam
body 1b are firmly bonded together due to the inter-engaged convex
and concave surfaces between the soft shell 61 and the second foam
body 1b. It should be noted that the soft shell 61 and the second
foam body 1b may be directly heat bonded to each other with similar
materials. Alternatively, an adhesive may further be employed to
further enhance the bonding of the soft shell 61 and the second
foam body 1b.
[0056] Referring to FIGS. 12-13, there is shown a third embodiment
of the foam product 300 according to the invention. The foam
product 300 of the third embodiment is generally identical to the
foam product 200 of the second embodiment in appearance and in
structure. For example, the foam core 1 of the foam product 300
also includes a first foam body 1a and a second foam body 1b.
However, the foam core 1 and the upper foam skin 2 of the foam
product 300 are bonded in a different manner.
[0057] As shown in FIGS. 12 and 12A, some outermost beads 11 of the
expanded beads are exposed and bulging outward from the top surface
of the first foam body 1a of the foam core 1 with different heights
to form a bubbly texture T. Referring to FIG. 13, the upper foam
skin 2 has at its bottom surface a plurality of concave cavities 20
each matedly surrounding a respective one of the bulging, outermost
beads 11 on the top surface of the first foam body 1a, except that
a small area of the bottom surface of the upper foam skin 2 is
adhered to the top surface of the second foam body 1b. In other
words, the upper foam skin 2 is partly bonded to the second foam
body 1b via adhesives, and is mostly bonded to the first foam body
1a via the inter-engaged convex and concave surfaces, as shown in
FIG. 13A. Likewise, the soft shell 61 is bonded to the second foam
body 1b via the inter-engaged convex and concave surfaces, as shown
in FIG. 13B.
[0058] Referring to FIGS. 14, 14A and 14B, there is shown a fourth
embodiment of the foam product 400 according to the invention. The
foam product 400 of the fourth embodiment is generally identical to
the foam product 300 of the third embodiment. For example, the foam
core 1 of the foam product 400 includes a first foam body 1a and a
second foam body (not shown); and the upper foam skin 2 is bonded
to the first foam body 1a via the inter-engaged convex and concave
surfaces, as shown in FIG. 14B. However, unlike the third
embodiment, the foam core 1 and the lower foam skin 3 of the foam
product 400 of this fourth embodiment are bonded in a different
manner, as shown in FIG. 14A.
[0059] In FIG. 14A, some outermost beads 11 of the expanded beads
are exposed and bulging outward from the bottom surface of the
first foam body 1a of the foam core 1 with different heights to
form a bubbly texture T. The lower foam skin 3 has at its top
surface a plurality of concave cavities 30 each matedly surrounding
a respective one of the bulging, outermost beads 11 on the bottom
surface of the first foam body 1a. As such, the lower foam skin 3
is firmly bonded to the first foam body 1a via the inter-engaged
convex and concave surfaces as well.
[0060] Referring to FIGS. 15, 15A and 15B, there is shown a fifth
embodiment of the foam product 500 according to the invention. The
foam product 500 of the fifth embodiment is generally identical to
the foam product 400 of the fourth embodiment, except that a
non-foam plastic film 35 is interposed in between the lower foam
skin 3 and the non-foam plastic plate 5.
[0061] In practice, the expanded beads of the foam core 1 may be
made of expanded polypropylene or expanded polystyrene. The upper
foam skin 2 may be made of expanded polyethylene. The upper
non-foam plastic film 4 may be made of ethylene. Furthermore, the
upper foam skin 2 has a thickness greater than that of the foam
core 1, but smaller than that of the upper non-foam plastic film
4.
[0062] It is noted that, the foam product 500 has a base structure
which includes the lower foam skin or layer 3 bonded to the bottom,
inner surface of the foam core 1, the non-foam plastic plate 5
joined to the bottom surface of the foam layer 3, the non-foam
plastic film 35 interposed in between the foam layer 3 and the
non-foam plastic plate 5, and a pattern (not shown) printed on the
non-foam plastic film 35 and visible through the non-foam plastic
plate 5. Preferably, the non-foam plastic film 35 and the non-foam
plastic plate 5 may both be made of ethylene.
[0063] Referring to FIG. 16, there is shown a sixth embodiment of
the foam product 600 according to the invention. The foam product
600 of the sixth embodiment is generally identical to the foam
product 300 of the third embodiment. For example, the foam core 1
of the foam product 600 includes a first foam body 1a and a second
foam body 1b; and the upper foam skin 1 is bonded to the first foam
body 1a via the inter-engaged convex and concave surfaces. However,
the soft shell 61 of the foam product 600 is slightly different
from that of the foam product 300.
[0064] As shown in FIG. 16, the soft shell 61 includes a shell body
611 and a pair of extensions 612 extending from opposite sides of
the shell body 611. Each of the extensions 612 has two sheets (not
numbered) attached to each other. The recess 10 of the second foam
body 1b of the foam core 1 is sized and shaped to receive the whole
soft shell 61, namely both the shell body 611 and the extensions
612.
[0065] Referring to FIGS. 17 and 18, there is shown a seventh
embodiment of the foam product 700 according to the invention. The
foam product 700 of the seventh embodiment is generally identical
to the foam product 300 of the third embodiment. For example, the
foam core 1 of the foam product 700 includes a first foam body 1a
and a second foam body 1b; and the upper foam skin 1 is bonded to
the first foam body 1a via the inter-engaged convex and concave
surfaces. However, the soft shell 61 of the foam product 700 is
slightly different from that of the foam product 300.
[0066] As shown in FIG. 17 or 18, the soft shell 61 includes a
shell body 611 and a flange 613 extending from a top edge of the
shell body 611. The recess 10 of the second foam body 1b of the
foam core 1 is sized and shaped to receive the whole soft shell 61,
namely both the shell body 611 and the flange 613.
[0067] As described above, the present invention provides a foam
product in which the soft shell and/or the foam skin may be firmly
bonded to the foam core using the characteristic of the expanded
beads of the foam core. The foam product may be one of a stand up
paddle board, sit on top kayak, small sail boat, a windsurf board,
a snow board, a skiing board, and other craft boards that are too
wide to be carried under the arm. It is noted that the foam product
is not limited to be shaped like a board or plate. Instead, the
foam product would be non-flattened with a different shape.
[0068] Referring to FIGS. 19 to 23, there is shown an eighth
embodiment of the foam product 800 according to the invention. The
foam product 800 of the eighth embodiment is directed to a bicycle
saddle having a foam structure similar to that of the
aforementioned embodiments.
[0069] As shown in FIG. 19, the foam product 800 in form of a
bicycle saddle includes a base structure 7, and a saddle cushion 8
mounted on the base structure 7. As shown in FIG. 20, the base
structure 7 generally includes a saddle shell 71 and a support rail
72 mounted underneath the saddle shell 71, as known in the art. As
shown in FIGS. 21 and 22, the saddle shell 71 has a flat top
surface 710 bonded to a flat bottom surface 810 of the saddle
cushion 8 with adhesives, for example. Preferably, the saddle shell
71 is made of a fiber-reinforced plastic.
[0070] As best seen in FIG. 23, the saddle cushion 8 of the bicycle
saddle 800 generally includes a foam core 81, a foam skin 82 and a
non-foam plastic film 83. The foam core 81 has its flat bottom
surface 810 bonded to the flat top surface of the saddle shell 71
of the base structure 7 with adhesives. The foam skin 82 has an
inner surface attached to the outer surface of the foam core 81,
and the non-foam plastic film 83 is disposed on an outer surface of
the foam skin 82. A pattern (not shown) may be printed on an inner
surface of the non-foam plastic film 83 and sandwiched in between
the foam skin 82 and the non-foam plastic film 83. Moreover, the
foam skin 82 has a thickness greater than that of the foam core 81,
but smaller than that of the non-foam plastic film 83. It is
understood that, the foam core 81 serves as a padding of the
bicycle saddle 800, and the foam skin 82 along with the non-foam
plastic film 83 serves as an overlying layer covering the
padding.
[0071] As depicted in FIG. 23A, the foam core 81 of the saddle
cushion 8 includes a tightly packed cluster of expanded beads 811.
Each of the expanded beads 811 may be made of a pre-expanded
polypropylene bead, a pre-expanded polystyrene bead, a pre-expanded
polyethylene bead or a pre-expanded polystyrene-polyethylene
composite bead. The foam core 81 of the expanded beads has an outer
surface on which some outermost beads of the expanded beads 811 are
exposed and bulging outward with different heights to form a bubbly
texture T. On the other hand, the foam skin 82 has an inner surface
attached to the outer surface of the foam core 81, and has at its
inner surface a plurality of concave cavities 820 each matedly
surrounding a respective one of the bulging, outermost beads 811 on
the outer surface of the foam core 8. The foam skin 82 and the foam
core 81 are firmly bonded together due to the inter-engaged convex
and concave surfaces therebetween. Besides, it should be noted that
the foam skin 82 and the foam core 81 may be directly heat bonded
to each other with similar materials. Alternatively, an adhesive
may be employed in between the foam skin 82 and the foam core 81 to
further enhance the bonding between the two. In contrast, the outer
surface of the foam skin 82 is relatively more flat than the inner
surface of the foam skin 82 and is bonded with the non-foam plastic
film 83.
[0072] As described above, the expanded beads of the foam core 81
may comprise a material of expanded polyolefin, expanded
polystyrene or copolymers. The foam skin 82 may comprise a material
of expanded polyethylene or expanded polypropylene with a thickness
of about 2 mm. The non-foam plastic film 83 may be made of a
wear-resistant material, such as polyethylene (PE) or a Surlyn.RTM.
resin, with a thickness of about 0.03 to 0.3 mm. As is known in the
art, the Surlyn.RTM. resin is a copolymer of ethylene and
methacrylic acid manufactured by DuPont, and generally has better
wear resistance than the polyethylene.
[0073] Referring to FIGS. 24 and 24A, there is shown a ninth
embodiment of the foam product 900 according to the invention. The
foam product 900 of the ninth embodiment is generally identical to
the foam product 800 of the eighth embodiment, except that the
saddle cushion 8a is slightly different from the saddle cushion 8
shown in FIG. 23. That is to say, a second, non-foam plastic film
84 is further employed on an outer surface of the first non-foam
plastic film 83. And, the second non-foam plastic film 84 is more
wear-resistant than the first non-foam plastic film 83. In this
embodiment, the first non-foam plastic film 83 is made of ethylene,
and the second non-foam plastic film 84 is made of the Surlyn.RTM.
resin with a thickness of about 0.6 mm.
[0074] It should be evident that this disclosure is by way of
example and that various changes may be made by adding, modifying
or eliminating details without departing from the fair scope of the
teaching contained in this disclosure.
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