Patent Publication Number: US-11649013-B2

Title: Three piece blank for forming a surf craft

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and is a non-provisional of U.S. Patent Application Ser. No. 62/203,361 for a “Three Piece Blank for Forming a Surf Craft” filed on Jul. 20, 2021, the contents of which are incorporated herein by reference in its entirety. 
    
    
     FIELD 
     This disclosure relates to the field of surf craft. More particularly, this disclosure relates to a blank for forming a surf craft. 
     BACKGROUND 
     Surf craft, such as bodyboards, kneeboards, surfboards, sailboards, wake surf boards, wakeboards, paddleboards, and other similar boards may be formed having cores made of foam, wood, and other lightweight materials. Existing surf craft may be formed with two pieces of a lightweight core foam material that are joined together along a centerline of the surf craft. The core, prior to any shaping, may be referred to as a blank. The blank is subsequently shaped into a desired form for the surf craft, and various additional layers or skins may be added (such as fiberglass, plastics, and other suitable materials). 
     Surf craft are commonly formed from blanks using hand shaping tools. However, it is difficult to form complicated shapes on the surf craft. For example, forming a channel on a bottom of a surf craft such as the channel disclosed in U.S. Pat. No. 10,974,797 may be difficult using traditional handheld tools. For example, forming opposing channel walls having a precise curve shape with perpendicular sidewalls may be difficult with traditional hand shaping methods. Further, more advanced shaping software and shaping machines commonly used for surfcraft may not be capable of shaping channels having curved perpendicular sidewalls. Shaping a surf craft channel having curved surfaces that, for example, vary simultaneously in two dimensions may be difficult and time consuming, particularly when sidewalls of the channel are perpendicular to a bottom of the channel. 
     What is needed, therefore, is a blank for forming a surf craft that allows for effective shaping of the surf craft and any features formed on the surf craft. 
     SUMMARY 
     The above and other needs are met by a blank for forming a surf craft and a method therefore that allows for forming of a surf craft having complex shapes. In a first aspect, a method of forming a surf craft includes: providing a bottom section including a surface thereon, wherein at least a portion of the bottom surface section defines a bottom portion of a channel formed on a bottom surface of the surf craft; joining a first side section with the bottom section towards a first side of the bottom section, the first side section having a shaped wall portion defining a first side wall of the channel formed on the bottom surface of the surf craft; joining a second side section with the bottom section towards a second side of the bottom section, the second side section having a shaped wall portion defining a second side wall of the channel formed on the bottom surface of the surf craft, the second side wall being opposed to the first side wall; and shaping one or more outer edges of the bottom section, first side section, and second side section into a desired shape of the surf craft. 
     The method may further include forming a curved portion in the shaped wall portion of the first side section prior to joining the first side section with the bottom section and forming a curved portion in the shaped wall portion of the second side section prior to joining the second side section with the bottom section. 
     The shaped wall portion of the first side section and the shaped wall portion of the second side section may be perpendicular to the bottom portion of the bottom section. Curved sides may be formed on the bottom section, the curved sides correspond to the curved portion of the first side section and the curved portion of the second side section. 
     The bottom section may define a center of the surf craft, the first side section may be located adjacent to a first side of the bottom section and defines a first side of the surf craft; and the second side section may be located adjacent to a second side of the bottom section and may define a second side of the surf craft. 
     The first side section may be located on the surface of the bottom section at a first side of the bottom section, and the second side section may be located on the surface of the bottom section on a second side of the bottom section. The one or more outer edges of the bottom section, first side section, and second side section may be shaped into the desired shape of the surf craft prior to joining the bottom section, first side section, and second side section. 
     The portion of the bottom surface section that defines the bottom portion of the channel may be formed with a sloped surface prior to joining the bottom section with the first side section and the second side section. 
     In a second aspect, a surf craft includes: a bottom section including a surface thereon, wherein at least a portion of the bottom surface section defines a bottom portion of a channel formed on a bottom surface of the surf craft; a first side section joined with the bottom section towards a first side of the bottom section, the first side section having a shaped wall portion defining a first side wall of the channel formed on the bottom surface of the surf craft; and a second side section with the bottom section towards a second side of the bottom section, the second side section having a shaped wall portion defining a second side wall of the channel formed on the bottom surface of the surf craft, the second side wall being opposed to the first side wall. The bottom portion of the bottom section, the first side wall of the first side section, and the second side wall of the second section may define a channel formed at least partially along a bottom of the surf craft. 
     The first side wall of the first side section and the second side wall of the second side section may be curved. The first side wall and the second side wall may be formed in asymptotic curves. 
     The bottom section may define a center portion of the surf craft; the first side section may be located adjacent to a first side of the bottom section and defines a first side of the surf craft; and the second side section may be located adjacent to a second side of the bottom section and defines a second side of the surf craft. 
     The bottom section may extend across a width of the surf craft; the first side section may be located on the surface of the bottom section at a first side of the bottom section; and the second side section may be located on the surface of the bottom section on a second side of the bottom section. 
     The portion of the bottom section that defines the bottom of the channel may be sloped. 
     In a third aspect, a surf craft includes a bottom section including a surface thereon, wherein at least a portion of the bottom surface section defines a bottom portion of a channel formed on a bottom surface of the surf craft; a first side section joined with the bottom section towards a first side of the bottom section, the first side section having a curved wall portion defining a first side wall of the channel formed on the bottom surface of the surf craft; and a second side section with the bottom section towards a second side of the bottom section, the second side section having a curved wall portion defining a second side wall of the channel formed on the bottom surface of the surf craft, the second side wall being opposed to the first side wall. The bottom portion of the bottom section, the first side wall of the first side section, and the second side wall of the second section define a channel formed at least partially along a bottom of the surf craft. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features, aspects, and advantages of the present disclosure will become better understood by reference to the following detailed description, appended claims, and accompanying figures, wherein elements are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein: 
         FIG.  1    shows a perspective view of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  2    shows a top exploded view of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  3 A  shows a top view of one of the opposing side sections of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  3 B  shows a side view of one of the opposing side sections of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  4 A  shows a top view of a center section of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  4 B  shows a side view of a center section of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  5 A  shows a top view of a blank assembled from the opposing side sections and the center section according to one embodiment of the present disclosure; 
         FIG.  5 B  shows a side view of a blank assembled from the opposing side sections and the center section according to one embodiment of the present disclosure; 
         FIG.  6 A  shows a top view of a blank assembled from the opposing side sections and the center section having a channel extending along a full length of the blank according to one embodiment of the present disclosure; 
         FIG.  6 B  shows a side view of a blank assembled from the opposing side sections and the center section having a channel extending along a full length of the blank according to one embodiment of the present disclosure; 
         FIG.  7 A  shows a top view of a blank having a channel along a substantial length of the blank with curved bottom ends according to one embodiment of the present disclosure; 
         FIG.  7 B  shows a side view of a blank having a channel along a substantial length of the blank with curved bottom ends according to one embodiment of the present disclosure; 
         FIG.  8    shows an exploded perspective view of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  9    shows a perspective view of a blank having shaped outer edges according to one embodiment of the present disclosure; 
         FIG.  10    shows a perspective view of a blank having a channel along substantially a full length of the blank having a variable depth according to one embodiment of the present disclosure; 
         FIG.  11    shows a perspective view of a blank having a channel along substantially a full length of the blank having a substantially constant depth according to one embodiment of the present disclosure; 
         FIG.  12    shows a perspective view of a blank having shaped outer edges and a channel along a full length of the blank according to one embodiment of the present disclosure; 
         FIG.  13    and  FIG.  14    show top views of a blank for forming a surf craft, with a shape of a resulting surf craft delineated in broken lines according to one embodiment of the present disclosure; 
         FIG.  15 A  shows a top view of a blank and a surf craft outlined thereon according to one embodiment of the present disclosure; 
         FIG.  15 B  shows a side view of the blank of  FIG.  15 A  according to one embodiment of the present disclosure; 
         FIG.  16 A  shows a top view of a blank and a surf craft with a full-length channel outlined thereon according to one embodiment of the present disclosure; 
         FIG.  16 B  shows a side view of the blank of  FIG.  16 A  with a full-length channel according to one embodiment of the present disclosure; 
         FIG.  17 A  and  FIG.  17 B  show a surf craft planshape on a blank having a full-length channel with both channel bottom and sidewalls curved along an entire length of the surfboard according to one embodiment of the present disclosure; 
         FIG.  18    shows a perspective view of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  19    shows an exploded plan view of a blank for forming a surf craft according to one embodiment of the present disclosure; 
         FIG.  20 A  shows a top view of a blank for forming a surf craft according to one embodiment of the present disclosure; and 
         FIG.  20 B  shows a side view of a blank for forming a surf craft according to one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various terms used herein are intended to have particular meanings. Some of these terms are defined below for the purpose of clarity. The definitions given below are meant to cover all forms of the words being defined (e.g., singular, plural, present tense, past tense). If the definition of any term below diverges from the commonly understood and/or dictionary definition of such term, the definitions below control. 
       FIG.  1    shows an embodiment of an assembled blank  10  for forming a surf craft. The blank  10  is preferably formed such that a resulting surf craft may be shaped from the blank, such as by sanding or cutting of the blank into a desired shape for the surf craft. The blank  10  is formed of a plurality of sections, such as three separate sections, that may be joined together as shown in  FIG.  1   . Embodiments of the blank  10  described herein advantageously allow for shaping of a surf craft having complex features or shapes in the surf craft, such as a channel  12 . 
     The channel  12  or other features of the surf craft may be shapes that are formed on surfaces of the surf craft. For example, the channel  12  may be formed according to the disclosure of U.S. Pat. No. 10,974,797, which is incorporated herein by reference in its entirety. Such channel may include a shaped bottom surface and opposing sidewalls that are perpendicular to the bottom surface. Further, the opposing sidewalls may be curved and extend parallel to one another along at least a partial length of the sidewalls. The channel may be formed along an entire length or a partial length of the surf craft. Opposing sidewalls may be curved along an entire length of the channel. The opposing sidewalls may be formed in asymptotic curves. 
     The blank  10  may be formed of opposing side sections  14 A and  14 B and a center section  16  extending lengthwise there between. As shown in  FIG.  2   , each of the opposing side sections  14 A and  14 B and the center section  16  may be formed in separate pieces or sections that are subsequently joined together to form the blank  10 . Prior to joining, each of the opposing side sections  14 A and  14 B and the center section  16  are formed in desired shapes. The opposing side sections  14 A and  14 B and the center section  16  are subsequently joined, such as by bonding the sections to one another with an adhesive or otherwise fastening the sections together, to form the blank  10  for further shaping of the blank  10  into a resulting surf craft. 
     The opposing side sections  14 A and  14 B and the center section  16  of the blank  10  may be formed of a variety of suitable materials. The opposing side sections  14 A and  14 B may be formed of a solid shapeable material, such as foam. It is also understood that the opposing side sections  14 A and  14 B and the center section  16  of the blank  10  may be formed of other suitable materials. In one embodiment, one or more portions of the blank  10  may be formed of inflatable or air-filled members, such as pre-shaped or pre-formed portions that are inflatable. Pre-shaped or pre-formed portions may be formed having one or more flexible or solid walls and may be inflatable to support a shape of the pre-shaped or pre-formed portions. 
     Each of the opposing side sections  14 A and  14 B may be formed having a curved side  18 , as shown in  FIGS.  2  and  3 A- 3 B . A shape of the curved side  18  may vary depending on a desired resulting channel to be formed in the blank  10 . The curved side  18  may be formed such that the curved side  18  is substantially perpendicular to a bottom surface  20  ( FIG.  2   ) of each of the opposing side sections  14 A and  14 B, with the bottom surface  20  eventually forming a bottom surface section of a surf craft after shaping of the resulting blank  10  including a surface thereon. The center section  16  may also include curved sides  22  having a shape corresponding to the curved side  18  of each of the opposing side sections  14 A and  14 B. 
     Referring to  FIGS.  3 A and  3 B , each of the opposing side sections  14 A and  14 B may have a thickness profile based on a desired shape of the blank  10  and resulting surf craft. For example, when forming the channel  12  ( FIG.  1   ), it may be desirable for each of the opposing side sections  14 A and  14 B to have a constant thickness along a length of each of the opposing side sections  14 A and  14 B. A thickness of the resulting blank may be subsequently modified by shaping of the blank into a desired surf craft. 
     Referring to  FIGS.  4 A and  4 B , the center section  16  may have a thickness profile based on a desired shape of the blank  10  and resulting surf craft. As shown in  FIG.  4 B , a thickness of the center section  16  may vary along a length of the center section  16 . For example, when forming the channel of  FIG.  1   , it may be desirable for the center section  16  to have a sloped or tapered thickness along at least a portion of the center section  16 . The center section  16  has a thickness that is substantially formed prior to joining the center section  16  with the opposing side sections  14 A and  14 B. Referring to  FIGS.  5 A- 5 B and  6 A- 6 B , a thickness of the center section  16  may vary in contrast to the opposing side sections  14 A and  14 B. For example, a thickness of the center section  16  may be the same as a thickness of the opposing side sections  14 A and  14 B along at least a partial length of the center section  16 , as shown in  FIG.  5 B . Alternatively, a thickness of the center section  16  may differ along an entire length of the center section  16  relative to the opposing side sections  14 A and  14 B. For example, as shown in  FIG.  6 B , a thickness of the center section  16  along its length is less than a thickness of the opposing side sections  14 A and  14 B. As shown in  FIG.  7 A  and  FIG.  7 B , a shape of the center section  16  may further be such that the center section  16  is sloped at both ends of the center section  16 . 
     Referring to  FIG.  8   , to form the blank  10 , each of the opposing side sections  14 A and  14 B and the center section  16  is individually formed based on a desired shape of the blank  10  and a surf craft to be formed from the blank. Shapes of the opposing side sections  14 A and  14 B and the center section  16  may be selected prior to joining of the opposing side sections  14 A and  14 B with the center section  16 . The opposing side sections  14 A and  14 B and the center section  16  may be substantially shaped prior to joining to form the blank  10 , thereby allowing shapes of walls of the channel and other surfaces of the blank  10  to be readily created. 
     To form the blank  10 , the opposing side sections  14 A and  14 B and the center section  16  are joined along one or more sides of the opposing side sections  14 A and  14 B and the center section  16 . As shown in  FIG.  1   , when the opposing side sections  14 A and  14 B and the center section  16  are joined, each of the opposing side sections  14 A and  14 B is adjacent to the center section  16 . The resulting blank  10  includes the channel  12  having a desired shape. The channel  12  is formed from the side  18  of each of the opposing side sections  14 A and  14 B and a bottom surface of the center section  16 . By forming each of the opposing side sections  14 A and  14 B and the center section  16  prior to joining to form the blank  10 , walls of the channel may be formed to have shapes that would otherwise be difficult if attempting to form the channel by cutting the channel into an existing blank  10 . 
     When the opposing side sections  14 A and  14 B are joined with the center section  16  to form the blank  10 , the resulting blank  10  may be formed having various shapes for further shaping to form a desired surf craft. For example, as shown in  FIGS.  1  and  5 A , the blanks  10  may be an unshaped slab or rectangular blank. Alternatively, and as shown in  FIG.  9   , the surf craft planshape cut out from the blank  10  may have rounded outer edges for further shaping into a desired surf craft. 
     As described herein, the channel  12  may be formed along a partial length of the blank  10 , as shown in  FIGS.  1  and  9   . As shown in  FIG.  10    and  FIG.  11   , and  FIG.  18   ; the channel  12  may alternatively be formed along an entire length of the blank  10 . The channel  12  may have a depth that varies along a length of the channel  12 , such as the channel  12  having a greater depth at one end of the blank  10 , as shown in  FIG.  10   .  FIG.  12    shows a resulting surf craft having the channel  12  with a varying depth along a length of the channel  12 . Alternatively, the channel  12  may have a substantially constant depth along a length of the channel  12 , as shown in  FIG.  11    and  FIG.  18   . 
     Referring now to  FIG.  13   ,  FIG.  14   , and  FIG.  15   , the blank  10  may subsequently be shaped into a desired surf craft after joining of the opposing side sections  14 A and  14 B with the center section  16 . A shape of the surf craft resulting from the blank  10  may vary, such as to form the blank  10  into a surf craft having a desired shape and size. For example, the blank  10  may be formed into a shorter surf craft, such as a bodyboard, or alternatively may be formed into a longer surf craft such as a surfboard.  FIG.  15 A  and  FIG.  15 B  illustrate channel exits before a tail end of a surf craft.  FIG.  16 A  and  FIG.  16 B  illustrate a full-length channel. It is also understood that a two-channel surf craft could be formed, such as from a five-piece blank. The surf craft may include two channel bottom sections and three sidewall sections. 
     Referring to  FIG.  17 A  and  FIG.  17 B , a surfboard planshape is illustrated. The surfboard planshape may be formed, for example, on a three-piece blank with a full-length channel located along the entire length of the surfboard. Both a channel bottom and sidewalls may be curved along an entire length of the channel. 
     Referring now to  FIG.  18   ,  FIG.  19   ,  FIG.  20 A , and  FIG.  20 B , the blank  10  may be formed in other suitable arrangements that allow for the channel  12  to be formed on the blank  10 . For example, the center section  16  may be formed such that the center section  16  extends substantially across a full width of the blank  10 . The center section  16  may extend to sides of the blank  10  such that outer edges of the center section  16  form at least a portion of sides of a resulting surf craft formed from the blank  10 . 
     The opposing side sections  14 A and  14 B may be located on the center section  16  as shown in  FIG.  18   . The opposing side sections  14 A and  14 B may be bonded to a surface of the center section  16  and may be located such that inner edges of the opposing side sections  14 A and  14 B define side walls of the channel  12 . Outer edges of the opposing side sections  14 A and  14 B may be substantially aligned with outer edges of the center section  16 . Outer edges of the center section  16  and the opposing side sections  14 A and  14 B may be shaped to create a desired shape of a surf craft formed from the blank  10 . 
     As shown in  FIGS.  18   ,  FIG.  20 A , and  FIG.  20 B , a thickness of the center section  16  may be greater than a thickness of the opposing side sections  14 A and  14 B. A thickness of the opposing side sections  14 A and  14 B may correspond to a desired depth of the channel formed on the blank  10 . A thickness of the center section  16  and the opposing side sections  14 A and  14 B may vary. For example, a thickness of the center section  16  and the opposing side sections  14 A and  14 B may vary along lengths of the sections, such as based on a desired shape of the channel formed on the blank  10 . 
     By forming each of the opposing side sections  14 A and  14 B and the center section  16  prior to joining to form the blank  10 , any surface features such as those that may be relatively complex to be formed by existing shaping methods are easily formed in the blank  10 . This allows the resulting surf craft to be formed having a desired shape, thereby allowing more accurate forming of shapes such as a channel in the surf craft. 
     The foregoing description of preferred embodiments of the present disclosure has been presented for purposes of illustration and description. The described preferred embodiments are not intended to be exhaustive or to limit the scope of the disclosure to the precise form(s) disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the disclosure and its practical application, and to thereby enable one of ordinary skill in the art to utilize the concepts revealed in the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the disclosure as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.