Patent Publication Number: US-6712657-B1

Title: Manufacturing process for surfboards and bodyboards and articles of manufacture

Description:
OTHER RELATED APPLICATIONS 
     The present application is a continuation-in-part of pending U.S. patent application Ser. No. 09/885,605, filed on Jun. 20, 2001, which is now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to surfboards and bodyboards and the process for manufacturing them, and more particularly, to such boards and process where the expanding foaming base is reinforced. 
     2. Description of the Related Art 
     Many processes for manufacturing surfboards and bodyboards have been developed in the past. Bodyboards are smaller than surfboards. None of these processes, however, includes a longitudinal reinforcement with PVC (poly vinyl chloride) self-adhesive tapes over the foam on one face and polystyrene sheets on the other face. The present process joins the PVC tapes and polystyrene sheets to the foam with PVC flexible joints and water-resistant glue. This novel process for manufacturing these boards is relatively simple and the resulting article of manufacture is versatile and sturdy. 
     Applicant believes that the closest reference corresponds to published British patent application No. 961,612 of Jun. 24, 1964 to David Peter Phillips for improvements in and relating to surf boards. Phillips&#39; invention is a process for manufacturing surfboards composed of an expanded polystyrene plate with a plastic cover. One of the expanded polystyrene materials used for this surfboard is known “poron”, characterized by its water repellence. The expanded polystyrene plate is covered with plastic. Although this combination provides a surfboard with water repellent characteristics and an external surface to support the users, the combination is not impact resistant. 
     Another reference corresponds to published European patent application No. 224 023 of Oct. 21, 1986 to Frank Wolfgang for a network body, especially sail-or waves ride board, as well as process to the manufacture the same. This publication attempts to provide a solution to the non-resistant characteristics of the previously mentioned invention. Wolfgang&#39;s invention uses a compound structure where the foaming core is covered with a synthetic resin and a thermoplastic material with a silver braid tissue sandwiched in-between. The silver braid tissue provides a more rigid foaming structure. 
     Also, another related reference corresponds to published French patent application No. 2 787 088 of Jun. 16, 2000 to Labey Mathieu for a sandwich-type structure for a surfboard. This invention refers to a surfboard including a soft foam core such as polystyrene and polyurethane. The invention in this published application has the foaming foam is sandwiched between fiberglass and carbon. The structure is mounted with an adhesive substance such as epoxy resin and laminated polymers. The invention is also complemented with a flexible over the hydrodynamic outline. 
     However, the above referenced publications differ from the present invention because none of them includes mounting longitudinal reinforcements with PVC tapes over the foam on one face and with polystyrene sheets on the opposite face for bodyboards. Nor do they teach the use of a flexible board member as a spine extending longitudinally along the board. Also, the present process and resulting article of manufacture joins the PVC tapes and polystyrene sheets to the foam with PVC flexible joints and water-resistant glue which not suggested in the references. The process and resulting article of manufacture use a shrinkable sheath that accepts the board blank and this is not taught by the references either. The overall result being a resilient board made out of a light and soft (polystyrene) material. 
     Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention. 
     SUMMARY OF THE INVENTION 
     It is one of the main objects of the present invention to provide a process for manufacturing surfboards and bodyboards and resulting articles of manufacture having impact and abrasion resistant characteristics while maintaining their lightweight. 
     It is an object of this invention, to provide impact resistant surfboards and bodyboards. 
     It is another object of this invention to provide surfboards and bodyboards with a soft and harmless surface for the user and a process for manufacturing these articles. 
     It is still another object of the present invention to provide a manufacturing process for soft surfboards and bodyboards that includes a resilient wood core resulting in a lighter surfboard while provides impact resistant surfboards and bodyboards. 
     It is yet another object of this invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness. 
     Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which: 
     FIG. 1 a  is a schematic representation of the solid block used in the manufacturing process for surfboards. 
     FIG. 1 b  is a schematic representation of the elongated board blank for surfboard, resulting of the cutting from the solid block represented in FIG. 1 a  for the surfboard manufacturing process. 
     FIG. 1 c  is a schematic representation of the elongated board blank for surfboard cut in two halves and body reinforcement is mounted the entire length of the board blank. 
     FIG. 1 d  is a schematic representation of the elongated board blank for surfboard when the body reinforcement has been mounted and board blank is cut to a substantially elliptical shape. 
     FIG. 1 e  is a schematic representation of the surfboard plate with the desired shape and dimensions and the body reinforcement mounted thereon. 
     FIG. 1 f  represent a cross-sectional view taken along line  1   f — 1   f  from FIG. 1 e , showing the position of the body reinforcement. 
     FIG. 1 g  is an enlarged view of one of the edges of the surfboard showing the position of the edge reinforcements. 
     FIG. 1 h  is a schematic representation the surfboard being inserted inside a sheath. 
     FIG. 1 i  is a schematic representation the surfboard inserted inside a sheath showing the protecting sealing being attached to the zipper. 
     FIG. 2 a  is a schematic representation of the solid block used in the bodyboard manufacturing process. 
     FIG. 2 b  is a schematic representation of the board blank for bodyboards, resulting from cutting the solid block represented in FIG. 2 a.    
     FIG. 2 c  is a schematic representation of the board blank for bodyboards cut in two halves and body reinforcement is mounted over the entire length of the board blank. 
     FIG. 2 d  is a schematic representation of a board blank for bodyboards when the body reinforcement has been mounted thereon and board blank is cut to the desired shape. 
     FIG. 2 e  is a schematic representation of a board blank for bodyboards when the transversal reinforcements are mounted thereon. 
     FIG. 2 f  is a schematic representation of a board for blank bodyboards when the longitudinal reinforcements are mounted. 
     FIG. 2 g  represents a cross-sectional view taken along line  2   g — 2   g  from FIG. 2 f , showing the position of the reinforcements. 
     FIG. 2 h  is an enlarged view of one of the edges of the bodyboard showing the position of the edge reinforcements. 
     FIG. 2 i  is a schematic representation the board blank being inserted inside a sheath. 
     FIG. 2 j  is a schematic representation the board blank inside a sheath showing the protecting seal being attached to the zipper. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, where the present invention is generally referred to with numeral  10 , it can be observed that the process for manufacturing surfboards basically includes the steps of cutting board blanks from polystyrene blocks (FIGS. 1 a ;  1   b ;  1   c  and  1   d ), mounting body reinforcements (FIG. 1 d ), mounting edge reinforcements (FIG. 1 g ) and inserting the board inside a sheath member (FIG. 1 h ). After that, heat is applied to shrink the sheath member, as represented in FIG. 1 i.    
     The cutting step involves cutting an elongated board blank  20  to predetermined dimensions and shape (FIGS. 1 a  and  1   b ), which is preferably polystyrene, from solid block  15 . Blanks  20  are cut to a substantially elliptical shape with one pointed front end  21  and a rear truncated end  23 , as shown in FIG. 1 c . Then, board blank  20  is longitudinally and centrally cut forming two halves, as seen in FIG. 1 d . Elongated reinforcement or spine member  52  is mounted longitudinally between the two halves of board blank  20  along their entire length, as seen in FIG. 1 d . Member  52  is a relatively flexible narrow board. This narrow board serves as the spine for board  20  and it can be made out of wood. The ends are thinner than the body of member  52 . The residuals are recycled to manufacture new blocks  15 . When reinforcement or spine member  52  is mounted, the cutting step continues by shaping end  21  to form a pointed end and end  23  to form a square end. 
     With the edge reinforcement step, elongated rubber covers  71  and  72  are peripherally affixed to edges  25  and  27  of board  24 . These covers are intended to protect board  24  against impact damage. 
     The step of inserting reinforced board  24  inside heat expandable sheath member  92  is accomplished by opening zipper  95  on opening  93  and sliding board  24  therein. This is done after sheath member  92  has been heated and expanded. After that, zipper  95  is closed and sheath member  92  is allowed to cool down and shrink. Any air pockets that may form are flushed out before cooling completely. Zipper  95  is closed. Then, protective zipper cover member  94  is mounted over zipper  95 . Member  94  is preferably made out of a thermoplastic material that is heated in place thereby sealing zipper  95 . 
     In the event there is water penetration, the absorption is minimal since the polystyrene is of the closed cell foam type. Opening  97  is designed to drain any water collected between board blank  20  and sheath member  92 . 
     An alternate embodiment for the present invention  100  is represented in FIGS. 2 a  through  2   j  for bodyboards. It can be observed in the drawings that the process for bodyboards basically includes the steps of cutting board blanks (FIGS. 2 a ;  2   b ;  2   c  and  2   d ), mounting body reinforcements (FIGS. 2 c ;  2   e  and  2   f ), mounting edge reinforcements (FIG. 2 h ) and inserting the board inside a heat expandable sheath member (FIG. 2 i ). After that, sheath member  192  is cooled down and allowed to shrink, as represented in FIG. 2 j.    
     The cutting step involves cutting an elongated board blank  120  to predetermined dimensions and shape (FIGS. 2 a  and  2   b ), which is preferably polystyrene, from solid block  115 . Board blank  120  is longitudinally and centrally cut forming two halves, as seen in FIG. 1 c . Elongated reinforcement or spine member  152  is mounted longitudinally between the two halves of board blank  120  along its entire length, as seen in FIG. 2 d . Member  152  is a relatively flexible narrow board. This narrow board serves as the spine for board blank  120  and it can be made out of wood. Then, blanks  120  are cut to a substantially frustro-elliptical shape with truncated front end  121  and truncated rear end  123 , as shown in FIG. 2 d , to form the board  124 . 
     The step of mounting body reinforcements includes mounting longitudinal reinforcements and transversal reinforcements on board blank  120 . Mounting transversal reinforcement step to board  124  is accomplished by mounting polystyrene sheets  144  transversally on top surface  129  of board  124  and kept in place with waterproof glue. PVC or rubber flexible strips  145  are also transversally attached to surface  129  of board  124  where polystyrene sheets  144  meet. PVC or rubber flexible strips  145  provide flexibility and elasticity to the transversal reinforcement. 
     The step of mounting longitudinal reinforcement on board  124  is accomplished by mounting a predetermined number of self-adhesive PVC (poly vinyl chloride) tapes  142  having predetermined dimensions. Self-adhesive PVC tapes  142  are longitudinally disposed on bottom surface  129  of board  124 . The combination of longitudinal and transversal reinforcements give board  124  more resistance to impact forces characteristic of waves of more than one meter high. The combination of longitudinal and transversal reinforcements also prevents the removal or fall from granules from polystyrene of board  124  as a result of wear and tear. 
     With the edge reinforcement step, elongated rubber covers  171  and  172  are peripherally affixed to edges  125  and  127  of board  124 . 
     The step of inserting reinforced board  124  inside sheath member  192  is accomplished by opening zipper  195  on opening  193  and sliding board  124  therein. This is done after sheath member  192  has been heated and expanded. After that, zipper  195  is closed and sheath member  192  is allowed to cool down and shrink. Any air pockets that may form are flushed out before cooling completely. Then, protective zipper cover member  194  is mounted over zipper  195 . Member  194  is preferable made out of a thermo-plastic material that is heated in place sealing zipper  195 . 
     The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.