Folding Sports Board, System and Method

Abstract

A sectional sports board with a structural composite hinge connecting sections together and providing hinged movement via material flexure allowing sections of the board to be folded into a compact shape for convenient transportation or storage.

Description

FIELD OF THE INVENTION

This application relates to sectionalized sports boards that can be folded into a compact shape using at least one hinge, along with related systems and methods for using a sectionalized sports board. More specifically, the sectionalized sports board can be a folding watersports board comprising at least one hinge that can be a composite and/or pinless hinge that is selectively rotatable via material flexure.

BACKGROUND OF THE INVENTION

Many watersports enthusiasts are required to travel to get to the destination where they can practice their sport. Traveling with a large board, such as a watersports board, can be challenging due to the size and volume of the board. Many transportation services may classify watersports boards as oversized which can incur additional costs and hardship for the watersports enthusiast.

Over the years many inventors have attempted to address this challenge by designing solutions where the board is sectionalized into smaller shapes that are easy to transport and can be reassembled when the user is at their watersports destination.

The concept of a sectional board was first patented in 1964 by Thomas D. Price and Karl D. Pope with their Collapsible surfboard design. Subsequent designs from other inventors have followed similar principles with the board sections requiring mechanical fasteners to hold the sections together and may also require additional structural elements to be inserted to create rigidity for the board.

The challenge with sectional boards can be maintaining the structural integrity of the board under stress and load during intense watersports maneuvers where undue movement or flex diminishes the performance of the board and enjoyment for the watersports enthusiast. The necessity of multiple fasteners and structural elements to connect the sections also increases the weight of the board which is undesirable as it reduces the buoyancy of the board and also increases the cost of manufacturing sectional boards at scale. Additionally, the assembly and disassembly of the board can be time consuming and complicated for the user.

Some inventors have added conventional hinges that attach the sections of the board together allowing the sections to fold together using dedicated hinge components such as a pin and barrel to enable the rotation to pivot on the axis of the pin. The folding board design can improve the simplicity for assembly and disassembly of the board for the user and can improve the structural rigidity of a sectional board. However, folding boards using conventional hinges can add measurable weight which will negatively impact the performance of the board. Additionally, the moving and mechanical components such as the pin and barrel components of the conventional hinge are subject to contamination from external elements such as sand, debris and potentially rust that can further compromise the integrity of the board.

Accordingly, it is desirable to provide a sectionalized sports board that can easily and quickly be reassembled by a user while maintaining the structural integrity of the board under stress and load.

SUMMARY

Presented herein are a folding sports board, a system for folding a sports board, and a method for folding a sports board. The folding board, system and method can lessen the burden and hardship of traveling or storing an oversized board, such as a watersports board and the like, by allowing the user to reduce the length of the board by folding it into a compact shape for easy handling without compromising the integrity and performance of the board when the user is using the board.

The sports board comprises a lightweight polymer composite hinge made of overlapping layers of tensile materials with a flexible hinge line that when bonded to adjacent sections of the board creates a very rigid platform for the rider when the hinge is in an extended or open position. A fastening device such as a bolt, a clasp and the like can be used to lock the sections together to restrict the hinge from pivoting on the hinge line when the board is in use.

When the board is not in use, the fastening device can be removed or unclasped and the hinge can be freed to pivot to a closed or folded position by flexure or bending of the material along the hinge line which enables the user to quickly fold the sections of the board into a compact shape for convenient transportation or storage of the board.

Unlike conventional hinges, the composite hinge can be a pinless lightweight monolithic structure with no moving mechanical parts and consequently is not subject to contamination by sand or debris, nor is it subject to rust or corrosion due to the nature of the polymer composite material. Additionally, the hinge can be bonded or laminated into the external shell of the board during the manufacturing process which typically is constructed of a similar polymer composite material, which not only simplifies the manufacturing process of a sectional board but can also improve the rigidity of the board when it is in the extended or open position. Thus, the composite hinge can reduce the weight, complexity and mechanical compromises of existing sectional and folding boards.

Related systems and methods of operation are also provided. Other apparatuses, methods, systems, features, and advantages of the folding sports board will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional apparatuses, methods, systems, features, and advantages be included within this description, be within the scope of sectionalized sports board, and be protected by the accompanying claims.

DESCRIPTION OF THE FIGURES

FIG. 1 is a top perspective view of the folding sports board in an open, extended position, wherein at least one hinge is bonded to both sections of the board, according to one aspect;

FIG. 2 is a cross-sectional view of a portion of the folding sports board of FIG. 1, showing the board in the open, extended position;

FIG. 3 is a cross-sectional view of a portion of the folding sports board of FIG. 1, showing the board in a closed, folded position;

FIG. 4 is a top perspective view of the folding sports board view of FIG. 1, showing the board in a partially folded position;

FIG. 5 is a bottom perspective view of the folding sports board of FIG. 1, showing the board in the open, extended position and a fastener in an unfastened position;

FIG. 6 is a side elevational view of the folding sports board of FIG. 1, showing the board in the closed, folded position;

FIG. 7 is a side perspective view of a portion of the folding sports board of FIG. 1, showing the board in the open, extended position;

FIG. 8 is a bottom perspective view of a portion of the folding sports board of FIG. 1, showing the board in the open, extended position.

FIG. 9 is a perspective view of the folding sports board of FIG. 1, showing the board in the closed, folded position; and

FIG. 10 is an exploded perspective view of the folding sports board of FIG. 1.

DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to the following detailed description, examples, and claims, and their previous and following description. Before the present system, devices, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific systems, devices, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known aspect. Those skilled in the relevant art will recognize that many changes can be made to the aspects described, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an “element” includes aspects having two or more such elements unless the context clearly indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The folding sports board is shown in FIGS. 1-10 according to various aspects. An example of a sports board divided in two sections with a at least one composite hinge and at least one bolt as a fastener will be used to illustrate this embodiment. Reference is made herein to a watersports board, which can comprise surfboards, kite boards, wing boards, wakeboards, windsurf boards, stand-up paddleboards, and many variations of foil boards. It is to be understood, however, that the present disclosure can be applied to other boards, such as for example and without limitation, land windsurf boards, long skateboards and the like. Further, while it is possible to sectionalize a board into two sections, it is contemplated that the board can be divided into more sections, such as, for example and without limitation, three, four, five, six, seven, eight, nine, ten, or more than ten sections.

With reference now to FIG. 1, a folding sports board 100 comprising a first section 200 and second section 202 is shown. At least one hinge 300 can be coupled to or formed integrally with both the first section 200 and the second section 202 so that the second section 202 can be selectively rotatable relative to the first section 200. Thus, the sports board 100 can selectively be moved from an open, extended position in which an upper surface 204 of the first section 200 is substantially parallel to and coplanar with an upper surface 206 of the second section (as shown in FIG. 1), to a closed, folded position in which the upper surface 204 of the first section 200 is substantially parallel and not coplanar to the upper surface 206 of the second section (as shown in FIG. 6). In use, described more fully below, with the sports board 100 in the open, extended position, a user can ride the board 100 as the at least one hinge 300 that is securedly attached to the first section 200 and the second section 202 of the board 100 creates a rigid platform for the user.

The at least one hinge 300 is shown in more detail in FIG. 2, which shows a cross-sectional view of the hinge 300 in the open, extended position. In one aspect, the hinge 300 comprises a first polymer composite material 303 such as but not limited to carbon fiber and the like, and a second polymer composite material 304 such as but not limited to carbon fiber and the like. The first and second polymer composite materials 303, 304 can be made rigid using composite manufacturing techniques that can infuse a polymeric hardening agent, such as an epoxy resin, a polyester resin and the like, into the first polymer composite material 303 and/or the second polymer composite material 304. A flexible polymer composite material 305 such as Kevlar or like materials with similar tensile strength and flexibility properties can be sandwiched between the first and second polymer composite materials 303 and 304.

In one aspect, a portion of the flexible polymer composite material 305 can be infused with a polymeric hardening agent, such as an epoxy resin, a polyester resin and the like, and a portion of the flexible polymer composite material 305 can be left untreated or can receive a lower level of polymeric hardening agent infusion than other portions. For example, a hinging portion 306 of the flexible polymer composite material 305 can be left untreated or can receive a lower level of polymeric hardening agent infusion than end portions 307, 308 of the flexible polymer composite material 305. Thus, the hinging portion 306 can allow the flexible polymer composite material 305 to rotate up to 180 degrees via material flexure.

In one aspect, the first polymer composite material 303, the second polymer composite material 304 and the flexible polymer composite material 305 can be formed from the same material. Alternatively, at least one of the first polymer composite material 303, the second polymer composite material 304 and the flexible polymer composite material 305 can be formed from different materials. In another aspect, the hinge 300 can have multiple layers of composite materials depending on the strength and weight requirements respective to the size or volume of the sports board 100. For example, the hinge 300 can comprise the first polymer composite material 303, the second polymer composite material 304, a third polymer composite material, a fourth polymer composite material or more than four polymer composite materials with the flexible polymer composite material 305 positioned between any two polymer composite material layers.

At least one of the first and second polymer composite material 303, 304 can be bonded to the upper surfaces 204, 206 of the sports board 100. For example, at least one of the first and second polymer composite material 303, 304 can be bonded to the upper surface 204 of the first section 200 of the sports board 100, and at least one of the first and second polymer composite material 303, 304 can be bonded to the upper surface 206 of the second section 202 of the sports board 100. Alternatively, at least one of the first and second polymer composite material 303, 304 can be layered into the composite shell of the sports board 100 during the manufacturing process.

In another aspect, at least one of the first and second polymer composite material 303, 304 can be bonded to lower surfaces 403, 404 of the sports board 100. For example, at least one of the first and second polymer composite material 303, 304 can be bonded to a lower surface 403 of the first section 200 of the sports board 100, and at least one of the first and second polymer composite material 303, 304 can be bonded to a lower surface 404 of the second section 202 of the sports board 100.

In one aspect, the first and second polymer composite materials 303, 304 can be positioned only on or in the first section 200 and the second section 202, while the flexible polymer composite material 305 can extend between the first section 200 to the second section 202. That is, the portion of the flexible polymer composite material 305 that extends from the first section 200 to the second section 202 need not be sandwiched between the first and second polymer composite materials 303, 304.

FIG. 3 illustrates the at least one hinge 300 coupled to the sports board 100 while in the closed, folded position, according to one aspect. As can be seen, in the closed, folded position, the second section 202 of the sports board 100 can be rotated relative to the first section 200 so that the second section 202 overlies the first section 200. In this aspect, the hinging portion 306 of the hinge 300 can flex so that the first polymer composite material 303 coupled to the first section 200 is positioned adjacent to the first polymer composite material 303 coupled to the second section 202. Thus, the second section 202 can rotate relative to the first section 200 such that the upper surface 204 of the first section 200 is substantially parallel, adjacent and/or flush to the upper section 206 of the second section 202.

As can be appreciated, while rotating from the open, extended position to the closed, folded position, the second section 202 can be rotated through angles between 0 and 180 degrees relative to the first section 200. For example and as shown in FIG. 4, the second section 202 can be rotated through intermediate positions between the open, extended position and the closed, folded position.

FIGS. 5-10 illustrate arrangements for securing the sports board 100 in the open, extended position and/or the closed, folded position, according to various aspects. In one aspect, the sports board 100 comprises at least one fastener 401 such as a threaded bolt, a plate, a clasp or buckle type locking system and the like. In order to secure the sports board 100 in the open, extended position, the fastener 401 can extend from the first section 200 of the board 100 and to the second section 202 of the board 100. Alternatively, in order secure the sports board 100 in the open, extended position, the fastener 401 can extend from the second section 202 of the board 100 and to the first section 200 of the board 100. It is contemplated that more than one fastener 401 can be used to secure the sports board 100 in the open, extended position. For example, two, three, four, five, six, seven, eight, nine, ten, or more than ten fasteners 401 can be used to secure the sports board 100 in the open, extended position.

In one aspect and as can be seen in FIG. 5, the at least one fastener 401 can be a bolt inserted through at least one fastener hole 402 such that the fastener 401 securedly attaches the first section 200 to the second section 202. In one example, the fastener hole 402 can be defined in the bottom surface 403 of the first section 200 and can extend into a portion of the second section 202. Optionally, the fastener hole 402 can be defined in the bottom surface 404 of the second section 202 and can extend into a portion of the first section 200.

The sports board 100 in the closed, folded position is shown in FIG. 6, according to one aspect. In this aspect, the fastener 401 has been backed out so that the fastener 401 does not extend into the second section 202. As can be appreciated, in this compact shape, transportation and/or storage of the board 100 is facilitated.

In other aspects, the at least one fastener hole 402 can be defined in a side wall 406 of the first section 200 and can extend into a portion of the second section 202, as illustrated in FIG. 7. Further, and as illustrated in FIG. 8, a first fastener hole 407 can be defined in the bottom surface 403 of the first section 200 and can extend into a portion of the second section 202, and a second fastener hole 408 can be defined in the side wall 406 of the first section 200 and can extend into a portion of the second section 202. In still another aspect and as shown in FIG. 9, the first fastener hole 407 can be defined in the bottom surface 403 of the first section 200 and can extend into a portion of the second section 202, a second fastener hole 408 can be defined in the side wall 406 of the first section 200 and can extend into a portion of the second section 202, and a third fastener hole 409 can be defined in a second side wall 410 of the first section 200 and can extend into a portion of the second section 202. While reference is made here to each fastener hole 402 extending from the first section 200 to the second section 202, it is contemplated that each fastener hole 402 can extend in either direction, that is from the first section 200 to the second section 202 or from the second section 202 to the first section 200.

In one aspect, a single hinge 300 can be used to rotatably couple adjacent sections of the sports board 100 together. In this aspect, the hinge 300 can extend for the width of the board 100. Alternatively, the hinge 300 can extend for a portion of the width of the board 100. In another aspect, a plurality of hinges 300 can be used to rotatably couple adjacent sections of the sports board 100 together. For example, two, three, four, five, six, seven, eight, nine, ten, or more than ten hinges 300 can be used to rotatably couple adjacent sections of the board 100 together. The plurality of hinges 300 can extend for the width of the board 100. Alternatively, the plurality of hinges can extend for a portion of the width of the board 100.

In one aspect, the first section 200 and/or the second section 202 can further comprise at least one end cap 500 or rib that can support the hinge 300 and/or the at least one fastener 401. As can be seen in FIGS. 9 and 10, the end cap 500 can be securedly attached to or formed integrally with the first section 200 and/or the second section 202. In this aspect, a first end cap 500 can be coupled to an end 501 of the first section 200 adjacent to the hinge 300 and/or a second end cap 502 can be coupled to an end 503 of the second section 202 adjacent to the hinge 300. That is, the first end cap 500 can cover the end of the first section 200 adjacent to the hinge 300, and the second end cap 501 can cover the end of the second section 202 adjacent to the hinge 300 so that in the closed, folded position, the first end cap 500 is substantially parallel to and coplanar with the second end cap 501. In another aspect, each section of the sports board 100, regardless of the number of sections of the sports board 100, can have an end cap 500 coupled to the end of the section adjacent to the hinge 300. In this aspect, the at least one end cap 500 can provide structural rigidity to the sports board 100 and provide support for attachment of the at least one fastener 401.

In another aspect, the at least one fastener hole 402 can extend through the at least one end cap 500. That is, the fastener hole 402 can extend from the first section 200, through the at least one end cap 500 and can extend into a portion of the second section 202. For example, and as shown in FIG. 10, the fastener hole 402 can extend from the first section 200, through the first end cap 500, through the second end cap 502 and into the second section 202.

To assemble the sports board 100, as noted above, the at least one hinge 300 can be coupled to or formed integrally with both the first section 200 and the second section 202. That is, in one aspect, the at least one hinge 300 can be formed separately from the first section 200 and/or the second section, and bonded to the sports board 100 as one of the final steps in the manufacturing process. In another aspect, the at least one hinge 300 can be integrated into the lamination of at least one of the first section 200 and the second section 202 during the manufacturing process.

Although several aspects of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention.

Claims

1. A sports board comprising: a first section having an upper surface;a second section having an upper surface, the second section being separate from the first section; andat least one composite hinge coupled to the first section and to the second section such that the second section is rotatable relative to the first section,wherein the second section is rotatable about and between an open, extended position in which the upper surface of the first section is parallel to and coplanar with the upper section of the second section, and a closed, folded position in which the upper surface of the first section is not coplanar with the upper section of the second section.

2. The sports board of claim 1, wherein the at least one composite hinge comprises: a first polymer composite material infused with a polymeric hardening agent;a second polymer composite material infused with the polymeric hardening agent; anda flexible polymer composite material positioned between the first polymer composite material and the second polymer composite material.

3. The sports board of claim 2, wherein a portion of the flexible polymer composite material is infused with the polymeric hardening agent, and wherein a hinging portion of the flexible polymer composite material is not infused with the polymeric hardening agent.

4. The sports board of claim 3, wherein the hinge portion is a hinge line comprising uncured flexible polymer composite fabric.

5. The sports board of claim 2, wherein the at least one hinge has a hinge width that extends for the width of the sports board.

6. The sports board of claim 2, wherein the at least one hinge comprises three hinges each coupled to the first section and to the second section.

7. The sports board of claim 2, wherein the at least one hinge is coupled to an upper surface of the first section and to an upper surface of the second section.

8. The sports board of claim 2, wherein the at least one hinge is formed separately from the first section and the second section, and wherein the at least one hinge is then bonded to an external laminate of the first section and the second section.

9. The sports board of claim 2, wherein the at least one hinge is formed integrally with at least one of the first section and the second section.

10. The sports board of claim 9, wherein the at least one hinge is layered into a laminate of at least one of the first section and the second section during construction.

11. The sports board of claim 2, wherein the at least one hinge is rotatable 180 degrees from an open, extended shape to a closed, folded shape.

12. The sports board of claim 2, further comprising at least one fastener configured to securedly attach the second section in the open, extended position relative to the first section.

13. The sports board of claim 12, wherein the at least one fastener comprises at least three bolts that extend from the first section into the second section.

14. The sports board of claim 13, further comprising at least one end cap coupled to one at least one of the first section and the second section and configured to provide structural rigidity to the sports board and to provide support for attachment of the at least one fastener.

15. The sports board of claim 14, wherein the at least one end cap comprises: a first end cap securedly attached to an end of the first section adjacent to the hinge; anda second end cap securedly attached to an end of the second section adjacent to the hinge,wherein in the closed, folded position, the first end cap is substantially parallel to and coplanar with the second end cap.

16. A method for unfolding a sports board comprising: providing a sports board comprising: a first section having an upper surface;a second section having an upper surface, the second section being separate from the first section wherein the second section is rotatable about and between an open, extended position in which the upper surface of the first section is parallel and coplanar with the upper section of the second section, and a closed, folded position in which the upper surface of the first section is not coplanar with the upper section of the second section;at least one composite hinge coupled to the first section and to the second section such that the second section is rotatable relative to the first section; andat least one fastener configured to securedly attach the second section in the open, extended position relative to the first section;rotating the second section to the open extended position relative to the first section; andinserting the at least one fastener into at least one fastener hole that extends from the first section into the second section to securedly attach the second section in the open, extended position relative to the first section.

17. The method of claim 16, wherein the at least one composite hinge comprises: a first polymer composite material infused with a polymeric hardening agent;a second polymer composite material infused with the polymeric hardening agent; anda flexible polymer composite material positioned between the first polymer composite material and the second polymer composite material.

18. The method of claim 17, wherein a portion of the flexible polymer composite material is infused with the polymeric hardening agent, and wherein a hinging portion of the flexible polymer composite material is not infused with the polymeric hardening agent.