Patent Application
20200102056
The present disclosure relates to the field of surfboards, and more particularly to an improved surfboard with a variable rocker.
A surfboard's rocker—it's longitudinal upwards curvature, measured from its bottom surface—affects that surfboard's balance between speed and maneuverability more than any other design aspect. A less curved (flatter) rocker increases straight-line speed but decreases maneuverability. A more curved rocker increases maneuverability but decreases straight-line speed.
This speed and maneuverability trade-off exists because typical surfboards are rigid which means their rockers are fixed shapes. Variable rockers potentially eliminate this trade-off.
Camber has been used in the ski and snowboard world for its edge control and ability to create a radius that may be used to initiate a turn. Camber is also effective at distributing a rider's weight across the length of skis or snowboards. Traditionally, this shape has not been effective for a surfboard profile. The concave nature of the snowboard camber creates a drag on the rear half of the board as its momentum creates lift in the tail, pushing the nose of the snowboard down in loose “powder” snow. This is the reason ski and snowboards designed for riding in deeper snow have borrowed the rocker shape from surfing.
The most common surfboard construction starts with rigid polyurethane (PU) or expanded polystyrene (EPS) foam slabs or “blanks”, typically reinforced with one or more stringers for further rigidity. After the foam is sculpted into the desired surfboard design, it is entirely encapsulated in a rigid skin by laminating fiberglass cloth to the foam, typically with polyester or epoxy resin. The fiberglass skin serves as a structural component, so typical surfboard construction is a monocoque design, which provides excellent rigidity. Furthermore, typical surfboards are shaped to have features that increase their monocoque rigidity compared to a monocoque design without that feature. For example, typical surfboards feature longitudinally convex (domed) deck shapes, as laminating the fiberglass to that contour increases the longitudinal rigidity of the fiberglass itself and therefore the board as well.
Typical surfboard construction emphasizes rigidity, so the speed and maneuverability trade-off caused by fixed rockers is considered normal.
The next most common type of surfboard, colloquially called a “soft top”, “foamie” or “foam board”, is designed with soft exteriors in the interests of user and bystander safety, lower cost, and impact durability. The soft exteriors are not structural, so soft tops are commonly reinforced for rigidity either internally with stringers or externally such as with a fiberglass layer bonded to the bottom surface, yet these still are less rigid than conventional fiberglass monocoque surfboards. Despite a degree of flexibility, soft tops do not deliver the benefits potentially available from a variable rocker. Quite the opposite, the flexibility of soft tops typically decreases both speed and maneuverability
Soft tops are generally “floppy” meaning they have flexibility without predefined flex patterns, and they lack an ideal rate of “snap back” to their original shape when relieved from flex inducing forces. As such, soft tops tend to push water forward, rather than under the board, making them slow. And their floppy nature means soft tops tend to be less responsive to surfer input and thus are more difficult to maneuver. Soft top surfboards demonstrate that flexibility alone does not create the benefits of a variable rocker.
A flexible surfboard is provided in an embodiment. The surfboard includes a foam body having a length, width, and thickness. The surfboard includes a flexible structural component tapered in at least one dimension, and disposed within the foam body. The flexible structural component has as dimensions a length, width, and thickness, and is configured to flex under induced forces during use. The flex characteristics of the flexible surfboard are primarily dependent on flex characteristics of the flexible structural component. The tapered flexible structural component is oriented within the foam body such that the length, width, and thickness of the tapered flexible structural component align with the length, width, and thickness of the foam body, respectively. The thickness of the soft body is less than the width of the soft body, and the width of the soft body is less than the length of the soft body. The thickness of the tapered flexible structural component is less than the width of the tapered flexible structural component, and the width of the flexible structural component is less than the length of the tapered flexible structural component. The length of the tapered flexible structural component is 6 to 12 inches shorter than the length of the foam body.
The foregoing, and other features and advantages of the disclosure, will be apparent from the following, more particular description of the embodiments of the disclosure, the accompanying drawings, and the claims.
For a more complete understanding of the present disclosure, the objects and advantages thereof, reference is now made to the ensuing descriptions taken in connection with the accompanying drawings briefly described as follows.
Preferred examples of the present disclosure and their advantages may be understood by referring to
The disclosure provides for a variable rocker by giving surfboards a range of flexibility when flex-inducing forces are applied, sufficient snap back to their original shape when flex-inducing forces are relieved, along with a flex pattern. When boards based on such embodiments flex, such a board typically will not flop or bend in arbitrary ways. The various rocker shapes formed through a range of flexibility are deliberately designed to balance speed and maneuverability for a desired degree of flex.
In reference to
In an embodiment, panel 5 is formed of a rigid panel material that is able to flex when a force is applied. The panel material for panel 5 is typically wood. The wood may be a single piece of wood or a laminated piece formed of two or more pieces of wood. In an embodiment, a panel including laminated wood may utilize vertical lamination, horizontal lamination, or a combination of the two. In the example, the grain of the wood will be typically aligned with the longitudinal length to provide increased strength over the longitudinal axis. The skin material for panel 5 is typically fiberglass, laminated to the panel with an epoxy resin. The skin may be fiberglass, another fiber-reinforced cloth such as carbon fiber, Kevlar, or flax, or a solid material such as wood or plastic.
In an example, wherein a wood panel is used, the wood used may be paulownia, aspen, beech, birch, bamboo, popular, another wood deemed suitable for the application, or a laminate comprised of multiple wood species. Generally, the wood should be free of knots, holes, and other inconsistencies that may affect the flex and strength of the panel.
In an embodiment, the panel may be a single plank of paulownia wood with dimensions of 5′×6″×0.375″ (length×width×thickness). In the example, this panel may be provided for a finished board between the lengths of 5′6 to 6′, wherein the panel does not extend all the way through the length of the board. The panel dimensions may be modified appropriately to suit any board length.
In another embodiment, the panel may be formed of a composite material, polymer, foam, honeycomb, or other material which is mostly rigid, but is also able to flex under an applied force. For example, the composite panel 5 may be a piece of wood laminated with fiberglass, carbon fiber, Kevlar, aramid, or other fiber-reinforced cloths to provide strengthen and/or stiffen the panel.
In another embodiment, foam, honeycomb, or other composite materials may be used in conjunction with or to replace wood to create the panel of panel 5. Differing panel materials may be used to create a desirable flex pattern in a composite panel. For example, softer panel materials may be used where more flex is desired for the panel, and stiffer panel materials may be used where less flex is desired for the panel.
In an embodiment, the panel 5 is tapered to create desirable flex characteristics. Because the panel 5 has less flex (stiffer) where its dimensions are larger, and more flex (softer) where its dimensions are smaller, its flex pattern can be controlled by tapering its width and thickness. In reference to
In another example, as shown in
In another example, wherein a fiber-reinforced cloth is used, the cloth may be tapered, layered, and overlapped to create a desirable flex pattern. For instance, where increasing flex is desired toward the ends of a panel, the center of the entire length of the panel may be provided with 4 layers of cloth. In contrast, the center can be provided with an additional 2 layers of cloth, such that the center of the panel will be stiffer compared to the ends of the panel.
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In an example, the soft body 10 of the surfboard blank 1 is comprised of a low density, soft, and flexible material. The soft body 10 in an embodiment is preferably formed of polyethylene (PE) foam with a density of approximately 2 pounds per cubic foot (PCF), but may also be comprised of arcel, polypropylene, polyurethane, polystyrene, a blend of these, or other materials deemed suitable for the application.
In an example, the soft body portions of surfboard blank 1, will then be shaped into a surfboard design. The blank can be shaped with hand tools, power tools, or by a computer numeric controlled (CNC) cutting machine. In an example, after being shaped, the blank is laminated with a high-density skin. In the preferred example, the high-density skin is comprised of PE foam of approximately 8 PCF; however, other common skin materials such as ethylene vinyl acetate (EVA) and polyvinyl chloride (PVC) may be used. The high-density skin may be hand laminated to the shaped blank, vacuum bagged, or heat-bonded. The excess skin is then trimmed off or sanded away to bring the blank back to its desired shape.
In an embodiment, the soft body 10 and high-density skin will have relatively little rigidity or elasticity on their own. The objective for such an embodiment, is that the created surfboard blank 1, will have flex characteristics which are primarily dependent on panel 5.
In reference to
The ideal result of the flexible panel is that in straight-line travel, its flex enables the length of the surfboard to be relatively flat against the dynamic surface of the wave beneath it for maximum speed. In cornering, the surfer's weight and feet position against the surfboard's area of water contact flexes the length of the surfboard to increase its rocker for better maneuverability. Under normal circumstances, the board examples described herein have less (flatter) rocker than typical surfboards which allow for increased maximum straight-line speed. Since cornering forces operate relative to how hard a surfer turns, flex increases rocker to the degree needed to match the arc of the surfer's intended turn.
In another example, panel 5 may be constructed with a degree of upward longitudinal curvature before it is disposed partially or entirely into soft body. The curvature may be designed to correspond with a final surfboard shape in order to, for example, reduce the effort or time required to work the soft body into that surfboard's shape. The curvature may also serve to help the surfboard's nose remain above the surface of the water while riding a wave.
In reference to
In an embodiment, the panels 900, 905, and 910 are formed of a rigid panel material which is able to flex to a predefined stressed shape when a force is applied and rebound to its unstressed shape when the force is removed. The preferred panel material is wood, but other options include and are not limited to a composite material, polymer, foam, honeycomb, or other material which is mostly rigid but is also able to flex under an applied force and return quickly to an unstressed shape when force is eased.
In an example, panels 900, 905, and 910 may be laminated with a preferred skin material fiberglass, laminated to the panel with an epoxy resin. The skin may be fiberglass, another fiber-reinforced cloth such as carbon fiber, Kevlar, or flax, or a solid material such as wood or plastic.
In reference to
In an embodiment, a side view of relaxed panel 1020 indicates that the thickness does not taper. When a force is applied in the direction of vector X, the panel will become stressed. Keeping the majority of the width in the center of rigid panel 1025 results in less flex around the max-width of panel 1025 and more flex towards tapered ends 1030 and 1035. This potentially affords a great elastic deformation in the direction of vectors Y and Z to create an advantageous shape for maneuvering a soft surfboard, while the unstressed shape 1020 is more suited for speed generation.
In reference to
In an example, when a force is applied in the direction of vector X the panel will become stressed. It is understood by keeping the majority of the width in the center of rigid panel 1120. There will be less flex around the max-width of panel 1120, which tapers towards end 1125. This will afford a great elastic deformation in the direction of vectors Y to create a more advantageous shape for maneuvering soft surfboard then non stressed shape 1115, which is more suited for speed generation.
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In an example, it is demonstrated that panel 1410 can have filleted corners 1415, which have been determined in some embodiments to provide ease of manufacturing and strength of blanks. Additionally, sharper edges 1420 may put undue stress from inside of soft surfboard (not shown) that the panel 1410 is disposed within while being weighted by a rider.
In reference to
Camber 1505 allows for the weight of a rider to be more evenly distributed across the length of panel 1500. This will tend to increase the stability and control of the finished soft surfboard (not shown) in which the panel 1500 is disposed. Camber 1505 will improve the flex response of panel 1500 by introducing internal stresses which improve the elastic deflection of the panel when force is applied in the direction of vector X. When camber 1505 has a load applied in the direction of vector X it will compress the bend of the camber 1505 in the direction of vector Y. This will extenuate the rocker 1510 which, when stressed, will further raise end 1515 in the direction of vector Z toward a flatter unstressed panel shape. The addition of camber 1505 thus allows panel 1500 to potentially be made thinner than other flatter panels without sacrificing loss of performance.
In another example of panel 1520, some of the unique features previously described also appear. The maximum width and thickness of panel 1520 is located at tail end 1535 and tapers in both the width and thickness to nose end 1535. Camber 1525 is at the tail end of panel 1520 and transitions to rocker 1530. This tapering of panel 1520 potentially results in more significant displacement of end 1540 in the direction of vector C, when a force is applied in the direction of vector A as compared with end 1515 in the direction of vector Z of panel 1500 assuming same materials are used.
In an example, panel 1520 has also had a fin cut out placed so that a fin (not shown) or fin enclosure box (not shown) may be securely anchored in the panel 1520 when it is disposed in soft surfboard (not shown). A mechanism for securing a fin will improve the endurance of the surf on a single fin (not shown), which would act as a steering mechanism for a surfboard 2 of
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In some embodiments, the panel is formed in an asymmetric shape, which may be used as part of an assymetric or symmetric surfboard. Additionally, in some embodiments, a symmetric panel is used in an asymmetric finished surfboard. Such designs may be used at the discretion of those shaping a finished surfboard. The panel may be expected to be formed to taper in a manner consistent with the embodiments shown and described herein.
The disclosure has been described herein using specific examples for the purposes of illustration only. It will be readily apparent to one of ordinary skill in the art, however, that the principles of the disclosure can be embodied in other ways. Therefore, the disclosure should not be regarded as being limited in scope to the specific examples disclosed herein, but instead as being fully commensurate in scope with the following claims.
The present application is a Continuation In Part for U.S. patent application Ser. No. 15/437,126 filed on Feb. 20, 2017, entitled “VARIABLE_ROCKER SURFBOARDS” the entire disclosure of which is incorporated by reference herein which claims priority U.S. Provisional Patent Application No. 62/299,443 filed on Mar. 24, 2016, entitled “FLEXIBLE SURFBOARDS BY WAY OF HORIZONTALLY LAMINATED SANDWICH PANEL AND SOFT EXTERIOR” the entire disclosure of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62299443 | Feb 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15437126 | Feb 2017 | US |
| Child | 16701138 | US |
