The present disclosure pertains to water sports board riding equipment and methods of making water sports board riding equipment.
Board riding on water has been used for various sports and/or activities such as, for example, surfing, bodyboarding, bodysurfing, wakeboarding, riverboarding, riding waves, and being towed behind a boat. A water sports board is generally understood to be a buoyant device made of wood, foam, plastic, fiberglass, carbon fiber, epoxy resins, and/or various combinations thereof, used to aid the rider while traveling on the surface of the water. Many of the materials currently used to form water sports boards can be toxic to very toxic to the environment and when used in combination with one another can be very difficult to recycle, or in combination, cannot be recycled.
In use, riders of water sports boards must maintain purchase (firm hold, grip and/or position) on the board throughout the ride or they may fall, crash, lose their balance, or ability to perform maneuvers or tricks. Riders can maintain purchase through various methods and products such as straps, handles, applied waxes, grips, and/or textures applied to and/or formed into the board. The board surfaces may be textured during manufacturing, for example, by stamping, etching, cutting, or other texture forming processes.
In some instances, the same devices or solutions designed to aid the purchase of a rider can also create problems for the rider such as interference to the rider's position which can be unique to each rider and/or to each ride, or textured surfaces or waxes can cause irritation or chafing of the skin of the rider during use. Riders will sometimes sacrifice purchase to alleviate interference or irritation from these methods or devices.
Expanded polypropylene foam (EPP) has been used to create watersports equipment as disclosed in U.S. Pat. No. 4,961,715. EPP is a foam manufactured using steam-chest molding practices, where polypropylene (PP) beads are inserted into a mold cavity through fill guns. Steam is introduced into the mold cavity, and the PP beads expand as a result of being exposed to steam. After bead expansion, the steam is then released from the mold through steam vents installed into the mold. The bodyboard part is then removed from the tooling using ejector pins and placed in an oven to cure. During the steam-chest molding process, various witness marks are formed on the surface of the molded board, by the steam vents, fill gun heads (nozzles), and ejector pins. The witness marks can be of various depths and heights, which can, depending on location, size and shape, alter a board's surface and can leave the board with undesired aesthetical properties and/or can impede or interfere with the flow of water across the board which can slow a rider or alter the performance of the board.
A cured EPP water sports board, although very light and durable, can be damaged during prolonged storage or when on display for sale when the weight of the board is left to rest on the tail, nose, or small surface area of the board. During steam-chest molding, the outer layer of foam beads creates a “skin” that helps with the durability of the board as well as water intrusion. EPP is a closed-cell foam but can absorb water with prolonged submersion especially when the skin of the molded part is damaged or manipulated when attaching accessories such as leashes, cameras, fins, straps, or handles, or by stamping or press-forming after molding to add surface textures, etc. A known practice to overcome the susceptibility of foam boards to water absorption and damage, and to provide a smooth surface covering the molded witness marks, is the addition of a polymer or resin coating or shell, applied, sprayed, or molded onto the foam board in a typical construction. However, the addition of the applied coating, and/or molded shell adds weight and cost to the board, and also reduces and/or eliminates the ability to recycle the board efficiently.
A sports board and method of forming the sports board is provided herein. In an illustrative example, the sports board is configured as a water sports board suitable for use as a wave riding device or for use as any of water, snow, or sand sports equipment. Water sports boards can range in size from 6″ hand planes to 12′0″ surfboards or paddleboards. In a non-limiting example, the accompanying drawings illustrate a water sports board configured as a bodyboard. The water sports board can also be referred to herein as a bodyboard. It should be understood that the example of a bodyboard and/or the use of the term bodyboard interchangeably with the term water sports board or sports board in the description is non-limiting, such that each term is intended to include all types, shapes and sizes of sports boards including water sports boards and bodyboards.
The sports board described herein is advantaged by being molded of a single material, expanded polypropylene (EPP) foam, without any over molding, coating, shell, or adhesives, such that the EPP foam board is fully recyclable. Further, the steam-chest molding process used to form the board is configured such that, during molding of the board, clusters of protrusions are intentionally formed on the board's as-molded exterior surface by extrusion of the EPP material into vent apertures of steam vents positioned in the mold cavity, where the clusters of protrusions are configured, positioned and designed to define integral purchase surface areas on the exterior surfaces of the board. As such, the clusters of protrusions, which in a typical molding operation may be considered molding defects or detrimental to the appearance or surface characteristics of a typical molded product, are instead intentionally and advantageously formed on the exterior surface of the board as disclosed herein, to form one or more integral purchase surface areas as a functional feature of the finished board. Further, the mold cavity and components are configured such that the board is molded to form a continuous skin, absent any perforations or sharp corners or edges, advantageously enhancing fluid flow over the board surface, and, as a continuous skin, sealing the board against water ingression during use. In one example, the tail portion of the board includes a contoured tail feature, shaped to provide a resting surface for the board when stored in an upright position and without any sharp edges, such that the contoured tail feature resists damage and breakage of the type which could be incurred during upright storage if the tail feature terminated in a sharp edge. The board including the one or more integral purchase surface areas is fully formed in the mold cavity, such that no post-molding processing is required to seal or texture the surface of the board, providing a cost advantage in manufacturing, and a relatively lighter weight board as compared with boards of similar size including a molded shell or overcoating.
The above features and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like or similar components throughout the several views, and wherein:
While the present disclosure may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure. Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” etc., are used descriptively of the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the disclosure in any way.
The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.
The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.
Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description.
A sports board 100 and method 200 of forming the board 100 is provided herein. In an illustrative example, the sports board 100 is configured as a water sports board suitable for use as a wave riding device or for use as any of water, snow, or sand sports equipment. Water sports boards can range in size from 6″ hand planes to 12′0″ surfboards or paddleboards. In a non-limiting example, the accompanying drawings illustrate a water sports board configured as a bodyboard 100. It should be understood that the example of a bodyboard and/or the use of the term bodyboard interchangeably with the term water sports board or sports board in the description is non-limiting, such that each of the terms sports board, water sports board, bodyboard, and/or board 100 is intended to include all types, shapes and sizes of sports boards including water sports boards and bodyboards.
Referring to the drawings wherein like reference numbers represent like components throughout the several figures, the elements shown in
The board 100 is characterized by a board width BW, a board length BL, and a board height BH. In non-limiting examples, the board length can range in size from about 6 inches for a hand plane to about 12 feet for surfboards or paddleboards. In a non-limiting example, the board 100 is configured as a bodyboard having a board width BW in a range of about 20 to 22 inches, a board length BL in a range of about 44 to 46 inches, and a board height BH in a range of about 4 to 6 inches.
In an illustrative example, the board 100 has a board width BW in a range of about 6 to 18 inches, and a board length in a range of about 6 to 18 inches, such that the board 100 can be configured for use, in a non-limiting example, as a handplane. In an illustrative example, the board 100 has a board width BW in a range of about 20 to 36 inches, and a board length in a range of about 32 to 50 inches, such that the board 100 can be configured for use, in a non-limiting example, as a bodyboard. In an illustrative example, the board 100 has a board width BW in a range of about 20 to 48 inches, and a board length in a range of about 40 to 100 inches, such that the board 100 can be configured for use, in a non-limiting example, as a surfboard. In an illustrative example, the board 100 has a board width BW in a range of about 20 to 36 inches, and a board length in a range of about 44 to 46 inches, such that the board 100 can be configured for use, in a non-limiting example, as a rescue sled, such as a watercraft rescue sled used to be towed behind watercraft such as a jet ski to pick up a person from tow-surfing and step-off surfing, or for water rescue events, for example, by a lifeguard or water rescue personnel.
The board 100 is made of expanded polypropylene (EPP) foam 28 by molding using a steam chest molding process 200 as further described herein, such that the board 100 is a monolithic structure, formed by a method of monolithic construction, being formed completely of EPP foam including the exterior skin 70 formed of EPP foam during the steam chest molding process 200, such that the board 100, as molded and cured, is finished for use and does not require any subsequent processing. The term “monolithic structure” as used herein to refer to the board 100, refers to a structure which is formed of a single homogeneous material, in the present example, EPP foam 28, as a unitary component, e.g., in a single continuous piece of EPP foam 28 including a continuous exterior skin 70 comprising the EPP foam 28, the continuous exterior skin 70 defining the shape of the unitary component. The term “monolithic construction” as used herein to refer to the method 200 of forming the board 100, refers to a process where, using a single homogeneous material, in the present example, EPP beads processed (expanded, softened and fused) to form EPP foam 28, the board is fully constructed, in the present example, by molding the board 100 using steam chest molding to form the board 100 and surface features of the board 100 as further described herein, and curing the board, such that after curing, the molded EPP board 100 is a finished product having a monolithic structure, and is not subject to, and does not require, any subsequent processing. As such, the monolithic construction of the board 100 provides the advantages of relatively lower manufacturing and material costs, by using only one material, EPP beads molded to form EPP foam, by not requiring any coating or shell to encapsulate the foam such that the monolithic structure, e.g., the board 100 is lighter weight than a coated board of comparable size, and by not requiring any subsequent processing such as cutting, drilling, stamping or pressing the foam material to add features to the board such as leash plug holes, logos, surface texturing, etc., as these are all molded into the board during the molding process described herein. The monolithic construction of the board 100 forms a continuous exterior skin 70 which is compressed during molding such that the continuous exterior skin 70 is highly resistant to water absorption, eliminating the need to add an overcoat or shell to the board 100 to prevent water absorption. Advantageously, the board 100, as further described herein, is formed without any sharp edges, sharp corners, or sharp markings, as these features, if formed into the board, would be relatively more susceptible to breakage, chipping, and/or providing a water absorption path. Contoured features of the board 100 include a contoured edge rail detail 14, a contoured tail edge feature 18, a debossed logo marking 22, a contoured leash plug hole 20, contoured ejection pin markings 30 and contoured injector head markings 36, each of which are contoured to increase resistance to water ingression and to decrease susceptibility to damage to the exterior skin 70 at these feature locations, and such that in use, the flow of water, snow, sand, etc. over the exterior skin 70 of the board 100 is not affected by and/or minimally impeded by the contoured features.
In a non-limiting example, as shown in
Referring to
Referring again to
In another example, shown in
The examples illustrated in the Figures are non-limiting, and it would be understood that combinations of different types and sizes of steam vents 50 can be included in the mold halves 40 and arranged to define various purchase surface areas 60 each characterized by different purchase or gripping properties and performance, as defined by the particular combination of steam vents 50 used to form the protrusion clusters 62 within the respective purchase surface area 60. These protrusions 64 can range in size, shape, spacing, etc., based on which type of steam vent 50 is used and based on the arrangement and size of the vent apertures 66, 68 within the steam vent 50. By way of non-limiting illustration, steam vents 50 used to mold the protrusions 64 described herein can have a diameter in a range from about 4 mm to 15 mm, where the diameter of the vent 50 is directly related to, e.g., defines the vent width VW of the protrusion cluster 62 (see
In a non-limiting example, it is preferred to use salt and pepper style steam vents 50, each having a vent diameter of 8 mm (defining the vent width VW of a protrusion cluster 62 formed by the steam vent 50) and including vent apertures 68 having an aperture diameter of 0.6 mm (defining the protrusion width PW of protrusions 64 formed within the protrusion cluster 62) in diameter, with the steam vents 50 spaced from each other at 19 mm on center, to form vent markings 26 within purchase surface areas 60 formed on any surface of the board 100, e.g., on either or both of the top deck 34 or bottom 32. These salt and pepper vent markings 26 create excellent purchase that may require the board rider to wear a rash guard or wetsuit to protect the rider's skin from rashes that can be caused by prolonged use in contact with the purchase surface areas 60 including the salt and pepper vent markings 26. Advantageously, these purchase surface areas 60 including salt and pepper vent markings 26 spaced on 19 mm centers eliminate the need for a board user/rider to obtain and/or apply aftermarket purchase enhancing products. Advantageously, these purchase surface areas 60 including salt and pepper vent markings 26 can also act as a base for applied after-market surf waxes, improving retention of the wax to the exterior skin 70 of the board 100.
In a non-limiting example, to have a more aesthetically appealing board and/or for use in warmer water climates where a board rider/user may not possess chafe protective apparel such as a wetsuit or rash guards, it is preferred to form the purchase surface areas 60 of the board 100 including ultra-fine 8 mm salt and pepper microvent markings 24 spaced at 24 mm on center to create ultra-fine protrusions 64 of the type shown in
An exemplary method 200 of monolithic construction of the board 100 is illustrated by
At step 210, the mold halves 40 are closed to form the mold cavity 46 in shape of board 100. At step 215, a single homogeneous material, which in the present example is non-expanded polypropylene (PP) beads 38 is inserted into the mold cavity 46 via PP fill nozzles, also referred to herein as PP fill guns 42. In a non-limiting example, the rate of feed and/or volume of PP beads 38 fed into the mold cavity 46 via the PP fill guns 42 is controlled such that the density of the monolithic board 100 after forming and curing is about 1.9 lbs/cu.ft. The non-expanded PP beads 38 are sized such that after expansion and curing, the expanded polypropylene (EPP) beads fused together to form the EPP foam 28 each have a diameter, after expansion, in the range of about 3 mm to 5 mm.
At step 220, high-pressure steam 48 is flowed into the mold cavity 46 via steam nozzles 56. At step 225, the PP beads in reaction to the high-pressure steam, expand, soften and fuse to each other to form expanded polypropylene (EPP) foam 28 in the mold cavity 46, and in the shape of the board 100, such that the board 100 can be described as a monolithic structure and consisting of a single homogeneous material, e.g., the EPP foam 28. Step 225 includes steps 227 and 229, where at step 227, the expanded PP beads which are adjacent and/or in contact with the mold cavity surface 52 are compressed against the cavity surface 52 during expansion, and fuse (heat-bond) to each other to form the contoured exterior skin 70 of the board 100. As shown in
Continuing at step 227, the expanded PP beads which are adjacent and/or in contact with the mold cavity surface 52 are compressed against the cavity surface 52 during expansion, to form contoured features of the board 100 including a contoured edge rail detail 14, a contoured tail edge feature 18, a debossed logo marking 22, a contoured leash plug hole 20, contoured injector head markings 36, each of which are contoured to increase resistance to cracking and/or water ingression in use and to decrease susceptibility to damage to the exterior skin 70 at these feature locations, and such that in use, the flow of water, snow, sand, etc. over the exterior skin 70 of the board 100 is not affected by and/or is only minimally impeded by the contoured features. Referring to
At step 227, a contoured edge rail detail 14 is formed at the parting line of the mold halves 40. As shown in
At step 227, as shown in
At step 227, as shown in
At step 227, contoured injector head markings 36, also indicated in the figures as located in the boxes labeled M2, may form where the bead injector (fill gun) heads 44 interface with the mold cavity surface 52. To minimize and/or substantially avoid the formation of the injector head markings 36, the fill gun heads 44 are contoured to blend to the contour of the mold cavity surfaces 52, such that injector head markings 36, if formed, are minimized as shown in
Referring again to the method 200 shown in
At step 230, the steam is released through the steam vents 50 and the mold 40 and board 100 formed within the mold cavity 46 is cooled.
At step 235, the mold halves 40 are opened and the finished board 100 if ejected by ejector pin(s) 54 and removed from the mold cavity 46. Similar to the injector fill gun heads 44, the ejector pins 54 are contoured to conform to the exterior shape of the board 100, to minimize any markings to the exterior skin 70 of the board 100 during the forming process. Additionally, the ejector pin pressure can be controlled and/or minimized to minimize formation of an ejector pin marking 30 on the exterior skin 70 during ejection of the board 100 from the mold. Referring to
Continuing with step 235, after removal of the fully formed board 100 from the mold cavity 46, the molded board 100 is cured, for example, by heating the board 100 in an oven to 175 degrees Fahrenheit for about 6 hours. Once cured, the board 100 is ready for its intended use, without further processing.
The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.
This application claims the benefit of U.S. Provisional Application No. 63/340,104, filed May 10, 2022, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63340104 | May 2022 | US |