AU2005201781B2 - Subassembly designed to produce an aquatic gliding board - Google Patents

Description

S&F Ref: 590706D1 00

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AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address of Applicant: Actual Inventor(s): Address for Service: Invention Title: Salomon of Lieudit La Ravoire, F-74370, Metz- Tessy, France Philippe Renard Eric Metrot Spruson Ferguson St Martins Tower Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) Subassembly designed to produce an aquatic gliding board The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c Page -1- SUBASSEMBLY DESIGNED TO PRODUCE AN AQUATIC GLIDING BOARD [0001] The invention relates to a subassembly adapted to produce an aquatic gliding 00 board, especially a surfboard.

[00021 It also relates to a method for manufacturing such a subassembly and to a board obtained from the subassembly.

00 [0003] Conventionally, a surfboard is obtained from a foam cake, especially polyurethane foam cake, that is shaped in a mold. The foam cake is machined by O planing and sanding over a small thickness to locally personalize its shape, then it is n covered with a casing made of resin-impregnated glass fibers that forms a reinforcing outer shell and provides the board with its final shape. A decoration and a glassing provide the board with its final appearance.

[00041 In certain cases, the foam cake is cut longitudinally into two portions that are then glued to a wooden lath that reinforces its structure and imparts a predetermined longitudinal camber thereon.

[0005]The disadvantage of such a construction technique is the weight.of the final board. Indeed, the foam is relatively thick; typically, its density is about 50 kg/m3.

In addition, it is a priori not possible to reduce the density of the foam without negatively affecting the mechanical properties of the board.

[0006] According to another construction technique derived from the sailboard, one begins with a relatively low density foam cake that is machined to shape. This cake is covered with a layer of resin-impregnated glass fibers. A casing made of a higher density foam is attached around this subassembly. Webs of resign-impregnated glass fibers are then applied in order to form the outer shell.

[0007]Such a construction mode enables a savings in weight of about 20% or more while maintaining a good rigidity beneath the feet. However, its implementation is relatively complex. Moreover, the central foam cake is generally made of polystyrene foam. This material has the flaw of taking in water. Over the course of its lifetime,the board sometimes hits a reef or a rock. If the outer shell is damaged, there is a risk of water penetration, the water weighing down the board and being particularly difficult to evacuate.

[00081 Finally, it is known to obtain hollow boards with sandwich layers.

Alternatively, two half-shells are obtained and then assembled to one another, or yet the assembly is obtained in a closed mold with an inner bladder that is inflated to push and press the sandwich layers against the walls of the mold.

I I o This manufacturing technique makes it possible to obtain lightweight boards.

SHowever, it is not possible to personalize the shape of the board. In this case, the shape of the outer shell depends exclusively upon the shape of the mold.

00oO It is therefore desirable to provide an improved subassembly, which makes it

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possible to obtain surfboards that are lighter while preserving a shape that can be personalized, or more voluminous for an equal weight.

00 It is the object of the present invention to substantially overcome or at least ameliorate one or more of the disadvantages of the prior art or to meet one or more of the t above desires.

Accordingly, in a first aspect, the present invention provides a method of manufacturing an aquatic gliding board, said method comprising the following steps: forming an upper half-shell comprising a thermoformed foam layer covered on its lower surface with an inner layer of resin-impregnated fibers forming a lower half-shell comprising a foam layer covered on its upper surface with an inner layer of resin-impregnated fibers assembling the two half-shells so that said inner layers of resinimpregnated fibers form a hollow shell covered with a casing made of foam.

In a second aspect, the present invention provides a hollow aquatic gliding board, comprising an upper half-shell comprising a layer of thermoformed extruded polystyrene foam covered on its lower surface with an inner layer of resin-impregnated fibers, a lower half-shell comprising a foam layer covered on its upper surface with an inner layer of resin-impregnated fibers, an outer layer of resin-impregnated fibers, and at least one partition made of foam connecting vertically the two half-shells.

A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings, wherein: Figure 1 is a top view of a surfboard; Figure 2 is a side view of the board of Figure 1; Figure 3 is a transverse cross-sectional view of a board obtained according to the prior art; Figure 4 shows a transverse cross-sectional of the structural subassembly according to a first embodiment of the invention; [R:\LIBLL]1 6796.doc:mad r Figure 5 is a longitudinal cross-sectional view of the board obtained from the Ssubassembly of Figure 4; Figure 6 shows the same board in a transverse cross-section; 00 Figures 7, 8 and 9 are transverse cross-sectional views showing three alternative embodiments of the invention; and Figures 10-13 show transverse cross-sectional views of a fourth alternative 00 0 embodiment of the invention in which the structural subassembly is obtained in the form of two half-shells.

With reference to Figures 1 and 2, a surfboard, in a known fashion, is in the form lo of an elongated board with a central portion 2, a tapered and slightly turned up front shovel 3, and a slightly turned up tail 4 and with a reduced width.

Conventionally, as shown in Figure 3, the board is made of a foam cake typically a polyurethane foam with a density of 50 kg/m3, which is coated with a web 6 of resin-coated fibers. Usually, the foam cake is made in a mold, and it is available in various models of variable length, width, volume and camber. Once selected by the shaper, the foam cake is provided with the desired final shape by local planning over a small thickness, and only thereafter, it receives its outer [R:\LBLL]16796.doc:mad

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Page -3covering. This covering makes it possible to increase the mechanical features of the Sfoam, and to protect the foam cake as well.

[0016] Figures 4 and 5 show in a transverse cross-section and in a longitudinal cross- 00 section, respectively, a structural subassembly of the board according to the invention, the subassembly that is located beneath the outer covering of the final board.

00 [0017According to this first embodiment of the invention, the subassembly is formed by an inner shell 7 that is covered with a casing 8 made of foam.

S[0018] The inner shell is hollow. This is a structural element made, for example, of in glass fibers, carbon fibers or fibers of other synthetic material coated with resin, polyester resin, epoxy or the like.

'I [0019] For example, the inner shell is obtained with a thickness between 0.15 and 0.2 millimeters, or between 0.10 and 0.25 millimeters, or even more depending on the use intended for the board and the type of resin used. In certain cases, and depending on the material used, the thickness can reach 1-2 millimeters.

[0020] The inner shell can be obtained according to various techniques. For example, it is formed around a central core made of polyester beads glued with vinyl glue, which is then dissolved in hot water. Other types of soluble mandrel or yet an inflatable bladder can be used.

[0021]According to another embodiment technique, the shell is obtained in a plurality of portions assembled to one another. For example, the shell can be obtained from two half-shells which are nested into one another. The two portions are assembled by gluing or any other appropriate means. Still other possibilities exist.

[0022]The shell 7 can also be constructed with other materials than resinimpregnated fibers, for example a thermoplastic material, thermoplastic loaded with fibers, fibers projected with a polyester matrix, stamped metal or any other material having a high elastic modulus.

[0023] The shell is covered with a casing 8. The casing is made of foam, but various types of foams can be used. For example, one can use a relatively dense PVC foam, with a density of 50-70 kg/m3. One can also choose to use less dense foams, for example polyurethane foams of about 50 kg/m3. One can also use (extruded or expanded) polystyrene foams of 30-50 kg/m3 or yet polyether imide foams or any other waterproof foam.

[0024]The thickness of the casing is determined so as to enable a subsequent machining of this subassembly over this small thickness while having a final I Page -4- N, resistant and lightweight subassembly. For example, the thickness is comprised between 3 and 15 millimeters, or even 20 millimeters. Possibly, one can provide a thickness that is greater along the lateral and front/rear edges of the subassembly, 00 and smaller on the top and bottom. One can also provide different thicknesses on the top and bottom, front and rear.

[0025]To obtain the foam casing, foam plates are glued and curved to the shape of 00 the shell by applying pressure, for example under vacuum by maintaining the interior of the shell at the atmospheric pressure so as not to deform this shell. An Salternative is to place the shell at the center of a mold into which the foam is injected, ('4 t or yet to cast or pulverize this foam on the shell and to allow it to expand in the open air. The polymerization of the foam ensures its superficial bonding with the shell. A primer can be applied to the surface of the shell to improve the performances.

[0026]The subassembly thus obtained has the advantage of being lightweight and resistant. Indeed, since the inner shell 7 is hollow, a significant savings in weight is achieved in relation to a conventional foam cake.

[00271 It is more resistant than a conventional foam cake in view of its structure, with the inner shell and the relatively dense foam casing. The two elements intervene complementarily, the shell, due to its own resistance and to the closed shell effect, and the foam, due to its own resistance and the spreading effect of the constraints which it generates at the surface of the shell and the role of the core in the final sandwich after the addition of the last superficial layer.

[00281]In addition, due to the aforementioned savings in weight, one can select a more resistant and more condensed foam than a conventional foam, while preserving a markedly lower weight than that of the conventional board.

[0029] Moreover, due to the thinness of the foam used and to the support of the shell, the surface beneath the feet can be reinforced by the addition of a honeycombed structure (plastic, cardboard, aluminum) at the time the foam is made.

[0030] Other filling materials, such as wood, or generally any material with a density of less than 1 can also be used.

[0031] The subassembly can be machined in the same manner as a conventional foam cake, depending on the shaper's preference, provided that the machining thickness remains less than the thickness of the foam.

[00321 As for the conventional cakes, the invention provides to obtain a plurality of models of structural subassemblies with a variable length, width, thickness and camber. However, one can use a same model of shell for a plurality of models of Page r, boards, and can vary the form and thickness of the foam casing to obtain the desired final forms.

[0033] Finally, once shaped, the structural subassembly with its machined foam layer 00 8' is provided to be coated with a web 9 made of resin-coated glass fibers or the like,

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and to receive the finishing operations in the same manner as a conventional board.

This is shown in Figure 6.

00 [00341 During use, given that the inner shell is hollow, a user would have less difficulty in evacuating, if necessary, the water which would have infiltrated Sfollowing an impact due, in particular, to the incorporation of a drain plug. In this t regard, one can provide inside the shell an inflated bladder that reduces the water penetration within the shell. This bladder can even be inflated with a lighter gas than air, for example helium, in order to lighten the structure even more.

[0035] Figure 7 relates to an alternative embodiment of the invention. According to this alternative, the inner shell 10 is reinforced by a central partition 11. Such a partition is commonly used, in particular for longboards, in order to provide them with a predetermined camber and a better longitudinal rigidity.

[0036] In the present case, the central partition 11 is made of foam or wood, for example. It extends over the length of the shell. The shell 10 is formed around this partition. Possibly, the partition is edged with two layers 13 and 14 of resinimpregnated fibers, which are continuously connected to the wall of the shell.

[0037] As in the preceding case, the shell 10 is covered with a casing 12 made of foam.

[0038] Figure 8 relates to another alternative embodiment, where the upper wall of the shell 15 is supported by a previously curved foam plate 16.

[0039]To obtain the subassembly, for example, the plate 16 is shaped by thermoforming or any other appropriate technique.

[0040] Initially, the lower wall of the shell is obtained, on which the plate 16 is positioned.

[0041] Next, the shaping of the shell is completed by covering the plate 16 with the web of resin-impregnated fibers, the foam casing 17 is then formed.

[0042] This plate 16 increases the resistance to depression in the upper portion of the subassembly, beneath the surfer's feet.

[0043] According to the alternative embodiment shown in Figure 9, the plate 18 is made of two parts 18a, 18b that are joined at the level of a central partition 19 of the same type as the partition 11. As in the preceding case, the shell 20 is closed above the plate 18, and the envelope 21 is formed around the shell

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Page -6- [0044] Figures 10-13 show another alternative embodiment of the invention in which the structural subassembly is obtained from two assembled half-shells. The subassembly can thus be formed of an upper half-shell 22, which will form the 00 bridge of the final board, and of a lower half-shell 24 which will form the bottom.

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Each half-shell is formed of a foam plate 26, 28 that is first thermoformed in a mold, and then covered, over an inner surface 30, 32, with at least one layer of resin- 00 impregnated cloth. Advantageously, the operation of laminating the inner surface 32 of the half-shells 22, 24 is performed under vacuum, whereas the previously thermoformed foam plate 26, 28 is still in the thermoforming mold, so that the layer tn of resin-coated cloth hardens on the thermoformed plate, while the latter is still pressed against the mold. The form of the half-shell is thus guaranteed at best before Sthe assembly.

[0045] When the two half-shells 22, 24 are assembled to one another, for example by gluing, one directly obtains the rigid inner shell 7, which is formed by the layers of resin-coated cloths arranged on the inner surfaces of the half-shells, on the one hand, and the outer foam casing 8 capable of being machined, on the other hand. The foams used are for example plates of extruded polystyrene foam having a density on the order of 30-50 kg/m3.

[0046] To implement this alternative embodiment, it can be advantageous to provide that one of the half-shells, for the example the lower half-shell 24, also be laminated on its outer surface 34 before the assembly of the two half-shells. The half-shell thus laminated on its two surfaces 32, 34 is then particularly rigid during assembly with the other half-shell, which makes it possible to better control the precision of the assembly, and therefore the precision of the form of the subassembly. Of course, the foam casing covering the shell is then no longer capable of being machined over its entire area. Indeed, since one of the surfaces is already laminated at the time of assembly, the geometry of this surface can no longer be substantially modified.

However, it has been noted that to substantially modify the final behavior of the gliding board, it often suffices to modify the geometry of the lateral edges of the board (generally referred to as the rails of the board). However, this geometry can be modified even if one of the outer surfaces of the board (for example the lower surface) is already laminated.

[00471 In the example shown in Figures 10-13, one can see that the two half-shells are not symmetrical. Indeed, one can see that the lower half-shell 24 does not include any lateral edges. During the shaping, the plate is bent longitudinally (which is therefore not visible in the drawings) so as to follow the longitudinal cambering Page -7rcurve (sometimes called the rocker curve or scoop curve). It could also be bent Stransversely, for example to form a V-shaped or concave double bottom, but in the example shown, the lower half-shell does not have any transverse curvature. In this 00 case, given that the deformation of the foam plate in relation to its initial planar state is relatively minimal, the shaping of the plate can be done without thermoforming, simply by applying the plate against the mold by depression- at the time of 00 lamination. After the resin is cured, the rigidity of the resin-coated cloth sufficesto maintain the plate in the shape desired for the half-shell.

[00481 Conversely, the upper half-shell 22 is thermoformed so as to be bent t' longitudinally, but also transversely to form downwardly curved lateral edges 36.

According to the invention, the inner surfaces the lower surface 30 of the upper r, half-shell 22 and the upper surface 32 of the lower half-shell 24) are laminated with one or several layers of thermosetting resin-impregnated fiber clothes. As can be seen in Figure 10, the lower surface 34 of the lower half-shell 24 is also laminated, before the assembly of the two half-shells.

[0049] As can be seen in Figure 11, the assembly of the two half-shells is obtained by gluing the lower edge of the lateral edges 36 of the upper half-shell 22 against the upper surface 32 of the lower half-shell 24. The glue is selected so that it is not too difficult to machine, so that it does not create any hard spot in the constituent foam of the lateral edge of the subassembly.

[0050] With this construction, it is seen in Figure 12 (which shows in more detail the lateral edge of .the subassembly right after the assembly) that the largest portion at the top of the lateral edge 38 of the structural assembly is formed by the lateral edges 36 of the upper half-shell whose outer surface 40 is made of foam. The lower portion of these lateral edges is constituted by the lateral edge of the lower half-shell which has a foam thickness 28 sandwiched (top and bottom) by two resin-impregnated cloth thicknesses 32, 34. As the cloth thicknesses 32, 34 are very thin, they do not impede the shaping by machining of the lateral edges. Thus, one can see in Figure 13 that the geometry of the lateral edge 38 of the structural subassembly has been modified over the entire height of the lateral edge 38, for example by planing and sanding.

[0051] However, in an alternative embodiment (not shown), it can be provided that the peripheral portion of the upper surface 32 of the lower half-shell 24 not be laminated, so that the lateral edges 36 of the upper half-shell 22 are in support against the foam 28, in order to ensure a better continuity of the material forming the lateral edge 38, which then is only made of foam.

Page -8- [0052]The lamination of the outer surface, in this case the lower surface 34 of the lower half-shell, can be integral (as. illustrated). It can also only affect a portion of the surface, for example the central portion, to preserve a perfect machinability of 00 the lateral edge 38.

[0053] With this construction, the precise assembly of the two half-shells is facilitated by the'substantial rigidity of the lower half-shell, and the subassembly remains 00 capable of being machined over its entire upper surface and on its lateral edges, which allows a great possibility to personalizde the subassembly. Once personalized, Sthe structural subassembly is covered with an outer layer of resin-impregnated fn fibers. As the case may be, one can choose to also cover the already laminated outer surface 34 of the subassembly with this outer layer so as to increase the rigidity and strength of the board, or conversely can choose not cover this already laminated surface 34 in order to limit the weight of the board.

[0054] Of course, in the case where one would prefer the possibility to personalize the bottom of the board, it could be provided that the half-shell laminated on its two surfaces be the upper half-shell, the lower half-shell then only being laminated on its upper surface 32. In both cases, the subassembly thus obtained is a subassembly which, in the context of the invention, comprises a hollow and rigid inner shell, and a foam casing capable of being machined which entirely covers this inner shell.

Optionally, a portion of this casing (the geometry of which one does not wish to modify, for example the upper surface of the upper half-shell or the lower surface of the lower half-shell), can be covered with a rigid outer layer.

[0055]As in the case of the embodiments of Figures 7 and 9, one can provide advantageously to provide the subassembly of Figures 10-13 with a longitudinal central partition that vertically connects the two half-shells.

[0056]Naturally, the present description is provided for guidance only, and other embodiments thereof can be adopted without leaving the scope of the present invention. For example, one can double the inner shell and therefore obtain a stacking alternately including webs of fibers and layers of foam for the subassembly. One can also have a plurality of longitudinal, transverse, or otherwise appropriately directed partitions, these partitions forming connections between the bridge and the bottom of the board. Possibly, these partitions can create a partitioning of the inner shell into a plurality of waterproof compartments.

[0057] Moreover, the invention could be applied to the construction of boards other than surfboards, for example, boards for sailboards, boards adapted for swimming Page -9- 0 C1 on waves and, generally, any aquatic activity in which the board operates mostly in Sthe lift-off mode.

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Claims (10)

1. A method of manufacturing an aquatic gliding board, said method comprising the following steps: 00 5 forming an upper half-shell comprising a thermoformed foam layer covered on its lower surface with an inner layer of resin-impregnated fibers; 0- forming a lower half-shell comprising a foam layer covered on its 00 r- upper surface with an inner layer of resin-impregnated fibers; S- assembling the two half-shells so that said inner layers of resin- n 10 impregnated fibers form a hollow shell covered with a casing made of foam.

2. The method according to claim 1, wherein, in the step forming the upper half shell, the foam layer is first thermoformed then covered, on its lower surface, with an inner layer of resin-impregnated fibers.

3. The method according to any one of the preceding claims, further comprising the supplementary step consisting in laminating at least a part of the outer surface of at least one of the two half-shells before the assembling of the two half-shells.

4. The method according to any one of the preceding claims, wherein the foam layer of at least one of the half-shells comprises extruded polystyrene. The method according to any one of the preceding claims, wherein the upper half-shell is thermoformed to so as to form downwardly curved lateral side-walls, and wherein the lower half-shell does not include any lateral side-wall.

6. The method according to any one of the preceding claims, further comprising the step of providing at least one partition made of foam connecting vertically the two half- shells.

7. The method according to any one of the preceding claims, further comprising the step of covering the assembled half-shells with an outer layer of resin-impregnated fibers.

8. A hollow aquatic gliding board, comprising an upper half-shell comprising a layer of thermoformed extruded polystyrene foam covered on its lower surface with an R:ALIBLL\I 6796.doc:KJC 11 inner layer of resin-impregnated fibers, a lower half-shell comprising a foam layer C, covered on its upper surface with an inner layer of resin-impregnated fibers, an outer Slayer of resin-impregnated fibers, and at least one partition made of foam connecting vertically the two half-shells. 00 (N

9. A hollow aquatic gliding board according to claim 8, wherein the foam layer of Sthe lower half-shell is made of extruded polystyrene. 00 A hollow aquatic gliding board according to claim 8 or 9, further comprising a plurality of longitudinal, transverse, or otherwise appropriately directed partitions. (N

11. A method of manufacturing an aquatic gliding board, said method being substantially as hereinbefore described with reference to Figs. 10 to 13 of the accompanying drawings.

12. A hollow aquatic gliding board substantially as hereinbefore described with reference to Figs. 10 to 13 of the accompanying drawings. DATED this twenty-eighth Day of April, 2005 Salomon S.A. Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON R:\LIBLL\16796.doc:KJC