GB2544710A

GB2544710A - Water boards

Info

Publication number: GB2544710A
Application number: GB1507963.5A
Authority: GB
Inventors: Edward Martin Richard; James Martin Christopher
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-05-11
Filing date: 2015-05-11
Publication date: 2017-05-31
Also published as: GB201507963D0

Abstract

A water board and method of manufacture of the same are disclosed. The water board 1 comprises a core 3 which is substantially solid and comprises at least one section having a first elongate surface 17 and a second elongate surface 19, opposite to and separated from the first surface by a wall 21 extending around and joining edges of the first and second surfaces. The first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose (23, Fig 1) at a first end and a tail (25, Fig 1) at a second, opposite end. A deck 5 comprises at least one sheet which is heat bonded to the first surface of the core and shaped to substantially conform with the first surface of the core. A base 9 comprises at least one sheet which is heat-bonded to the second surface of the core and shaped to substantially conform with the second surface of the core. Also a rail 11 comprises at least one elongate strip which extends around the wall of the core and is heat-bonded to the wall of the core, the deck and the base.

Description

Water Boards

The invention relates to water boards, and particularly, but not exclusively, to surfboards, paddleboards, crossover surf/paddle boards, bodyboards, skimboards and wakeboards.

Many types of board for use on water, such as surfboards, paddleboards and crossover surf/paddle boards, exist. These comprise a basic elongate shape, providing a flat deck or platform for a user to stand on and a generally curved base which contacts the water. Surfboards are made in various lengths, from 'longboards' of lengths between 2.4m and 3.7m to 'shortboards' of lengths between 1.8m and 2.1m and several varieties inbetween. Paddleboards (where the user lies, kneels or stands on the board) are also made in different lengths, from 3.7m to 5.5m or more. The curve of the base of these water boards, referred to as the rocker, can be concave and/or convex, continuous or staged, steep or shallow. Details of the outline shape of these boards, particularly at the front end, the nose, and at the rear end, the tail, varies, for example the tail shape can be square, rounded, pin (pointed), swallow, etc. Water boards are normally provided with one or more fins, usually attached to the tail of the board. One, two, three or more fins can be used, providing various degrees of stability and manoeuvrability. The variation of the characteristics of water boards which is available allows boards to be created which can be used for different functions, e.g. surfing or paddling, and which can be customised to suit the user's skill and experience.

Water boards as described above can be 'hard' boards, usually made from plastic or fiberglass, or 'soft' boards usually made from a foam material. Soft boards, in particular, generally comprise a number of components, such as a core of foam material, surrounded by a deck, a base and a rail, which are attached together using a variety of methods. Such soft water boards are light and buoyant and sufficiently strong to support the user, and are designed and manufactured to different levels of robustness and durability.

Soft water boards are often used by beginners and less experienced users, such users can subject the boards to a high level of abuse. Soft water boards are also often used in schools for teaching surfing and paddleboarding, etc. and are used a large number of times per day. The boards are also subject to varying temperatures, from cold seas to summer sun. All of these can result in problems with the robustness of the boards. For example, delamination may occur, where the base or deck separates from the rest of the board. When the base of the board is made from plastic, sharp edges can be created on the base through damage. These problems cannot usually be repaired and renders the board useless. It is an objection of the invention to provide enhancement of robustness in water boards.

According to a first aspect of the invention there is provided a water board comprising a core which is substantially solid and comprises at least one section having a first elongate surface and a second elongate surface, opposite to and separated from the first surface by a wall extending around and joining edges of the first and second surfaces, the first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose at a first end and a tail at a second, opposite end, a deck comprising at least one sheet heat-bonded to the first surface of the core and shaped to substantially conform with the first surface of the core, a base comprising at least one sheet heat-bonded to the second surface of the core and shaped to substantially conform with the second surface of the core, and a rail comprising at least one elongate strip and extending around the wall of the core and heat-bonded to the wall of the core, the deck and the base.

The core may comprise a foam material. The foam material may comprise any of polyethylene foam, polyurethane foam, polystyrene foam. The foam material may comprise a sheet form, with a thickness of, for example, 80mm.

The deck may comprise a foam material. The foam material may comprise ethylene vinyl acetate foam. The foam material of the deck may be of a higher density than the foam material of the core. The deck may have a thickness of approximately 23mm.

The base may comprise a foam material. The foam material may comprise polyethylene foam. The polyethylene foam may be a high density polyethylene foam. The foam material of the base may be of a higher density than the foam material of the core. The base may have a thickness of approximately 2mm.

The base may comprise a plurality of tabs, which are spaced at intervals around an outer edge of the base and which extend outwardly from the outer edge of the base. The tabs may extend across the wall of the core. The tabs may be heat-bonded to the wall of core. The tabs may extend across the wall of the core to reach the deck. The tabs may be heat-bonded to the wall of core and the deck. Preferably the base comprises ten tabs, with a first tab extending across the wall of the core at the tail of the core, a second tab extending across the wall of the core at the nose of the core, third, fourth, fifth and sixth tabs extending across the wall of the core at spaced intervals along a first side of the core between the tail and the nose, and seventh, eighth, ninth and tenth tabs extending across the wall of the core at spaced intervals along a second side of the core between the tail and the nose. The tabs may have a width of approximately 2mm to approximately 8mm.

The base may comprise a curve. The curve of the base may be concave and/or convex, continuous or staged, steep or shallow.

The rail may comprise a foam material. The foam material may comprise polyethylene foam. The foam material of the rail may be of a higher density than the foam material of the core. The rail may have a thickness of approximately 18mm to approximately 28mm. The rail may comprise a first strip extending around the wall of the core along the tail of the board and one or more further strips extending around a remainder of the wall of the core.

Heat-bonding of the components of the water board, means that no adhesives are used. The bonds formed by heat do not break down in the same way as bonds formed with adhesive. This results in a decrease in the risk of deterioration and eventual failure of the water board.

The water board may comprise at least one stringer comprising at least one elongate rod positioned within and along the core between the first and second surfaces thereof. The at least one stringer may be positioned within a cavity provided in the core. The at least one stringer may be positioned substantially equidistant between the first and second surfaces of the core. The at least one stringer may be shaped at either end to match a profile of the nose and a profile of the tail of the core. The at least one stringer may have a diameter which varies along its length to match the profile of the nose and the profile of the tail of the core. The at least one stringer may have a diameter of approximately 30mm at a midpoint thereof. The at least one stringer may comprise any of a plastic material, polyvinyl chloride, balsa wood, basswood, whitewood, ash, epoxy laminates, carbon fiber.

When the water board comprises one stringer, this may be positioned substantially along a mid long axis of the core. When the water board comprises two stringers, these may be positioned on either side of and substantially equidistant from a mid long axis of the core. When the water board comprises three stringers, a first stringer may be positioned substantially along a mid long axis of the core and the remaining two stringers may be positioned on either side of and substantially equidistant from the mid long axis of the core. The stringer or stringers provide stiffness and allow the board to keep its shape, i.e. flat on top and shaped along the bottom.

The water board may comprise at least one fitting for attaching at least one fin to the board. The at least one fitting may comprise a fitting cavity provided through the board in proximity to the tail of the board. The at least one fin may be attached to the tail of the board using a connection device located in the at least one fitting cavity of the board.

The water board may comprise a leash and an attachment for the leash.

The water board may comprise any of a surfboard, a paddleboard, a crossover surf/paddle board, a bodyboard, a skimboard, a wakeboard.

The pre-determined profile of the water board may be such as to allow the board to be used for a particular function, e.g. surfing or paddling, and to suit a user's skill and experience. For example, the pre-determined profile of the water board may provide a longboard surfboard having a length between 2.4m and 3.7m, or a shortboard surfboard having a length between 1.8m and 2.1m, or a paddleboard having a length from 3.7m to 5.5m or more.

According to a second aspect of the invention there is provided a method of manufacture of a water board comprising shaping a substantially solid core to comprise at least one section having a first elongate surface and a second elongate surface, opposite to and separated from the first surface by a wall extending around and joining edges of the first and second surfaces, the first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose at a first end and a tail at a second, opposite end, heat-bonding a deck comprising at least one sheet to the first surface of the core and shaping the deck to substantially conform with the first surface of the core, heat-bonding a base comprising at least one sheet to the second surface of the core and shaping the base to substantially conform with the second surface of the core, and heat-bonding a rail comprising at least one elongate strip to the wall of the core, the deck and the base to extend around the wall of the core, and shaping the rail.

At least one template may be used to obtain the pre-determined profile of the board. The or each template may be fixed to the core and the core shaped to match the or each template.

The base may comprise a plurality of tabs, which are spaced at intervals around an outer edge of the base and which extend outwardly from the outer edge of the base. The tabs may extend across the wall of the core. The method may comprise heatbonding the tabs to the wall of core. The tabs may extend across the wall of the core to reach the deck. The method may comprise heat-bonding the tabs to the wall of core and the deck. Preferably the base comprises ten tabs, with a first tab extending across the wall of the core at the tail of the core, a second tab extending across the wall of the core at the nose of the core, third, fourth, fifth and sixth tabs extending across the wall of the core at spaced intervals along a first side of the core between the tail and the nose, and seventh, eighth, ninth and tenth tabs extending across the wall of the core at spaced intervals along a second side of the core between the tail and the nose. The tabs may have a width of approximately 2mm to approximately 8mm.

Shaping the rail may comprise forming the rail to match the profile of the core and rounding off top and bottom edges of the rail. When the rail comprise two or more elongate strips, the method may comprise heat-bonding adjacent ends of the strips.

The method may further comprise generating at least one stringer in the shape of at least one elongate rod and positioning the stringer within and along the core between the first and second surfaces thereof. Positioning the at least one stringer within and along the core between the first and second surfaces thereof may comprise boring a cavity in the core and installing the stringer in the cavity.

The method may further comprise providing at least one fitting in the water board for attaching at least one fin to the board. Providing the at least one fitting may comprise boring a fitting cavity through the board in proximity to the tail of the board. The at least one fin may be attached to the tail of the board using a connection device located in the at least one fitting cavity of the board.

An embodiment of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic representation of a top view of a water board according to the first aspect of the invention;

Figure 2 is a schematic representation of a side view of the water board of Figure 1; Figure 3 is a schematic representation of a cross sectional view of the water board of Figure 1, and

Figure 4 is a flow chart of the method of manufacture of a water board according to the second aspect of the invention.

Referring to Figures 1 to 3, the water board 1 comprises a core 3, a deck 5, stringers 7, a base 9, a rail 11, fins 13 and a leash 15. In this embodiment, the water board is a surfboard, but it will be appreciated that the water board may be other types of boards.

The core 3 is substantially solid and comprises one section having a first elongate surface 17 and a second elongate surface 19, opposite to and separated from the first surface by a wall 21 extending around and joining edges of the first and second surfaces, 17, 19. The first and second surfaces 17, 19 and the wall 21 of the section provide a pre-determined profile of the water board 1 with a nose 23 at a first end and a tail 25 at a second, opposite end. The pre-determined profile is that of a surfboard. The core 3 has a thickness of 80mm. A foam material is used for the core 3 because of the strength, durability, low water absorption and ease of shaping of this material.

The deck 5 comprises one sheet heat-bonded to the first surface 17 of the core 3. The deck 5 is shaped to substantially conform with the first surface 17 of the core 3. The deck 5 comprises ethylene vinyl acetate foam. EVA foams are hard wearing, ultra violet radiation and salt water resistant, and have very low water absorption. The material of the deck 5 is of a higher density than the material of the core 3. The deck 5 has a thickness of approximately 23mm.

The stringers 7 each comprise one elongate rod. These are each positioned within and along the core 3 in a cavity. The stringers 7 are positioned to each side of a mid long axis of the core 3. The stringers 7 are shaped at either end to match a profile of the nose 23 and a profile of the tail 25 of the core 3. Each stringer 7 has a diameter which varies along its length to match the profile of the nose 23 and the profile of the tail 25 of the core 3. The stringers 7, in this embodiment, have a diameter of approximately 30mm at a midpoint thereof. The stringers 7 comprise a plastic material.

The base 9 comprises one sheet heat-bonded to the second surface 19 of the core 3. The base 9 is shaped to substantially conform with the second surface 19 of the core 3. The base 9 comprises a high density polyethylene foam. The material of the base 9 is of a higher density than the material of the core 3. The base 9 has a thickness of approximately 2mm. The base 9 comprises a plurality of tabs 27 (Figure 3). These are spaced at intervals around an outer edge of the base 9 and extend outwardly from the outer edge of the base 9. The tabs 27 extend across the wall 21 of the core 3 and are heat-bonded to the wall 21 of core 3. In this embodiment, the base 9 comprises ten tabs 27, with a first tab extending across the wall of the core at the tail of the core, a second tab extending across the wall of the core at the nose of the core, third, fourth, fifth and sixth tabs extending across the wall of the core at spaced intervals along a first side of the core between the tail and the nose, and seventh, eighth, ninth and tenth tabs extending across the wall of the core at spaced intervals along a second side of the core between the tail and the nose. The tabs 27 have a width of approximately 5mm. The base 9 comprises a continuous, concave curve, as shown in Figure 2.

The rail 11 comprises a first strip 31 extending around the wall 21 of the core 3 along the tail 25 of the board 1 and a second strip 33 extending around a remainder of the wall 21 of the core 3. The strips 31, 33 of the rail 11 are heat-bonded to the wall 21 of the core 3, the deck 5 and the base 9. The material of the rail 11 is of a higher density than the material of the core 3. The rail 11 has a thickness of approximately 23mm.

The water board 1 comprises a plurality of fittings 35 for attaching two fins 13 to the board. Each of the fittings comprises a fitting cavity provided through the board in proximity to the tail 25. The fins may be attached to the tail 25 of the board 1 using a connection device (not shown) located in the fitting cavities 35. The fins are usually attached to the board by a user of the board.

The water board 1 comprises a leash 15 also attached to the tail 25 of the board 1, as shown.

Referring to Figure 4, the method of manufacture of the water board 1 comprises the following steps: shaping a substantially solid core to comprise at least one section having a first elongate surface and a second elongate surface, opposite to and separated from the first surface by a wall extending around and joining edges of the first and second surfaces, the first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose at a first end and a tail at a second, opposite end (40), heat-bonding a deck comprising at least one sheet to the second surface of the core and shaping the deck to substantially conform with the second surface of the core (42), heat-bonding a base comprising at least one sheet to the first surface of the core and shaping the base to substantially conform with the first surface of the core (44), heat-bonding a rail comprising at least one elongate strip to the wall of the core, the deck and the base to extend around the wall of the core, and shaping the rail (46).

Shaping the core 3 comprises using a template to obtain the pre-determined profile of the board, fixing the template to the core raw material and shaping the core 3 to match the template. The core 3 can be shaped by cutting. Details of the profile or outline shape of the board, particularly at the nose 23 and the tail 25 can vary, for example the tail shape can be chosen from any of square, rounded, pin (pointed), swallow, etc.

Starting at the nose 23 of the board 1, the deck 5 is heat-bonded using a hot air gun and nozzle to the first surface 17 of the core 3. The deck 5 is then shaped e.g. by cutting away excess material, to substantially conform with the first surface 17 of the core 3.

Starting at the nose 23 of the board 1, the base 9 is heat-bonded using a hot air gun and nozzle to the second surface 19 of the core 3. The base 9 is then shaped, e.g. by cutting away excess material, to substantially conform with the second surface 19 of the core 3 and to provide the plurality of tabs 27. The tabs 27 are heated and folded to extend across the wall 21 of the core 3 and then heat-bonded to the wall 21 of core 3. The tabs 27 increase the robustness of the board 1.

Starting at one end of the tail 25 of the board 1, the first strip 31 of the rail 11 is heat-bonded to the wall 21 of the core 3, the deck 5 and the base 9 along the length of the tail 25. Starting at one end of the tail 25 of the board 1, the second strip 33 of the rail 11 is heat-bonded to the wall 21 of the core 3, the deck 5 and the base 9 along the remainder of the wall 21 of the core 3. Where the first and second strips 31, 33 meet, additional heat-bonding is used to join adjacent ends of the strips together. The rail 11 is then shaped to match the profile of the core 3 by cutting to remove excess rail material. Top and bottom edges of the rail 11 are then rounded off.

The method may further comprise generating two stringers 7 in the shape of elongate rods and positioning the stringers 7 within and along the core 3 between the first and second surfaces 17, 19 thereof. Generating the stringers 7 comprises using a template to define the shape of the stringers particularly at either end where they match the profile of the nose 23 and the profile of the tail 25 of the core 3. The template is fixed to stringer plastic raw material and each stringer 7 cut to match the template. Two cavities are bored in the core 3 and a stringer 7 is then placed in each cavity of the core 3. The stringers 7 provide stiffness and allow the board 1 to keep its shape, i.e. flat on top and shaped along the bottom.

The method may further comprise providing a plurality of fittings 35 in the water board 1 for attaching two fins 13 to the board. Providing the fittings comprises marking and boring fitting cavities 35 through the board in proximity to the tail of the board. The fins 13 are attached to the tail of the board using a connection device located in the fitting cavities 35 of the board. This comprises fitting the fins 13 from the underside of the board 1 and securing them using a threaded fastener from above.

The method may further comprise attaching a leash 15 to the water board 1. This comprises marking and drilling a hole at the tail 25 of the board 1, fitting the leash and its holder from the top side of the board 1 and securing using a threaded fastener from below.

Using the heat-bonding method to attach the components of the board 1 together, slightly melts the material of each component, making it tacky and ready for bonding. When two components are at the correct temperature, they are pressed together and once cooled they become one unit. When the material of the base, deck and rail is similar to, but of higher density than, the material of the core, the components can be easily heat-bonded together. As no adhesives are used in the manufacture of the board 1, it is much more robust and resistant to the action of ultra violet radiation and abrupt changes in temperature. This results in a decrease in the risk of deterioration and eventual failure of the water board 1.

The water board 1 may also be easily repaired, even if it has been severely damaged. For example, if the rail is sliced in half, a repair can be made using a heat gun to heat the area between the slice and heat-bond the areas on either side of the slice. The board can thus be easily and cheaply fixed - it will not collapse, chip or soak up water as might otherwise occur, and thus maintains its structural integrity.

Claims

1. A water board comprising a core which is substantially solid and comprises at least one section having a first elongate surface and a second elongate surface, opposite to and separated from the first surface by a wall extending around and joining edges of the first and second surfaces, the first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose at a first end and a tail at a second, opposite end, a deck comprising at least one sheet heat-bonded to the first surface of the core and shaped to substantially conform with the first surface of the core, a base comprising at least one sheet heat-bonded to the second surface of the core and shaped to substantially conform with the second surface of the core, and a rail comprising at least one elongate strip and extending around the wall of the core and heat-bonded to the wall of the core, the deck and the base.

2. A water board according to claim 1 in which the core comprises any of polyethylene foam, polyurethane foam, polystyrene foam.

3. A water board according to claim 1 or claim 2 in which the deck comprises ethylene vinyl acetate foam.

4. A water board according to any preceding claim in which the base comprises polyethylene foam.

5. A water board according to any preceding claim in which the base comprises a plurality of tabs, which are spaced at intervals around an outer edge of the base and which extend outwardly from the outer edge of the base.

6. A water board according to claim 5 in which the tabs extend across the wall of the core and are heat-bonded to the wall of core.

7. A water board according to any preceding claim in which the rail comprises polyethylene foam.

8. A water board according to any preceding claim in which the rail comprises a first strip extending around the wall of the core along the tail of the board and one or more further strips extending around a remainder of the wall of the core.

9. A water board according to any preceding claim further comprising at least one stringer comprising at least one elongate rod positioned within and along the core between the first and second surfaces.

10. A water board according to claim 9 in which the at least one stringer is positioned within a cavity provided in the core.

11. A water board according to claim 9 or claim 10 in which the at least one stringer is shaped at either end to match a profile of the nose and a profile of the tail of the core.

12. A water board according to any preceding claim further comprising at least one fitting for attachment of at least one fin to the board.

13. A water board according to any preceding claim comprising any of a surfboard, a paddleboard, a crossover surf/paddle board, a bodyboard, a skimboard, a wakeboard.

14. A water board substantially as described herein with reference to the drawings.

15. A method of manufacture of a water board comprising shaping a substantially solid core to comprise at least one section having a first elongate surface and a second elongate surface, opposite to and separated from the first surface by a wall extending around and joining edges of the first and second surfaces, the first and second surfaces and the wall of the or each section providing a pre-determined profile of the board with a nose at a first end and a tail at a second, opposite end, heat-bonding a deck comprising at least one sheet to the first surface of the core and shaping the deck to substantially conform with the first surface of the core, heat-bonding a base comprising at least one sheet to the second surface of the core and shaping the base to substantially conform with the second surface of the core, and heat-bonding a rail comprising at least one elongate strip to the wall of the core, the deck and the base to extend around the wall of the core, and shaping the rail.

16. A method according to claim 15 further comprising generating at least one stringer in the shape of at least one elongate rod and positioning the stringer within and along the core between the first and second surfaces.

17. A method according to claim 15 or claim 16 further comprising providing at least one fitting for attaching at least one fin to the board.