Surfboard and method of manufacturing

Abstract

A surfboard includes a core covered with a laminate and having perforations where the user places his feet, in order to prevent air blisters from forming between the core and laminate. The core is formed from an extruded closed-cell polystyrene foam block which has been shaped by restraining it against a shaped form using shaped restraining tools and straps, and heating it; and by cutting using a hot wire. The core is laminated with FIBERGLAS® and epoxy resin, and the perforations are formed using a perforating tool that has a planar or curved working surface and one or more heated needles extending perpendicularly from the working surface.

Description

RELATED APPLICATIONS [0001] This application is a divisional of U.S. patent application Ser. No. 10 / 403627, filed Mar. 28, 2003, and currently co-pending.FIELD OF THE INVENTION [0002] The present invention relates generally to water sports equipment. The present invention relates more particularly, though not exclusively, to a water sports board made of laminated closed-cell foam with perforation vents in the laminate for preventing deformations of the surface of the board. The present invention is useful for surfboards, sailboards, wave skis and other applications requiring buoyant, rigid, and durable boards. BACKGROUND OF THE INVENTION [0003] Many water sports boards and craft (e.g., surfboards, sailboards, wave skis, etc.) are made of expanded open-cell rigid polymer foam. Where the discussion herein refers to a surfboard or “board”, it applies to surfboards, sailboards, body boards, wave skis, and other types of water sports boards and craft as well. To make a board of open-cell...

AI Technical Summary

Benefits of technology

"The present invention is a surfboard made of laminated closed-cell foam that has perforations to prevent air blisters. The foam is shaped by heat and pressure, and then laminated with water-proofing materials to make it more durable. The shaping process involves using tension devices and a hot wire to further shape the foam. The laminated foam is then perforated in multiple locations to allow air or gas to escape from between the foam and laminate. The resulting board has improved durability and buoyancy, and is easier to use for water sports and other purposes."

Problems solved by technology

A problem with open-cell foam is that it absorbs water.

Unfortunately, even though covered with a water-proofing material, in the event the board is bumped or the water-proofing materials are breached, the board absorbs water through that breach.

A board made with open-cell foam that has absorbed water is significantly more difficult to use because of its increased weight and decreased buoyancy.

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