Sports device structures and compositions

Abstract

The present invention relates to a sports device, such as a surf board, water board, and the like for use by persons in moving over a water surface. The device generally has:a) a central foam core;b) a cover fabric laminated around the central foam core;c) a laminating adhesive securing the cover fabric to the central foam core; andd) a water resistant polymeric coating covering the laminated cover fabric and laminating adhesive.The laminating adhesive generally has a specific gravity of less than 2.0 g / m3. The laminating adhesive may have a Shore A hardness of at least 70 and may be a water-based polyurethane emulsion, a methacrylate-acrylate copolymer emulsion, an epoxy or epoxy-acrylate hybrid emulsion adhesive or a mixture of at least any two of these adhesives.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The invention relates to improved surfboard constructions and compositions.[0003]2. Background of the Art[0004]Normally, surfing devices having a board-like body, so-called surfboards, are provided with a foam core that is encased with a bonded laminate for strength and have an upper side and a lower side. Commonly used resins for bonding the laminate to the foam core to create strength are the unsaturated polyester resins that contain up to about 40% by weight styrene as the curing agent or 2-part epoxy resins cured with amine functional hardeners. Styrene is officially classified as a volatile organic compound (VOC) and hazardous air pollutant (HAP) and has worker safety issues from long term exposure to its vapors requiring workers to wear protective breathing equipment to protect them. While the 2-part epoxy resins do not contain styrene, they expose workers using them to safety hazards that can include painful skin...

AI Technical Summary

Benefits of technology

The present invention is related to a sports device, such as a surf board or snow board, that is used on water surfaces by people. The device has a foam core, a fabric cover that is attached to the foam core using a special adhesive, and a water-proof coating. The adhesive has a low gravity, which makes the device lightweight. The technical effects of this invention include improved buoyancy, durability, and reduced friction for better performance.

Problems solved by technology

Styrene is officially classified as a volatile organic compound (VOC) and hazardous air pollutant (HAP) and has worker safety issues from long term exposure to its vapors requiring workers to wear protective breathing equipment to protect them.

While the 2-part epoxy resins do not contain styrene, they expose workers using them to safety hazards that can include painful skin irritation and the potential for sensitization leading to rashes, etc. from skin contact.

Thus each of these two major classes of materials commonly used to manufacture surfboards have serious worker safety and environmental pollution issues that must be carefully managed through proper handling procedures including the use of personal safety equipment and air quality management in the work area and beyond.

Limiting the environmental impact of styrene evaporation from the resins during the manufacturing process of surfboards is problematic in that highly specialized and expensive air handling and treatment equipment such as carbon bed absorbers are required to capture the vapors from the work environment atmosphere before release to the environment.

Furthermore, the commonly used laminate bonding resins (unsaturated polyesters with styrene, and two-part epoxy resins) are rigid and brittle materials after curing with limited flexibility and energy dissipating properties as measured by dynamic impact tests such as the Gardner Impact Test (ASTM D5420-10).

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