Method for manufacturing a rigid aquatic float

Abstract

The invention relates to a method for manufacturing a rigid aquatic float comprising a length extending between a first end and a second end, a thickness, a width, a deck (22a), and a hull (22b); remarkable in that said method comprises the following steps: a) modeling a rigid aquatic float or parts of said rigid aquatic float from said main length, said thickness, and said width; b) producing a reinforcing element (21); c) producing an internal skeleton (20) by 3D printing comprising a plurality of raw material filaments; said 3D printing being configured to produce at least one part of the rigid aquatic float obtained in step a); each part of the rigid aquatic float comprises a male part or a female part; d) assembling said reinforcing element (21) with said internal skeleton (20) by assembling the male part with the female part.Figure for the summary: Fig. 3.

Description

Title of the invention: Method for manufacturing a rigid aquatic float. Technical field of the invention

[0001] The present invention relates to a method for manufacturing a rigid aquatic float. It is applicable, in particular, in the fields of industry, water sports, and the manufacture of surfboards, canoes, and other nautical sports equipment. Previous technique

[0002] Surfing, as a sport undergoing professionalization and democratization, has experienced a stagnation in innovation in the design of rigid aquatic boards for the past sixty years. This stagnation creates friction and obstacles to the practice of the sport, both for professional surfers seeking extreme performance and for beginners and amateurs seeking equipment adapted to their skill level and surfing conditions.

[0003] The surf industry faces major challenges, including the difficulty for surfers to choose a suitable rigid water board from a multitude of models in stores, the low presence of online sales despite strong demand, and the predominance of many intermediaries increasing the carbon footprint throughout the value chain.

[0004] Furthermore, although surfing is often associated with increased environmental awareness, traditional rigid watercraft present obstacles to "green" consumption. The long-distance transport of components during production also contributes to the environmental impact.

[0005] From a technical standpoint, the surfing industry has evolved little, largely due to a stifling production chain. Conventional materials, such as polyurethane and expanded polystyrene, remain the main components of rigid water floats, despite being toxic to produce.

[0006] Some prior art documents also propose methods for manufacturing a rigid aquatic float. For example, publication document FR2103611 is known, which describes a method for manufacturing a rigid aquatic float such as a rigid aquatic float or a surfboard.

[0007] The majority of surf floats are still made of polyurethane foam or polyester foam with epoxy resin, which poses environmental problems due to their toxicity and fragility, compromising the long-term performance of rigid aquatic floats. Presentation of the invention

[0008] The present invention aims to remedy these drawbacks with a totally innovative approach.

[0009] More specifically, the invention aims to provide a method

[0010] One objective of the invention is to provide such a method, which can be easily adapted to existing systems.

[0011] These objectives, as well as others which will appear subsequently, are achieved using a method for manufacturing a rigid aquatic float comprising a main length extending between a first end and a second end, a thickness, a width, a deck, and a hull; remarkable in that said method comprises the following successive steps: - a) model a rigid aquatic float or parts of said rigid aquatic float from said main length, said thickness, and said width; - b) create a reinforcement element from the modeling of step a); - c) produce an internal skeleton by 3D printing comprising a plurality of raw material filaments; said 3D printing being configured to produce at least one part of the rigid aquatic float obtained in step a); each part of the rigid aquatic float comprises a male part or a female part; - d) assemble said reinforcement element from step b) with said internal skeleton from step c) forming the rigid aquatic float by assembling the male part with the female part.

[0012] Thanks to these provisions, this process aims to produce high-performance, customized rigid aquatic floats while being environmentally friendly, by exploiting the latest technological advances in the fields of additive manufacturing and composite materials.

[0013] Manufacturing only a portion of the rigid aquatic float improves the manufacturing speed of the entire assembly. In case of an error or printing problem, it is not necessary to remanufacture the entire assembly; it will suffice to reprogram the printer or print the missing portion.

[0014] The invention is advantageously implemented according to the embodiments and variants set out below, which are to be considered individually or according to any technically operative combination.

[0015] In one embodiment, said process further comprises a preliminary waste collection step; said waste being sorted, recycled and configured to be transformed into raw material forming raw material filaments used in step b).

[0016] According to one example, the raw materials being in the form of pellets.

[0017] Thanks to these provisions, the rigid aquatic float is manufactured in a way that is sustainable for the environment.

[0018] In one embodiment, the process includes a step of bonding at least one composite plate composed of fiber and resin around said internal skeleton of step c); said composite plate being configured to form a hull of the rigid aquatic float.

[0019] In one embodiment, the process includes a step of laminating the rigid aquatic float by adding successive layers of fiber and resin onto said hull.

[0020] Thanks to these provisions, these two steps allow for the sealing of the rigid aquatic float.

[0021] In one embodiment, the process includes a step of sanding a surface of the composite plate obtained after the lamination step of the rigid aquatic float.

[0022] Thanks to these provisions, this step makes it possible to have the final result of the rigid aquatic float.

[0023] In one embodiment, the reinforcing element is made of wood, said wood being at least one of the following species: balsa, linden, pine, poplar, paulownia and cedar.

[0024] Thanks to these provisions, the reinforcing element allows for better strength of the rigid aquatic float.

[0025] According to one example, the reinforcing element is machined by a CNC (acronym for Computer Numerical Control) or a laser cutter.

[0026] In one embodiment, following the assembly of step d), a step of adding a radio frequency identification tag or near field communication tags to the assembly.

[0027] Thanks to these provisions, this step makes it possible to: have the history of the rigid aquatic float, to know the title of ownership of the rigid aquatic float, to have a detailed description, to create connected advertising, and to geolocate the rigid aquatic float in case of loss or theft. More generally, to have a means of communication with the user.

[0028] In one embodiment, the method includes a step of assembling at least one block on the rigid aquatic float, said retaining block being at least one of the following: a retaining block for a fin box, a rope attachment block, a block including a decompression valve, and at least one block configured to attach fins to the rigid aquatic float.

[0029] Thanks to these provisions, this step allows the proper use of the rigid aquatic float in an aquatic environment.

[0030] In one embodiment, the raw material filaments of step c), have a thickness between 1 mm and 6 mm, a width between 1 and 10 mm. Brief description of the figures

[0031] Other advantages, purposes and features of the present invention will become apparent from the following description, given for explanatory purposes and in no way as a limitation, with reference to the accompanying drawings, in which:

[0032] Fig. 1 represents an overview of the rigid aquatic float;

[0033] Figure 2 shows a view of the hull of the rigid aquatic float cut into three parts.

[0034] Fig. 3 represents an overview of the bridge and hull with the wooden assembly;

[0035] Fig. 4 shows the location of the three retaining blocks on the rigid aquatic float;

[0036] Fig. 5 represents a cross-sectional view of the rigid aquatic float;

[0037] Fig. 6 represents the junctions of the different printed parts of the rigid aquatic float;

[0038] Fig. 7 represents another view of the junctions of the different printed parts of the rigid aquatic float;

[0039] Fig. 8 represents an exploded view of the machined reinforcing parts of the rigid aquatic float;

[0040] Fig. 9 represents the internal skeleton of the rigid aquatic float;

[0041] Fig. 10 represents the addition of fins on the rigid aquatic float;

[0042] Figure 11 shows the coating of a composite alloy on the float rigid aquatic environment. Description of the implementation methods

[0043] Fig. 1 shows an overview of the rigid aquatic float.

[0044] This view shows the rigid aquatic float horizontally.

[0045] The structure comprises a certain length, a width, a thickness, a bridge 22a, a hull, and three housings

[0046] The three housings include at least one retaining block 23 on the rigid aquatic float, said retaining block 23 being at least one of the following: a retaining block 23 of a fin housing, a block including a decompression valve, and at least one block configured to attach fins to the rigid aquatic float.

[0047] According to an example carried out, the rigid aquatic float is modeled in three dimensions.

[0048] This modeling is done using CAD (registered trademark) or CAM (registered trademark) software.

[0049] The terms CAD and CAD refer respectively to computer-aided design and computer-aided drafting.

[0050] The modeling also makes it possible to ensure optimal hydrodynamic characteristics when using the rigid aquatic float.

[0051] The CAD or CAM software creates a three-dimensional design of the internal structure of the rigid aquatic float. This design is adjusted according to the defined length, width, and thickness.

[0052] According to one embodiment, the design of the rigid aquatic float is made by 3D printing and machining.

[0053] 3D printing involves a plurality of raw material filaments. Said raw material is a material derived from marine waste.

[0054] Each printed filament has a thickness between 1 mm and 6.5 mm.

[0055] According to one variant, the thickness is between 1.5 mm and 5 mm.

[0056] The raw material contributes to a preliminary waste collection stage; said waste being sorted, recycled and configured to be transformed into raw material forming raw material filaments.

[0057] According to one variant produced, 3D printing prints the internal skeleton 20 of the rigid aquatic float.

[0058] The internal skeleton 20 is printed in several parts. These parts comprise at least one female part and at least one male part.

[0059] The junction between the female part and the male part forms an assembly.

[0060] These printed parts are assembled with tenon-mortise fastening mechanisms.

[0061] The tenon-mortise fixing mechanism consists of inserting a tenon cut on one end of a piece into a corresponding mortise made on another piece, thus ensuring a robust and durable connection.

[0062] This assembly ensures the connections between each part of the internal skeleton 20.

[0063] According to an example produced, the 3D printing is done with an FDM type 3D printer (registered trademark).

[0064] The term 3D means, in French, "three dimensions"

[0065] FDM type 3D printing, meaning Fused Deposition Modeling in English, is a 3D printing technique that works by extruding thermoplastic materials, such as PLA or ABS, through a heated nozzle, thus creating successive layers that solidify to form a three-dimensional object.

[0066] The acronym PLA stands for "polylactic acid". It is a biodegradable polymer-type material.

[0067] The term ABS means a thermoplastic polymer.

[0068] The rigid aquatic float is machined using a reinforcing element. This reinforcing element is machined to obtain slats.

[0069] According to one variant, the reinforcing element is wood.

[0070] The wood chosen for the reinforcing element is wood, said wood is at least one of the The following species: balsa, linden, pine, poplar, paulownia and cedar.

[0071] According to another variant, one of the slats is customized by the manufacturer.

[0072] The machining of the rigid aquatic float is done by a CNC type machine (registered trademark).

[0073] CNC machining, which stands for Computer Numerical Control, is a manufacturing process where cutting tools are controlled by a computer to remove material from a raw workpiece and shape it, following precise instructions programmed in terms of numerical coordinates.

[0074] These slats are elongated, forming a wave shape, and assembled together to form a solid structure. This structure is assembled with the internal skeleton 20, which is produced by 3D printing. This results in the outer hull of the rigid aquatic float. This outer hull is divided into a first face and a second face.

[0075] After assembly, the process includes a step of adding a radio frequency identification tag or near field communication tags to the assembly.

[0076] According to an example produced, the radio frequency identification tag or the near field communication tag is a chip. This chip is integrated into the rigid aquatic float.

[0077] The chip is an NFC chip, which is a chip integrated into electronic devices to enable near-field communication. The term NFC stands for Near Field Communication.

[0078] According to one variant, the chip is an RFID. RFID stands for "Radio-Frequency Identification." It is a technology that uses electromagnetic fields to identify and track objects equipped with RFID tags.

[0079] This chip interacts with a control unit having a microcontroller. The chip contains the following information: a title of ownership, a history of the rigid aquatic float, a detailed description of the rigid aquatic float, connected advertising and / or geolocation.

[0080] The title deed helps prevent theft or loss of the rigid aquatic float.

[0081] The history of the rigid aquatic float allows visibility into the information of the rigid aquatic float (invoices, number of owners, repairs...)

[0082] Geolocation makes it possible to locate and know the position of the rigid aquatic float.

[0083] According to an example carried out, the chip is connected with a mobile terminal.

[0084] The mobile terminal is one of the following: a smartphone, a computer, a digital tablet, a smartwatch.

[0085] After assembly, the rigid aquatic float includes a lamination stage. This stage is produced with the following elements: the outer hull, a composite plate, and a first flexible plate.

[0086] The composite plate is created to provide a load-bearing support above the outer shell, and the first flexible plate helps to distribute the vacuum force without creating pockets in the outer shell.

[0087] The stratification step is divided into several sub-steps.

[0088] The outer shell is sanded to obtain a smooth surface.

[0089] The composite plate is created by laminating a fiberglass layer. This lamination is done on waxed marble. The composite plate has an inner face.

[0090] According to one embodiment, the glass fiber has a surface mass between 190 g / m2 and 500 g / m2. According to a variant, the surface mass is 2*190 g / m2.

[0091] The composite plate has a thickness of between 0.1 mm and 1 mm. According to one variant, the thickness is 0.4 mm.

[0092] According to one embodiment, the composite plate has a surface mass between 650 g / m2 and 850 g / m2. According to a variant, the surface mass is 714 g / m2.

[0093] The composite plate is cut to obtain the same shape as the outer shell.

[0094] According to an example produced, the composite plate is sanded and degreased.

[0095] The outer shell and the composite plate will be bonded according to a defined bonding zone. The adhesive is mixed with resin and then spread on the inner surface.

[0096] The bond is held in place by adhesive tape.

[0097] According to one embodiment, the first flexible plate is placed on the composite plate and held in place by adhesive tape.

[0098] The outer shell assembly with the composite plate and with the first flexible plate is turned over so as to prevent the resin from flowing into the outer shell.

[0099] A second flexible plate is added on the opposite side of the bond. It prevents deformation of the assembly.

[0100] According to one example, the assembly is placed under a tarpaulin for a period of at least 6 hours at a temperature between 15 degrees and 30 degrees. According to a variant, the temperature is 20 degrees.

[0101] At the end of this substep, the adhesive tape and the tarpaulin are removed.

[0102] These substeps were performed for the first face of the rigid aquatic float. The The sub-steps are repeated for the second side with another composite plate.

[0103] For the first side and the second side, there is sanding and degreasing of the composite plates and the outer shell.

[0104] The assembly is cut out so as to obtain the zones for the three blocks.

[0105] The previously laminated fiberglass is cut. This will allow the first face to be structured with the outer shell up to the other composite plate of the second face. After cutting, the fiberglass is laminated with resin.

[0106] The assembly proceeds to a drying and then a cutting of the fiberglass and resin lamination.

[0107] According to one embodiment, the outer shell is sanded and has a gripping surface.

[0108] As a preliminary step, a preparation for glazing based on liquid resin is made.

[0109] The glaze is applied to the entire rigid aquatic float, which is sanded and degreased.

[0110] According to one variant, resin is applied with a brush to the rigid aquatic float.

[0111] The block housing a decompression valve, and the block with hooks will be glued during the glazing of bridge 22a.

[0112] Before the rigid aquatic float is finished, a final glazing sanding step is carried out.

[0113] Naturally, the invention is described above by way of example. It is understood that a person skilled in the art is able to carry out different embodiments of the invention without departing from the scope of the invention.

[0114] Fig. 2 shows a view of the hull 22b of the rigid aquatic float cut into three parts.

[0115] According to one embodiment, the hull 22b and the deck 22a are 3D printed in three parts each.

[0116] The hull 22b corresponds to the underside of the rigid aquatic float, and the deck 22a corresponds to the top of the rigid aquatic float.

[0117] Fig. 3 shows an overview of the bridge 22a and the hull 22b with the assembly made with the reinforcing element 21.

[0118] The assembly shows the reinforcement element 21 assembled with the internal skeleton 20 and with the retaining blocks 23.

[0119] Fig. 4 shows the location of the three retaining blocks on the rigid aquatic float.

[0120] The three blocks are manufactured by 3D printing. When the three blocks are placed, the internal skeleton 20 and the reinforcing element co-hold the blocks.

[0121] This figure further shows a rope attachment block 25.

[0122] According to one embodiment, the support block 23 of the rigid aquatic float has a length between 30 cm and 40 cm.

[0123] Fig. 5 shows a cross-sectional view of the rigid aquatic float.

[0124] This cross-sectional view is positioned relative to the hull 22b of the aquatic float rigid and shows the assembly of the internal skeleton 20 with the reinforcing element 21.

[0125] Fig. 6 shows the junctions of the different printed parts of the rigid aquatic float.

[0126] The three parts of the bridge and the three parts of the hull each have a male or female socket. The male and female sockets represent the mortise and tenon joint.

[0127] The joints are made using two fixing methods: a mortise and tenon joint and a butterfly joint.

[0128] The male grips represent the tenon and the female grips represent the mortise.

[0129] During assembly, the two fixings are made to compose the inter 20 skeleton.

[0130] Fig. 7 shows another view of the junctions of the different printed parts of the rigid aquatic float.

[0131] This other view shows the attachment in the shape of a “butterfly”.

[0132] This attachment is made between the three parts of the bridge and the three parts of the hull to form the internal skeleton 20.

[0133] According to one variant, the butterfly-shaped fastener is secured with a mortise and tenon joint. This fastener has at least one male socket and at least one female socket.

[0134] The male socket is made from a part of the deck or a part of the hull, and it will be fixed with the female socket made on a part of the deck or a part of the hull forming the fixing with the shape of a "butterfly".

[0135] Fig. 8 shows an exploded view of the machined parts of the reinforcing element 21 of the rigid aquatic float.

[0136] The reinforcement elements 21 have a curved shape with material removals on the thickness and on the width.

[0137] According to another example, not shown, the shape is straight.

[0138] These material removals make it possible to reduce the weight of the rigid aquatic float.

[0139] The parts of the reinforcing element 21 represent the slats. These slats have a thickness of between 3 mm and 10 mm.

[0140] Fig. 9 shows the internal skeleton 20 of the rigid aquatic float.

[0141] It shows, after the slats are assembled together, the shape of the float is visible rigid aquatic environment.

[0142] Fig. 10 shows the addition of 24 fins on the rigid aquatic float.

[0143] After the rigid aquatic float lamination step, fins 24 are installed and inserted into the retaining blocks 23 of the fin boxes 24.

[0144] Fig. 11 shows the coating of a composite alloy on the rigid aquatic float.

[0145] In this figure, the overlap is made on the bridge 22a, above the internal skeleton and the reinforcing element 21.

[0146] The composite alloy comprises a fiber and an epoxy resin.

[0147] According to one embodiment, the fiber is: glass, basalt, flax, hemp.

[0148] The coating has a thickness of between 0.7 mm and 3 mm.

[0149] It is emphasized that all features, as they are apparent to a person skilled in the art from the present description, drawings and attached features, even if in practice they have only been described in relation to other specific features, both individually and in any combinations, may be combined with other features or groups of features disclosed herein, provided that this has not been expressly excluded or that technical circumstances render such combinations impossible or meaningless. List of reference signs

[0150] [Tables 1] References Designations 20 Internal skeleton 21 Reinforcing element 22a deck 22b hull 23 Support block 24 keel 25 Rope attachment block

Claims

Demands

1. A method for manufacturing a rigid aquatic float comprising a main length extending between a first end and a second end, a thickness, a width, a deck (22a), and a hull (22b); characterized in that said method comprises the following successive steps: - a) modeling a rigid aquatic float or parts of said rigid aquatic float from said main length, said thickness, and said width; - b) producing a reinforcing element (21) from the modeling in step a); - c) producing an internal skeleton (20) by 3D printing comprising a plurality of raw material filaments; said 3D printing being configured to produce at least one part of the rigid aquatic float obtained in step a); each part of the rigid aquatic float comprises a male part or a female part;- d) assemble said reinforcement element (21) from step b) with said internal skeleton (20) from step c) forming the rigid aquatic float by assembling the male part with the female part.;

2. A method according to claim 1, wherein said method further comprises a preliminary waste collection step; said waste being sorted, recycled and configured to be transformed into raw material forming raw material filaments used in step b).

3. A method according to claim 1, wherein the method comprises a step of bonding at least one composite plate composed of fiber and resin around said internal skeleton (20) of step c); said composite plate being configured to form a hull of the rigid aquatic float.

4. A method according to claim 1, wherein the method comprises a step of laminating the rigid aquatic float by adding successive layers of fiber and resin onto said hull.

5. A method according to claim 4, wherein the method comprises a step of sanding a surface of the composite plate obtained after the step of laminating the rigid aquatic float.

6. A method according to claim 1, wherein the reinforcing element (21) is made of wood, said wood being at least one of the following species: balsa, linden, pine, poplar, paulownia and cedar.

7. A method according to claim 1, wherein following the assembly in step d), the method comprises a step of adding a radio frequency identification tag or near field communication tags to the assembly.

8. A method according to claim 1, wherein the method comprises a step of assembling at least one block on the rigid aquatic float, said retaining block (23) being at least one of the following: a retaining block (23) for a fin box, a rope attachment block, a block comprising a decompression valve, and at least one block configured to attach fins (24) on the rigid aquatic float.

9. A method according to claim 1, wherein the raw material filaments of step c), have a thickness of between 1 mm and 6 mm, and a width of between 1 and 10 mm.

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