Tether end components for surfing devices

Abstract

Abstract The present invention relates in a first aspect to a surfing tether end component comprising an end component body having one or more end component body layers, a tether connector for connecting the surfing tether end component to a tether of a surfing device, and fastening means. Also provided are second and third aspects comprising methods of manufacturing the surfing tether end component.

Description

[Technical field]

[0001] This application claims priority from No. AU2021900288, filed in Australia on February 8, 2021, and No. AU2021107003, filed in Australia on November 17, 2021, the entire contents of both of which are incorporated herein by reference.

[0002] The present invention relates generally to the field of surfing equipment, and more particularly to the field of tether end components for surfing equipment. [Background technology]

[0003] Surfing, and therefore surfing equipment, has seen an increase in consumer demand and usage. Surfing equipment is manufactured in many ways, comes in multiple shapes and sizes commonly known as surfboards, boogie boards, body boards, soft surfboards, foam surfboards, softies, foam eyes, etc., and can be ridden in many ways, including lying down, kneeling, standing, etc. There have also been many advancements in performance enhancing features of surfing equipment, such as strengtheners, fins, plugs, tethers, etc.

[0004] Surfing tether devices for attachment to surfing equipment were originally made from rope or cord, but in recent years advances have been made in surfboard tether design and materials to create surfboard tethers that are lightweight, durable, and comfortable. Prior Art Referring to FIG. 1, most current prior art for surfing equipment tether end component P-10 is comprised of three main components: an end component body P-12, one or more fastening means P-14, and a prior art connector P-16 that receives a surfing equipment tether P-18. The elements of the end component P-10 are secured together by seams P-20, which are depicted in enlarged view in inset FIG. 1A. Prior art end components P-10 were typically constructed from multiple materials, such as hook and loop fasteners, typically made from nylon, webbing, typically made from polyester, and neoprene. The manufacturing method of the prior art end component P-10 involved assembling multiple layers along a vertical axis and joining all layers by sewing the multiple layers together on a flat surface with the aid of a sewing machine.

[0005] The use of different materials and sewing the various components together means that the resulting cuff P-10 is not flexible. Additionally, the seams can induce localized weaknesses in the cuff, making it more likely to break or otherwise fail.

[0006] Additionally, although several variations for surfing tether devices exist and are well documented in the prior art, all prior art has negative aspects, such as aesthetic limitations as a result of available materials, vulnerability to failure as a result of materials and manufacturing methods, or lack of performance as a result of manufacturing limitations. Summary of the Invention [Problem to be solved by the invention]

[0007] There is therefore a need to provide an improved surfing tether end component and / or to reduce or at least ameliorate the deficiencies of the prior art. [Means for solving the problem]

[0008] In a first aspect, the present invention relates to a surfing tether end component comprising an end component body having one or more end component body layers, a tether connector for connecting the surfing tether end component to a tether of a surfing device, and fastening means.

[0009] In one embodiment, one or more of the tether connector and fastening means are molded from, onto or into one of the one or more end piece body layers.

[0010] In one embodiment, at least one adjacent pair of the end component body, one or more layers of the end component body, the tether connector, and the fastening means are secured to one another by being at least partially bonded.

[0011] In one embodiment, at least a portion of at least one of the one or more end component body layers, at its contact portion, is comprised of at least one polymer selected from a single polymer class, and at least one of the fastening means and the tether connector is comprised of a contact surface comprised of at least one polymer selected from a single polymer class, the contact surface contacting and bonding to the contact portion.

[0012] In one embodiment, the contact surface is thermally bonded to the contact portion. In one embodiment, the contact surface is welded to the contact portion. In one embodiment, the thermal bond is a molecular or intermolecular bond.

[0013] In one embodiment, the contact surface and the contact portion are fused together. In one embodiment, the contact surface and the contact portion are heat welded together by an internal heat welding process or an external heat welding process. In one embodiment, both internal and external heat welding processes are used to thermally join the contact surface and the contact portion.

[0014] In one embodiment, the thermal bond is formed at least in part through an internal heat welding process, which is either an electromagnetic welding process or a mechanical welding process, hi one embodiment, both electromagnetic and mechanical welding processes are used.

[0015] In one embodiment, the thermal bond is formed at least in part through an external heat welding process, and the external heat welding process is a thermal welding process.

[0016] In one embodiment, the single polymer class is one of a set of classes consisting of thermoplastics, thermoplastic elastomers, thermosets, polypropylenes, polyketones, polyethylenes, polyurethanes, vinyls, polyolefins, or suitable derivatives thereof. In one embodiment, the contact portion is formed substantially from a single polymer. In one embodiment, the contact surface is formed substantially from the same single polymer as the contact portion.

[0017] In one embodiment, the end component body is made up of two or more end component body layers, with the contact being provided by the outermost end component body layer.

[0018] In one embodiment, the end component body is comprised of two or more end component body layers, at least one end component body layer being disposed on an end component body layer providing a contact portion so as to surround at least a portion of at least one of a fastening means and a tether connector having a contact surface joined to the contact portion within the end component body.

[0019] In one embodiment, the end component body is comprised of two or more end component body layers, each end component body layer extending over at least a portion of the length of the end component body, and at least two adjacent end component body layers formed of at least one polymer selected from a single polymer class and at least partially attached to one another by thermal bonding.

[0020] In one embodiment, the surfing tether end component further comprises a secondary element bonded to, molded from, or bonded into one or more end component body layers.

[0021] In one embodiment, the surfing tether end component is configured to attach a tether to a user's limb, the tether end component body is configured to encircle the user's limb, and the fastening means comprises a first fastening structure and a second fastening structure arranged to releasably engage one another when the user's limb is encircled by the tether end component body.

[0022] In one embodiment, at least one of the at least two adjacent end component body layers constitutes a cushioning layer. In one embodiment, at least one of the at least two adjacent end component body layers is an expanded polymer layer. In one embodiment, at least one of the at least two adjacent end component body layers is configured to retain a curved shape memory determined by the curve of the surfer's limbs. In one embodiment, the expanded polymer layer is at least one of the at least two adjacent end component body layers configured to retain a curved shape memory.

[0023] In one embodiment, the surfing tether end component is configured to attach the tether to a surfing device and the fastening means is configured to engage a tether receiver on the surfing device.

[0024] In one embodiment, the surfing tether end component does not include adhesives, additional cross-linked polymers, or other additional fastening means between adjacent two of the one or more end component body layers, the tether connector, and the fastening means that are secured to one another by being bonded to one another.

[0025] A second aspect of the invention is a method of manufacturing a surfing tether end component comprising an end component body having one or more end component body layers, a fastening means, and a tether connector, the method comprising: 1) forming one or more end component body layers; 2) arranging one or more end component body layers in a desired configuration to form an end component body; 3) if the end component body is comprised of a plurality of end component body layers, laminating the plurality of end component body layers together to form the end component body; 4) placing a tether connector adjacent to the end piece body layer; 5) placing a fastening means; 6) attaching the tether connector and fastening means to the end piece body; Equipped with At least one adjacent pair of one or more layers of end component bodies, end component bodies, tether connectors and fastening means are secured to one another at least in part by bonding.

[0026] In one embodiment, the end component body is comprised of a plurality of end component body layers, and either or both of steps (IV) and (V) are performed before step (III), and if step (IV) is performed before step (III), step (III) comprises attaching tether connectors to adjacent end component body layers and attaching the plurality of end component body layers together to form the end component body, and / or if step (V) is performed before step (III), step (III) comprises attaching fastening means to each adjacent end component body layer or layers and attaching the plurality of end component body layers together to form the end component body, and step (VI) comprises attaching any of the tether connectors and fastening means not already attached to the end component body.

[0027] In embodiments in which both step (IV) and step (V) are carried out before step (III), steps (III) and (VI) are carried out substantially simultaneously.

[0028] In one embodiment, at least a portion of at least one of the one or more end component body layers, at its contact portion, is comprised of at least one polymer selected from a single polymer class, and at least one of the fastening means and the tether connector is comprised of a contact surface comprised of at least one polymer selected from a single polymer class, the contact surface contacting and bonding to the contact portion.

[0029] In one embodiment, the end component body is made up of two or more end component body layers, with the contact portion being provided by the outermost end component body layer.

[0030] In one embodiment, the end component body is comprised of two or more end component body layers, at least one end component body layer being disposed on an end component body layer providing a contact portion so as to surround at least a portion of at least one of the fastening means and the tether connector within the end component body having a contact surface joined to the contact portion.

[0031] In one embodiment, the at least partial attachment by bonding is at least partial attachment by thermal bonding. In one embodiment, the contact surfaces are welded to the contact portions. In one embodiment, the thermal bonding is a molecular or intermolecular bond. In one embodiment, the contact surfaces and the contact portions are fused together. In one embodiment, the contact surfaces and the contact portions are thermally bonded by an internal or external thermal welding process. In one embodiment, both internal and external thermal welding processes are used to thermally join the contact surfaces and the contact portions.

[0032] In one embodiment, the thermal bond is formed at least in part through an internal thermal welding process, which is either an electromagnetic welding process or a mechanical welding process, hi one embodiment, both electromagnetic and mechanical welding processes are used.

[0033] In one embodiment, the thermal bond is formed at least in part through an external heat welding process, and the external heat welding process is a thermal welding process.

[0034] In embodiments in which the tether end component body is configured to encircle a user's limb, the fastening means comprises a first fastening structure and a second fastening structure arranged to releasably engage one another when the user's limb is encircled by the tether end component body.

[0035] In embodiments where the end component body is comprised of two or more end component body layers, at least one of the end component body layers comprises a foam layer that is at least partially bonded to an adjacent end component body layer by thermal bonding.

[0036] In one embodiment, the foam layer is configured to retain a curved shape memory, and the method further comprises the step of thermally shaping the foam layer to thermally set the curved shape memory therein, the step of thermally shaping the foam layer being carried out prior to step (II).

[0037] In one embodiment, the fastening means is configured to engage a tether receiver of a surfing device.

[0038] In one embodiment, the surfing tether end component does not include adhesive, additional cross-linked polymer, or other additional fastening means between adjacent two of the one or more end component body layers, the tether connector, and the fastening means that are secured to one another by being bonded to one another.

[0039] A third aspect of the invention is a method of manufacturing a surfing tether end component comprising an end component body having one or more end component body layers, a fastening means and a tether connector, where at least one of the fastening means and the tether connector are moulded from, onto or into the end component body, the method comprising: 1) inserting a polymer of a single polymer class into a mold having a cavity of a desired shape comprising at least one end component body layer and one or more of a tether connector and a fastening means; 2) forming the polymer into a molded article having a desired shape; 3) removing the molded body from the mold; Equipped with The molded body comprises at least one end structure body layer and one or more tether connectors and / or fastening means having an integral structure.

[0040] In one embodiment, the method further comprises: 4) inserting the molded body into a molding tool with additional polymer of a single polymer class, the molding tool having a cavity with an additional desired cavity shape, the molding body further comprising one or more tether connectors and fastening means excluding any already formed as part of the molded body; 5) molding or overmolding the polymer onto or into the body to form a further body having a further desired shape; 6) removing the further molded article from the secondary mold; Equipped with.

[0041] In one embodiment the moulded body or further moulded body is used as an end component body layer in the method of embodiment of the second aspect of the invention.

[0042] Additional embodiments may be disclosed herein or may become apparent to those of skill in the art through the disclosure. These and other embodiments are within the scope of the invention as defined in the claims.

[0043] Next, an embodiment of the present invention will be described with reference to the drawings. [Brief description of the drawings]

[0044] [Figure 1] FIG. 1 shows a prior art surfing tether end component. [Figure 1A] FIG. 1A shows a prior art surfing tether end component. [Diagram 2]FIG. 2 shows two embodiments of the surfing tether end components of the present invention. [Diagram 3] FIG. 3 shows a cross section of an embodiment of the invention having multiple body layers. [Figure 4] FIG. 4 shows the layout of the stack and structure. [Diagram 5] FIG. 5 shows the layout of the stack and structure. [Figure 6] FIG. 6 shows the layout of the stack and structure. [Figure 7] FIG. 7 shows an embodiment of the method according to the second aspect of the invention. [Figure 8] FIG. 8 shows an embodiment of the method according to the second aspect of the present invention. [Figure 9] FIG. 9 shows an embodiment of the method according to the third aspect of the present invention. [Figure 10] FIG. 10 shows an embodiment of the method according to the third aspect of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] definition As used herein, the term "bond" refers to two or more elements that are firmly attached to one another by chemical, thermal, or pressure driven mechanisms, and excludes purely physical mechanisms such as rivets or stitches.

[0046] As used herein, "consisting essentially of" should not be interpreted strictly to exclude the presence of trace amounts of other materials that do not increase the complexity of the recycling of the element or article in question. Rather, "consisting essentially of" should be understood to mean that the element or article in question is not composed of materials other than the specified material or materials, or that other materials are present in negligible amounts. Similarly, "negligible" should be interpreted to mean that other materials in the composition of the element or article in question are present in proportions that are too small to substantially alter either the element or article in question or its ability to be recycled at the end of its life.

[0047] In a first embodiment, and referring to FIG. 2, the present invention relates to a surfing tether end component comprising an end component body 102, a tether connector 104 for connecting the surfing tether end component 100 to a tether 106 of a surfing device, and fastening means 108 for securing the surfing tether end component to either a user's limb or to the surfing device.

[0048] In one embodiment, the tether end component 100 can be a tether end component 100A that attaches the tether 106 to a surfer's limb (not shown), thereby linking the surfer to the surfing equipment. Such an embodiment of the tether end component 100A is typically referred to as a "cuff" or "tether cuff." In such an embodiment, the fastening means 108 can consist of a first fastening structure 108A and a second fastening structure 108B that are arranged to releasably engage with each other to tighten the surfing tether end component 100 about the user's limb when the limb is encircled by the tether end component body 102. In one embodiment, the first and second fastening structures 108A, 108B can consist of a press stud pair, a button and buttonhole, a hook and loop fastener, or any other suitable fastening means known in the art.

[0049] In an alternative embodiment, the tether end component 100 may be a tether end component 100B that attaches the tether 106 to a surfing device (not shown). Such an embodiment of a tether end component 100B is often referred to as a "rail saver." In such an embodiment, the fastening means 108 may consist of a loop, clip, or carabiner style fastener that extends from the end component body 102 and attaches to an anchor (not shown) on the surfing device.

[0050] As used herein, reference numeral 100 is used to refer to both forms of tether end components 100A, 100B. Although the two tether end components 100A, 100B have different appearances, their functional characteristics are substantially similar to each other. Unless otherwise specified, both tether end components 100A, 100B can embody any embodiment of the present invention.

[0051] In one embodiment, the surfing tether end component can further include a secondary element 110, such as a pull tab, a buckle loop, or a decorative element. Although Figure 2 depicts an exemplary secondary element 110 as a decorative element, one skilled in the art will understand that this is merely exemplary and should not be construed as being explicitly limiting.

[0052] In one embodiment, the end component body 102 may be constructed from one or more end component body layers. In a further embodiment, the end component body 102 may be constructed from a single end component body layer. In an alternative embodiment, with reference to FIG. 3, the end component body may be constructed from multiple end component body layers 112A, 112B, 112C. Each of the end component body layers 112A, 112B, 112C may extend over the entire length and / or width of the end component body. Alternatively, one or more of the multiple end component body layers 112A, 112B, 112C may extend over only a portion of the length and / or width of the end component body. Those skilled in the art will appreciate that references to end component body layers 112A, 112B, 112C in describing embodiments of the present invention are exemplary only and do not exclude from their scope end component bodies consisting of a single end component body layer, two end component body layers, or three or more end component body layers, unless expressly specified (and therefore expressly limited) for a particular embodiment.

[0053] 4, in some embodiments, a single "sheet" may be folded to form the two layers. Specifically, with reference to FIG. 5, body layers 112B and 112C are formed by a single "sheet" that is folded along the vertical dashed line.

[0054] Connected End Components In one embodiment, any adjacent two of the end component body 102, one or more layers of the end component bodies 112A, 112B, 112C, the tether connector 104, the fastening means 108, and the secondary element 110 (if present) may be at least partially secured to one another by being bonded thereto.

[0055] In one embodiment, two adjacent elements that are at least partially secured to one another by being bonded to one another may be completely secured by bonding and do not consist of additional fastening means known in the art, such as rivets, stitching, adhesives, etc.

[0056] In embodiments where the end component body 102 is comprised of multiple end component body layers 112A, 112B, 112C, each end component body layer may extend over at least a portion of the length of the end component body. In further embodiments, at least two adjacent end component body layers 112A, 112B, 112C may be at least partially attached to one another by thermal bonding. In further embodiments, at least one of at least two adjacent end component body layers 112A, 112B, 112C may include a cushioning layer.

[0057] 4 and 5, in one embodiment, at least a portion of one of the one or more end component body layers 112A, 112B, 112C may be the contact portion 114. In such an embodiment, at least one of the fastening means 108, the tether connector 104 and the secondary element 110 (if present) comprises a contact surface 116 adapted to contact and couple to or with the contact portion 114. In an embodiment, the contact surface may be located on a surface of the tether connector 104. In an embodiment, the contact surface may be located on a surface of the secondary element 110 (if present).

[0058] Referring specifically to FIG. 5, in embodiments in which a tether connector end component 100A attaches a tether 106 to a surfer's limb, the contact surface 116 can be present on either or both of the first and second fastening structures 108A, 108B of the fastening means 108.

[0059] In further embodiments, the end component body 102 may comprise multiple contact portions 114, either in the same end component body layer or separately. In such embodiments, one or more of the fastening means 108 (or the first and second fastening structures 108A, 108B, as appropriate), the tether connector 104, and the secondary element 110 (if present) may comprise contact surfaces and be affixed to the end component body by bonding.

[0060] In an embodiment where the end component body is made of multiple end component body layers, the contact portion 114 may be provided by the outermost end component body layer. In an alternative embodiment, at least one end component body layer 112B is disposed on the end component body layer 112A providing the contact portion 114 so as to surround at least a portion of at least one of the fastening means 108, the secondary element 110 (if present), and the tether connector 104 having a contact surface 16 joined to the contact portion 114 within the end component body 102. FIG. 4 particularly illustrates both an exemplary embodiment where the contact portion 114 is present on the outermost layer (end component body layer 112B in the illustrated example) and an embodiment where the end component body layer 112B is laminated over the bonded contact surface 116 and the additional contact portion 114 present on the end component body layer 112A. This lamination may provide a more secure structure of the surf tether end piece 100. Those skilled in the art will appreciate that the designation of the end component body layers with reference numerals 112A and 112B is for illustrative purposes only and illustrates that the contact portion 114 may be provided on the various end component body layers 112A, 112B, 112C.

[0061] As depicted in the drawings, some components such as the tether connector 104 and / or the fastening means 108 may include contact surfaces 116 on multiple sides. With reference to Figures 4 to 6, in a further embodiment, a further end component body layer 112B laminated over the mating contact portion 114 and contact surface 116 may have a further contact portion 114B that couples to a further contact surface 116B of any fastening means 108, secondary element 110 (if present), and tether connector 104 that constitutes the contact surface 116.

[0062] structural materials In one embodiment, at least the contacting portions 114 of the end component body layers 112A, 112B, 112C can be comprised of at least one polymer selected from a single polymer class. In such an embodiment, at least one of the fastening means 108, the secondary element 110 (if present) and the tether connector 104 are comprised of a contact surface 116 that is comprised of at least one polymer selected from the same single polymer class as that of the contacting portions 114.

[0063] With reference to FIG. 2, in embodiments in which the end component body is comprised of multiple end component body layers 112A, 112B, 112C, at least two adjacent end component body layers 112A, 112B may each be formed of at least one polymer selected from a single polymer class.

[0064] Those skilled in the art will understand that there are many known polymers, which can be classified in various ways depending on the classification criteria. For example, polymers can be classified based on source material (natural, synthetic or semi-synthetic), monomer chain structure (linear, cross-linked or branched), polymerization method (addition or condensation), monomer type (homomeric or copolymeric), and molecular force (elastomeric, fibrous, thermoplastic or thermosetting polymer). As used herein, polymer class refers to a group of polymers that can be recycled in the same or substantially similar recycling process.

[0065] In one embodiment, the polymers may be selected from groups such as thermoplastics, thermoplastic elastomers, thermosetting polymers, and recyclable thermosetting polymers. In one embodiment, the polymers may be selected from specific groups such as polyketones, polyesters, polyurethanes, polyolefins, vinyls, or suitable derivatives thereof. In one embodiment, one or more of the selected polymers may be copolymers. In further embodiments, the copolymers may be linear copolymers (including alternating, statistical, and block copolymers) or branched copolymers (including graft or star-branched copolymers, or branched copolymers with other architectures). In another embodiment, each of the selected polymers may be a homomer.

[0066] In one embodiment, the polyurethane may be a thermal polyurethane. In an embodiment, the vinyl may be vinyl acetate, vinyl chloride, polypropylene, polystyrene, polyethylene, or polyacrylonitrile. In one embodiment, the polymer may be a copolymer of ethylene and vinyl acetate, typically referred to as polyethylene-vinyl acetate (EVA), or a terpolymer formed by polymerizing styrene and acrylonitrile in the presence of polybutadiene, typically referred to as acrylonitrile-butadiene-styrene (ABS).

[0067] By providing fastening means (e.g., contact portion 14 and contact surface 16) comprised of at least substantially similar materials (such as polymers selected from the same polymer family), it is believed that manufacturing efficiencies may be improved. Furthermore, because bonding between elements comprised of substantially similar materials may be promoted, the use of additional fastening means may be reduced or eliminated. Furthermore, because when an embodiment of surfing tether end component 100 reaches the end of its useful life, separation of elements into multiple recycling streams directed to separate plastic classes, types, or categories is not required, and a single polymer class is selected from the polymer classes that may be recycled, the ability and / or efficiency with which surfing tether end component 100 may be recycled may be improved.

[0068] In at least one further embodiment, one or more of the tether connector 104, secondary element 110 (if present), and fastening means 108 may be at least partially formed from a polymer selected from the same polymer class as the end component body layers 112A, 112B, 112C to promote thermal, molecular, or interfacial bonding therebetween.

[0069] In further embodiments, the end component body layer 112 and / or one or more of the tether connector 104, secondary element 110 (if present), and fastening means 108 may each be essentially composed of at least one polymer selected from a single class of polymers. This may be the same at least one polymer, or each may be formed from a different polymer selected from a single class of polymers. This may further enhance or promote the ability of the contact portion 114 and contact surface 116 to thermally bond to one another, and may also promote the recyclability of the surfing tether end component 100 at end of life. In further embodiments, the surfing tether end component 100 as a whole may be essentially composed of at least one polymer selected from a single polymer class.

[0070] In further embodiments, the contact portion 14 is formed substantially from a single polymer selected from a single class of polymers. In further embodiments, the contact surface 16 is formed substantially from the same single polymer as the contact portion 14. In further embodiments, the end component body layer 112 and / or one or more of the tether connector 104, secondary element 110 (if present), fastening means 108, or the entire tether end component 100 may be substantially composed of a single polymer selected from a single class of polymers. This may be the same single polymer or each may be formed from a different polymer selected from a single class of polymers.

[0071] Other materials that may be present include dyes or other colorants, trace amounts of polymers from different polymer classes, remnants of the formation of foamable polymer beads such as blowing agents, additives used to thermally bond, sinter, and / or promote expansion of the foamable polymer beads to form the end component body layer 112 composed thereof, and other trace contaminants or additives that one of ordinary skill in the art would reasonably expect to be likely to be present in an element or body formed from polymers selected from essentially a single polymer class without affecting the structure, functionality, or recyclability of the element or body. One of ordinary skill in the art will appreciate that the foregoing list is not exhaustive.

[0072] In embodiments where at least two adjacent end component body layers 112A, 112B, 112C are bonded together, at least one of them may be comprised of an expanded polymer layer. In further embodiments, the expanded polymer layer may form a cushioning layer.

[0073] In embodiments where at least two adjacent end component body layers 112A, 112B, 112C are bonded together, at least one of the at least two adjacent end component body layers may be configured to retain a curved shape memory determined by the curves of the surfer's limbs. In further embodiments, the end component body 102 may be constructed from a foamed polymer layer configured to retain a curved shape memory. Alternatively, the curved shape memory may be provided by another end component body layer 112A, 112B, 112C formed from a polymer capable of exhibiting shape memory properties.

[0074] Binding Mechanism In one embodiment, the contact surface 16 and the contact portion 14 are adapted to contact and bond to one another. In an embodiment, the bond may be a thermal bond therebetween.

[0075] In one embodiment, the thermal bond may be formed by at least partial melting of either or both of the contact portion 14 and the contact surface 16. In one embodiment, the thermal bond may consist of a fusion between the contact surface 16 and the contact portion 14, where either or both of the contact portion and the contact surface are at least partially melted and then resolidified. In one embodiment, the thermal bond may be the welding of the contact surface 16 and the contact portion 14 together through one or more polymer welding methods known in the art. In one embodiment, the thermal bond may consist of the formation of either molecular or intermolecular bonds between some or all of the polymer of the contact surface 16 and the polymer of the contact portion 14. In some embodiments, an adhesive may be used to facilitate or enable the formation of a bond between the contact surface 16 and the contact portion 14. In some alternative embodiments, the bond between the contact surface 16 and the contact portion 14 may be a direct interfacial bond, where the contact surface 16 and the contact portion 14 are in direct contact with each other (i.e., there is no additional material between the contact surface 16 and the contact portion 14) prior to or as part of the bonding process.

[0076] In one embodiment, the contact surfaces and contact portions are thermally bonded together through either an internal or an external thermal welding process, or both. In a further embodiment where the thermal bond is formed at least partially through an internal thermal welding process, the internal thermal welding process is either an electromagnetic welding process or a mechanical welding process. The electromagnetic welding process may be selected from resistance welding, induction welding, dielectric welding, and microwave welding. The mechanical welding process may be selected from spin welding, stir welding, vibration welding, and ultrasonic welding.

[0077] In further embodiments where the thermal bond is at least partially formed through an external thermal welding process, the external thermal welding process is a thermal welding process that may be selected from hot gas welding, thermal wedge welding, extrusion welding, hot plate welding, infrared welding, and laser welding.

[0078] In a further embodiment, the surfing tether end component 100 does not include adhesives, cross-linked polymers, rivets, stitches, or other fastening means known in the art between adjacent two of the one or more end component body layers 112A, 112B, 112C, tether connectors 104, and fastening means 108 that are secured to one another by being bonded together. This allows for a reduction in the number of different materials present in the surfing tether end component 100, which may improve the ability of the surfing tether end component to be recycled at the end of its life.

[0079] Molded End Components In one embodiment, at least one of the tether connector 104, secondary element 110 (if present), and fastening means 108 can be molded from, onto, or into the end component body 102. The tether connector 104, secondary element 110 (if present), and / or fastening means 108 may be molded from, onto, or into one of the end component body layers, and one or more additional end component body layers may be laminated above or below. Those skilled in the art will understand that when one or more of the tether connector 104, secondary element 110 (if present), and fastening means 108 are molded to, onto, or from a layer of the end component body 102, each may be molded to, from, or into the same end component body layer, or into different end component body layers, without departing from the scope of the invention.

[0080] In one embodiment, the surfing tether end component may include one or more elements (tether connector 104, fastening means 108, secondary element 110) molded from, onto or into one of the end component body layers and one or more additional elements affixed to one of the end component body layers by being bonded thereto. In further embodiments, the one or more additional elements may be bonded to the end component body layer in a manner described in one or more of the above embodiments.

[0081] Forming method - installation A second aspect of the invention is a method of making a surfing tether end component comprising an end component body having one or more end component body layers, a fastening means, and a tether connector. With reference to Figure 7, in one embodiment, the method comprises: 201) Forming one or more end component body layers; 202) arranging one or more end component body layers in a desired configuration to form an end component body; 203) If the end component body is comprised of two or more end component body layers, attaching a plurality of the end component body layers together to form the end component body; 204) positioning a tether connector adjacent to the layer of end piece body; 205) disposing a fastening means adjacent to the layer of the end piece body; 206) affixing the tether connector and fastening means to the end piece body; Equipped with.

[0082] In one embodiment, at least one adjacent pair of one or more end component body layers, end component bodies, tether connectors and fastening means are at least partially secured to one another by bonding thereto, which may be through any of the bonding mechanisms described above in relation to the first aspect of the invention.

[0083] In further embodiments where the end component body is comprised of two or more end component body layers, either or both of steps 204 and 205 may be performed prior to step 203. In such embodiments, the tether connectors and / or fastening means may be disposed adjacent to respective receiving end component body layers such that step 203 comprises affixing the tether connectors and / or fastening means to respective end component body layers while forming the end component body, and step 206 comprises affixing the remaining elements to the end component body.

[0084] 8, in a further embodiment in which both steps 204 and 205 are performed before step 203, steps 203 and 206 may be performed substantially simultaneously in that the formation of the end component body and the attachment of the tether connectors and fastening means to the respective end component body layers are performed in a single bonding step. 201) Forming one or more end component body layers; 202) arranging one or more end component body layers in a desired configuration to form an end component body; 204) positioning a tether connector adjacent to the layer of end piece body; 205) placing a fastening means; 203) and 206) forming an end piece body and simultaneously attaching tether connectors and fastening means to adjacent layers of each of the end piece bodies; Equipped with.

[0085] In one embodiment, at least a portion of at least one of the one or more end component body layers, the contact portion thereof, is comprised of at least one polymer selected from a single polymer class. In one embodiment, at least one of the fastening means and the tether connector comprises a contact surface comprised of at least one polymer selected from a single polymer class, the contact surface contacting and bonding to the contact portion. In a further embodiment, the contact surface and / or the contact portion may be the contact surface 16 or the contact portion 114 of an embodiment of the first aspect of the invention.

[0086] In embodiments where the end component body is comprised of two or more end component body layers, the contact portion may be provided by the outermost end component body layer.

[0087] In an alternative embodiment where the end component body is comprised of two or more end component body layers, at least one end component body layer may be disposed on top of an end component body layer providing a contact portion with a contact surface disposed therebetween so as to enclose within the end component body at least a portion of at least one of the tether connector and the fastening means having a contact surface bonded to the contact portion. In a further embodiment, a portion of the element thus encapsulated may be contacted by and bonded to both layers of the end component body layer. This lamination may provide a more secure structure of the surfing tether end component.

[0088] In one embodiment, the at least partial attachment by bonding may be at least partial attachment by thermal bonding, as described above in relation to the first aspect of the invention. The thermal bond may be a molecular or intermolecular bond, or may be a direct bond, a direct thermal bond or a direct molecular or intermolecular bond, also as described above. Similarly, the bond may be formed through any of the mechanisms including an internal and / or external thermal welding process (or a combination thereof) as described above in relation to one or more embodiments of the first aspect of the invention.

[0089] In embodiments where the end component body is comprised of two or more end component body layers, at least one of the end component body layers may comprise a foam layer at least partially bonded to an adjacent end component body layer by thermal bonding, which foam layer may provide cushioning between at least the surfing tether end component formed from the method of this embodiment and the limb of the surfer encircled thereby.

[0090] In further embodiments, the foam layer may be configured to retain a curved shape memory. In such embodiments, the method may further include the step of thermally shaping the foam layer to thermally set a curved shape memory therein, which step is performed prior to step 202.

[0091] In one embodiment, the surfing tether end component does not include adhesive, additional cross-linked polymer, or other additional fastening means between adjacent two of the one or more end component body layers, tether connectors, and fastening means that are secured to one another by being bonded together.

[0092] In one embodiment, the surfing tether end component may include a secondary element, such as a pull tab, buckle loop, or decorative element. In such an embodiment, the method may include disposing the secondary element adjacent to the end component body layer, and step 206 includes affixing the secondary element to the end component body. This step may be performed as part of step 204 or step 205, or may exist as its own step 204A and be performed at any time prior to the performance of step 206. In a further embodiment, step 204A may be performed before step 203, such that step 203 is modified similarly to the previously described embodiment in which steps 204 and / or 205 are performed before step 203.

[0093] Forming method-molding A third aspect of the invention is a method of making a surfing tether end component comprising an end component body having one or more end component body layers, a fastening means and a tether connector, where at least one of the fastening means and / or tether connector are moulded from, onto or within the end component body.

[0094] Referring to FIG. 9, in one embodiment, the method comprises: 301) Inserting a polymer of a single polymer class into a mold having a cavity of a desired shape comprising at least one end component body layer and one or more tether connectors and fastening means; 302) forming the polymer into a molded body having a desired shape; 303) Removing the molded body from the mold; Equipped with The molded body is comprised of at least one end component body layer and one or more tether connectors and fastening means having an integral construction.

[0095] 10, in a further embodiment, the method may include overmolding an element onto the molded body produced by step 303. In such an embodiment, the method may include: 304) inserting the molded body, together with an additional polymer of a single polymer class, into a molding die having a cavity with an additional desired shape including the molded body and one or more additional tether connectors and fastening means other than those already formed as part of the molded body; 305) molding or overmolding the polymer onto or into the molded body to form a further molded body having a further desired shape; 306) removing the further compact from the secondary mold; Equipped with.

[0096] In further embodiments, the surfing tether end component may include a secondary element such as a pull tab, buckle loop, or decorative element. In such embodiments, the method may include using a mold having a cavity with a desired shape, or a secondary mold having a cavity with a further desired shape that contains the secondary element, such mold or further mold being formed to contain the secondary element.

[0097] In one embodiment, the method can include thermally bonding a cushioning layer to a surface of the molded article. The cushioning layer can be configured to be positioned against a user's limb when the surfing tether end component is worn by a user. In a further embodiment, the cushioning layer can be comprised of an expanded polymer foam.

[0098] In one embodiment, the moulded body or further moulded body may be used in an embodiment of the method of the second aspect of the invention as an end component body layer comprising an element moulded in, on or from the end component body layer. In such an embodiment, the method of the second aspect of the invention may be suitably modified to remove the need to fasten the element to the end component body during the implementation of the embodiment of step 206 or the modified embodiment of step 203.

[0099] Although the present invention has been described above with reference to preferred embodiments, those skilled in the art will appreciate that the present invention is not limited to these embodiments and may be embodied in many other forms, modifications and variations other than those specifically described. The present invention includes all such variations and modifications. The present invention also includes all steps, features, elements and / or devices referred to or shown in this specification, individually or collectively, and includes any and all combinations of steps or features or any two or more of them.

[0100] In this specification, unless the context clearly indicates otherwise, the word "comprising" is not intended to have an exclusive meaning such as "consisting only of," but rather a non-exclusive meaning such as "including at least." The same applies to other forms of the word, such as "comprise," with corresponding grammatical changes.

[0101] Other definitions of selected terms used herein can be found in the detailed description of the invention and are applied throughout. Unless otherwise defined, all other scientific and technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0102] The promises made herein should be understood to relate to some embodiments of the invention and are not intended to be promises made about the invention in all embodiments. If there are promises that are deemed to apply to all embodiments of the invention, the applicant / patent owner reserves the right to subsequently delete them from the specification and will not rely on those promises for the acceptance or subsequent grant of a patent in any country.

Claims

1. an end component body having one or more end component body layers; a tether connector for connecting the surfing tether end component to the tether of the surfing device; Fastening means; Equipped with A surfing tether end component, wherein the end component body, the one or more layers of the end component body, the tether connectors, and at least one adjacent pair of the fastening means are at least partially secured to one another by welding.

2. at least a portion of at least one of the one or more end component body layers, a contact portion thereof, comprises at least one polymer selected from a single polymer class; at least one of the fastening means and the tether connector has a contact surface comprised of at least one polymer selected from a single polymer class; The surfing tether end component of claim 1 , wherein the contact surface contacts and is welded to a contact portion.

3. The surfing tether end component of claim 2 , wherein the weld is a molecular or intermolecular bond.

4. 4. The surfing tether end component of claim 2 or 3, wherein the contact surface and the contact portion are welded by an internal heat welding process or an external heat welding process, or both the internal heat welding process and the external heat welding process are used to thermally bond the contact surface and the contact portion together.

5. the weld is formed at least in part through an internal thermal welding process; The surfing tether end component of claim 4, wherein the internal heat welding process is either an electromagnetic welding process or a mechanical welding process, or both the electromagnetic welding process and the mechanical welding process are used.

6. the weld is formed at least in part through an external thermal welding process; The surfing tether end component of claim 4 or 5, wherein the external heat welding process is a thermal welding process.

7. 7. The surfing tether end component of any one of claims 2 to 6, wherein the single polymer class is one of a set of classes consisting of thermoplastics, thermoplastic elastomers, thermosets, polypropylenes, polyketones, polyethylenes, polyurethanes, vinyls, polyolefins, or suitable derivatives thereof.

8. The surfing tether end component of claim 7 , wherein the contact portion is formed substantially from a single polymer, or the contact surface is formed substantially from the same single polymer as the contact portion.

9. the end component body being comprised of two or more end component body layers; A surfing tether end component according to any one of claims 2 to 8, wherein the contact portion is provided by an outermost end component body layer.

10. the end component body is comprised of two or more end component body layers; 10. A surfing tether end component according to any one of claims 2 to 9, wherein at least one end component body layer is arranged on top of the end component body layer providing the contact portion so as to surround, within the end component body, at least a portion of at least one of the tether connector and the fastening means having the contact surface welded to the contact portion.

11. the end component body is comprised of two or more end component body layers, each end component body layer extending over at least a portion of the length of the end component body; 11. A surfing tether end component as claimed in any one of claims 1 to 10, wherein at least two adjacent end component body layers are formed of at least one polymer selected from a single polymer class and are at least partially secured to one another by welding.

12. 12. A surfing tether end component according to any one of claims 1 to 11, further comprising a secondary element welded onto or into one or more end component body layers.

13. configured to attach the tether to a limb of a user; The tether end component body is configured to encircle a limb of the user.

13. A surfing tether end component according to any one of claims 1 to 12, wherein the fastening means has a first fastening structure and a second fastening structure arranged to releasably engage with each other when the user's limb is encircled by the tether end component body.

14. 14. The surfing tether end component of claim 13, wherein at least one of the at least two adjacent end component body layers comprises a cushion layer or an expanded polymer layer, or at least one of the at least two adjacent end component body layers comprises the cushion layer and the expanded polymer layer.

15. 15. The surfing tether end component of claim 1, wherein the surfing tether end component does not include adhesives, additional cross-linked polymers, or other additional fastening means between adjacent two of the one or more end component body layers, the tether connectors, and the fastening means that are secured to each other by being welded to each other.

16. 1. A method of manufacturing a surfing tether end component comprising an end component body having one or more end component body layers, a fastening means, and a tether connector, comprising: I. Forming one or more end component body layers; II. Arranging the one or more end component body layers in a desired configuration to form the end component body; III. if the end component body is comprised of multiple end component body layers, attaching the multiple end component body layers together to form the end component body; IV. placing a tether connector adjacent to the end piece body layer; V. Placing a fastening means; VI. Attaching the tether connector and fastening means to the end component body; Equipped with The method, wherein at least one adjacent pair of the one or more end component body layers, the end component body, the tether connector, and the fastening means are secured to one another at least in part by welding.

17. at least a portion of at least one of the one or more end component body layers, a contact portion thereof, comprises at least one polymer selected from a single polymer class; at least one of the fastening means and the tether connector includes a contact surface comprised of at least one polymer selected from the single polymer class; The method of claim 16 , wherein the contact surface contacts and is welded to the contact portion.

18. 18. The method according to claim 16 or 17, wherein the contact surfaces and the contact portions are welded together by an internal heat welding process or an external heat welding process, or both the internal heat welding process and the external heat welding process are used to weld the contact surfaces and the contact portions together.

19. the weld is formed at least in part through an internal thermal welding process; 20. The method of claim 18, wherein the internal heat welding process is either an electromagnetic welding process or a mechanical welding process, or both the electromagnetic welding process and the mechanical welding process are used.

20. A surfing tether end component manufactured by the method of claim 16.

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