Inflatable paddle board

Abstract

A water sports board formed of flexible planar material is provided which may be inflated from a collapsed configuration to a rideable water sports board. All connections of components forming the board are fused thereby eliminating the use of adhesives. A rail is formed around a circumferential edge of the board to provide additional rigidity and a bumper.

Description

[0001] INFLATABLE PADDLE BOARD

[0002] BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] This application claims priority to U.S. Provisional Patent Application serial number 63 / 688275, filed on August 28, 2025,

[0005] The invention herein disclosed relates generally to sports boards used for water sports. More particularly, it relates to a water sports board, such as a paddle board, which is formed from flexible half sections, which are permanently engaged without adhesive using a fused circumferential seam and reinforcement system.

[0006] 2. Prior Art

[0007] BACKGROUND OF THE INVENTION

[0008] Paddle boarding is a water sport in which participants ride atop a board configured to support them on an upper surface while the board floats upon the water. The riders are propelled when lying down or kneeling by a swimming motion using their arms while lying or kneeling on an upper surface of the water sports board. Alternatively, more experienced riders may stand on the upper surface and employ a paddle to propel the board over the water surface.

[0009] Paddle boarding can be accomplished on various floating sports boards including surfboards and paddle boards which are configured larger than surfboards and offer more buoyancy. Such paddle boards and surfboards are conventionally constructed from fiberglass, epoxy, and / or carbon fiber.

[0010] A currently emerging paddle board technology uses a configuration which is inflatable. This mode of paddle board construction is especially useful since the rider may deflate the board for storage and transport, and then reinflate the paddle board at a venue where they wish to ride it.

[0011] Conventionally, such inflatable paddle boards are formed of an outer shell of waterproof polymeric material such as polyvinyl chloride (PVC). The outer shell is formed of a top layer, which is connected around a perimeter edge to the bottom layer in an airtight seal between the two layers. An interior cavity is formed and surrounded by the outer shell. To help provide extra rigidity when the board is inflated, within the interior cavity is positioned a drop stitch material.

[0012] On the top flexible surface of the formed board, conventionally, is positioned an EVA foam material, which is held in position on the top surface by a strong and waterproof adhesive. The EVA is so positioned to provide better traction, as well as an anti-slip surface, for riders positioned on the top surface during use of the paddle board.

[0013] The forgoing background concerning the conventional manner in which boards are configured as paddle boards or surfboards and the limitations related therewith, are intended to be illustrative and not exclusive, and they do not imply any limitations on the Inflatable paddle board invention described and claimed herein. Various other limitations of the related art of paddle boards are well known or will become apparent to those skilled in the art upon a reading and understanding of the specification below and the accompanying drawings.

[0014] SUMMARY OF THE INVENTION

[0015] The disclosed device herein provides for a water sports board which is inflatable, and a method for construction of such, which yields a significant improvement in the quality and longevity of inflatable water sports boards, such as surfboards and paddle boards.

[0016] Forming the inflatable water sports board device herein, is a flexible top layer of waterproof fabric, as well as a flexible bottom layer thereof. Currently, by flexible waterproof material or polymeric material herein, is meant material which will not pass air such as PVC material, or thermoplastic polyurethane, laminated polyester, or other flexible sheets of material, which may be fused by heat or sonic welding. An interior cavity is formed inbetween the flexible top surface and bottom surface. Within the interior cavity is positioned drop-stitch material in order to provide extra rigidity when the board is inflated and to provide a determined thickness of the board, which is determined by the dropstitch material.

[0017] The water sports board in all configurations herein is formed without the use of adhesives, which are conventionally employed in the construction of conventional inflatable water sports boards. Instead, the water sports board herein, provides a circumferential rail reinforcement configuration, which forms a rail around the circumference of the board. The components forming this rail both seal the internal cavity between the top and bottom surfaces, as well as reinforces the rail of the formed board around the circumference, such that it provides padding from impacts and additional rigidity at the circumferential edge of the board. As such all seals and sealed engagements of one component to another herein are fused. By fused is meant that a heat and pressure, or a sonic welding component, capable of substantially melting the materials forming the components along engagement lines, is used to cause the flexible material to meld or form to a unitary structure along a seam or sealed engagement. Such components can include sonic welders, heated components, heated pressure bars, or other conventional means to momentarily melt and fuse polymeric, plastic, and other such materials to each other.

[0018] Currently, the rail reinforcement layer system herein includes a triple layering of reinforcing material. Each of the three layers are independently fused in sequential layers to form the enhanced rail of the inflatable sports board. By fused engagement or connections herein is also meant that no adhesive is employed to connect one layer of material with another to form a waterproof and air tight covering of the circumferential seam running between the top surface and bottom surface of the formed inflatable water sports board. Currently, fused engagements or seals are accomplished using sonic welding and / or communication of heat and compression, to momentarily melt and fuse layers of flexible polymeric material to a unitary structure.

[0019] In the method herein, a flexible top layer and a flexible bottom layer are cut to the desired shape of the inflatable water sports board to be formed. In an internal cavity, which is located in between the top layer and bottom layer, is positioned a section formed of a drop stitch material.

[0020] In order to eliminate the need for adhesives in the formation of the inflatable water sports board, all layers are connected to adjacent layers using sonic welding, or other means, to heat adjacent layers to cause them to melt to a fused connection. This has been found in experimentation to yield much stronger seams, and connections, as well as a substantial increase in the ability of the formed water sports board to not leak air from the interior cavity once inflated.

[0021] The water sports board device herein also employs a triple positioning of flexible material, which is placed in a fused engagement around the rail of the formed water sports board. This triple positioning of three layers of flexible material has been found to provide a substantial increase in impact resistance of the formed circumferential rail. It also helps prevent leaks of air from the interior cavity when the water sports board is inflated.

[0022] With respect to the above description, before explaining at least one preferred embodiment of the inflatable paddle board device and manufacturing system herein, it is to be understood that the invention is not limited in its application to the details of operation, nor the arrangement of the components or the steps set forth in the following description or illustrations in the drawings. The various methods of implementation and operation of the inflatable paddle board device herein are capable of other embodiments and of being practiced and carried out in various ways, which will be obvious to those skilled in the art once they review this disclosure. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description, and should not be regarded as limiting.

[0023] Therefore, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other inflatable water sports boards, and for carrying out the several purposes of the disclosed inflatable paddle board herein. Therefore, the objects and claims herein should be regarded as including such equivalent construction, steps, and methodology insofar as they do not depart from the spirit and scope of the present invention. It is an object of this invention to provide a lightweight and easily transported inflatable paddle board, or other water sports board.

[0024] It is a further object of this invention to provide such an inflatable paddle board which is formed without adhesive.

[0025] It is an additional object of this invention to provide an inflatable water sports board, such as a paddle board, which is formed of two layers of flexible material and has a circumferential edge rail of the formed water sports board, which is triple overlain to prevent punctures and blowouts and to stiffen and add rigidity to the sidewall.

[0026] These together with other objects and advantages, which will become subsequently apparent reside in the details of the construction and operation of the inflatable sports board system herein as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like parts throughout.

[0027] Further objectives of this invention will be ascertained by those skilled in the art as brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.

[0028] BRIEF DESCRIPTION OF DRAWING FIGURE

[0029] FIG. 1 depicts an overhead view of a top surface of the inflatable water sports board, such as a paddle board, showing circumferential triple fused connections engaging the flexible material forming the top surface and a bottom surface.

[0030] FIG. 2 shows a side view of the water sports board of figure 1, showing the circumferential connections which runs along the side surface of the formed inflatable water sports board.

[0031] FIG. 2A depicts a sectional view across the board of figure 1, showing the drop stitch material positioned within the interior cavity.

[0032] FIG. 3 shows an enlarged sectional view through the side edge of the water sports board of figure 1 , showing a first layer of material being applied to be fused to the two layers of flexible material forming the top surface and forming the bottom surface.

[0033] FIG. 4 shows the seam, as in figure ,3 once the first layer has been fused to the top and bottom layers of flexible material forming the water board.

[0034] FIG. 5 depicts the positioning of a second layer of flexible material for fusing to the material forming the top surface of the water sports board and to the first layer already engaged over the seam running between the top and bottom of the board.

[0035] FIG. 6 shows the second layer of flexible material in a fused engagement to the top surface and the first layer, and depicts a third layer of flexible material being positioned for engagement to the first layer and the bottom layer of the sports board.

[0036] FIG. 7 depicts the circumferential seam engaging the flexible top surface of the water sports board to the flexible bottom surface wherein the third layer is in a fused engagement to the bottom layer of material and to the first layer running over the seam thereby forming a reinforced rail around the circumference of the board with the first layer providing a projecting padded edge.

[0037] FIG. 8 depicts the top layer of the water sports board being attached to the bottom layer in a temporary fashion to maintain their alignment during the engagement of flexible layers over the circumferential seam.

[0038] FIG. 9 depicts an example of engaging the first layer of flexible material over the seam and to the top surface and bottom surface of the water sports board as shown in figures 3-4.

[0039] FIG. 10 depicts the employment of a sonic welder or heating machine to fuse the second layer of flexible material to the first layer and to the top surface of the water sports board and to the first layer as in figures 5-6.

[0040] FIG. 11 shows the employment of a fusing machine to fuse the third layer of flexible material to the first layer and to the bottom surface of the water sports board, as well as to the first layer, as in figures 6-7.

[0041] FIG. 12 shows a low profile valve for the inflatable sports board herein showing the removable cap.

[0042] FIG. 13 depicts the valve of figure 12 fused into operative engagement with the flexible material forming the top surface or bottom surface of the water sports board herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0043] In this description, the directional prepositions of up, upwardly, down, downwardly, front, back, top, upper, bottom, lower, left, right, and other such terms refer to the water sports board device as it is oriented and appears in the drawings and are used for convenience only. Any such terms are not intended to be limiting or to imply that the device has to be used or positioned in any particular orientation.

[0044] Now referring to drawings 1-13, there is seen in figure 1 an overhead view of a top surface 12 or top layer of the inflatable water sports board device 10 herein, which is in a sealed engagement around a perimeter or circumferential edge of the formed board device 10 to a flexible bottom surface 13 or bottom layer.

[0045] Also shown is a circumferential rail 14 or edge, which is configured to absorb impacts during use of the device 10 herein when inflated. The circumferential rail is formed around the perimeter or circumferential edge at an intersection of the flexible material forming the top surface 12 and the flexible material forming the bottom surface 13.

[0046] The rail 14 herein, is formed in a first mode using a first layer 16 of flexible material, such as a reinforced polymeric laminate material, such as PVC or polyethylene. This first layer 16 of reinforcing is fused such by sonic welding or heat and compression being imparted to a linear portion of both the top surface 12 and the bottom surface 13 around substantially the entire circumference of the board. The formed rail 14 covers an open seam positioned between the edge of the top surface 12 and bottom surface 13. It thus also forms a first seal to prevent air from exiting an internal cavity between the top surface 12 and bottom surface 13 once the water sports board device 10 is inflated.

[0047] In experimentation, it was found unexpectedly that with a second layer 18 and third layer 20 fused to the device 10 and over opposing sides of the first layer, this second layer 18 projects slightly and is much stiffer when the water sports board is inflated. This is preferred as it provides a bumper around the circumference to prevent dings and cuts and also provides increased rigidity to the circumferential edge of the inflated device 10.

[0048] As noted, a second layer 18 of flexible polymeric reinforcing material is in a fused connection with the first layer 16 and the top surface 12 of the formed inflatable water sports board device 10. This second layer 18 provides a second seal running along the edge of the first layer 16 where it is in fused engagement to the top surface 12.

[0049] Also noted, a third layer 20 of flexible polymeric material is shown in figure 2 and the enlarged section thereof. This third layer 20 is in a fused connection with the first layer 16 and the bottom surface 13. It thus covers the edge of the first layer 16 where it is in a fused engagement to the bottom surface 13 and provides another sealed engagement to prevent air loss when the device 10 is inflated without the use of adhesive.

[0050] Shown in figure 2 is a side view of the water sports board device 10 of figure 1 as can be seen on this right side view showing the circumferential connections which runs along the rail 14 of the formed inflatable water sports board device 10. As can also be seen, the first layer 16 projects slightly past the second layer 18 and third layer 20 to increase rigidity and form a protective bumper.

[0051] Depicted in figure 2A is a portion of a sectional view across the board of figure 1 showing the internal cavity 17 which is filled with drop stitch material 19 which is operatively positioned within the interior cavity 17. This drop stitch material 19 is formed of a large number of drop yarns 23, which are engaged at opposing ends to a top wall 25 and a bottom wall 27. The length of the drop yarns 23 is varied depending on the thickness of the sports board device 10 herein. When the interior cavity 17 is inflated, the drop yarns 23 will hold the top wall 25 and bottom wall 27 in place at a fixed distance, which is substantially the length of the drop yarns 23.

[0052] The positioning and fused engagement of the first layer 16 is shown in figure 3 prior to the fused connection, shown in figure 4 of the first layer 16 to the top surface 12 and bottom surface 13.

[0053] Another step in the formation of the water sports board device 10 herein is shown in figure 5. As shown, once the first layer 16 has been fused to the top 12 and bottom 13 layers of flexible polymeric material, the second layer 18 of material is fused by sonic welding, heat and compression, or other means for heating the flexible materials to a fused connection to the first layer 16 and to the upper surface 12 as shown in figure 6. This forms a secondary seal, as noted, over the intersection of the first layer 16 with the top surface 12.

[0054] Also shown in figure 6 is the third layer 20 of flexible material being positioned for fused engagement to the first layer 12 and the bottom layer 13 of the sports board device 10.

[0055] A final depiction of the connections of the three layers to the side of the formed water sports board device 10 is shown in figure 7 and an enlarged area thereof. As shown, the rail 14 running around the circumferential edge of the formed water sports board device 10 includes three layers of reinforced polymeric material where each is fused on opposing sides to underlying layers. As shown, the third layer 20 is in fused engagement to the bottom layer 13 of material and to the first layer 16 running over the seam. Also shown is the second layer 18 in fused connections on both side edges to the top surface 12 and to the first layer 16. This configuration forms an especially tough rail 14, which is stiffer than conventional sides or rails and resists impacts and better maintains a seal for the interior cavity 17 positioned between the top surface 12 and bottom surface 13.

[0056] A step in the formation method herein is shown in figure 8 which depicts the spot welding of the top surface 12 to the underlying bottom surface 13. Another step in the method of assembly is shown in figure 9, wherein the first layer 16 is fused using heat or a sonic welder or similar fabric fusing means, to both the top surface 12 and bottom surface of the formed water sports board device 10.

[0057] Shown in figures 10-11 are the next steps in the formation of the device 10 herein. As shown in figure 10, the second layer of flexible polymeric material is fused to the top surface 12 and the first layer 16. In a final view of figure 11, the step of fusing the third layer 20 of polymeric material to both the first layer 16 and bottom surface 13 is depicted.

[0058] FIG. 12 shows a low profile valve 30 for the inflatable sports board herein showing the removable cap. The valve is preferably operatively engaged with either the top surface 12 or bottom surface 13 of the inflatable water sports board. The valve 30 is also heat or sonically otherwise fused to the layer to which it is engaged to prevent leaking.

[0059] FIG. 13 depicts the valve of figure 12 fused into operative engagement with the flexible material forming the top surface 12 although as noted it can be fused into engagement with the bottom surface 13. Shown is the height H, which the valve 30 rises above the surface into which it engages to provide a route for air into and out of the interior cavity 17. Currently this height H is between 2-3 mm above the surface into which it engages. This very low height H above the top surface 12 or bottom surface 13 into which the valve 30 engages is preferred as a means to prevent rider injury should the rider fall onto the riding surface of the board.

[0060] While all of the fundamental characteristics and features of the inflatable water sports board with a triple reenforced circumferential seam have been shown and described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure, and it will be apparent that in some instances, some features of the invention may be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should also be understood that various substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations and substitutions are included within the scope of the invention as defined by the following claims.

Claims

What is claimed is:

1. An inflatable water sports board comprising: said sports board having a top surface formed of flexible material; said sports board having a bottom surface formed of said flexible material; said top surface in a sealed engagement to said bottom surface around a circumferential edge of said sports board; said sealed engagement including a first sealing layer having a first side thereof in a fused engagement with said top surface and having a second side thereof opposite said first side in a fused engagement thereof to said bottom surface; a cavity formed in between said top surface and said bottom surface; and a valve for communicating compressed air into said interior cavity to form said sports board to an inflated configuration.

2. The inflatable water sports board of claim 1 additionally comprising: drop stitch material positioned within said interior cavity.

3. The inflatable water sports board of claim 1 additionally comprising a rail formed around said circumferential edge, said rail including: a second sealing layer of flexible material in a first fused engagement thereof along a first side thereof to said top surface; said second sealing layer in a second fused engagement thereof along a second side thereof opposite said first side thereof, to said first sealing layer; a third sealing layer of flexible material in a first fused engagement thereof along a first side thereof with said bottom surface;said third sealing layer in a second fused engagement thereof along a second side thereof with said first sealing layer; and an exposed portion of said first sealing layer in between said second sealing layer and said third sealing layer, whereby said rail defines a bumper along said circumferential edge and imparts rigidity to said circumferential edge of said sports board in said inflated configuration.

4. The inflatable water sports board of claim 2 additionally comprising a rail formed around said circumferential edge, said rail including: a second sealing layer of flexible material in a first fused engagement thereof along a first side thereof to said top surface; said second sealing layer in a second fused engagement thereof along a second side thereof opposite said first side thereof, to said first sealing layer; a third sealing layer of flexible material in a first fused engagement thereof along a first side thereof with said bottom surface; said third sealing layer in a second fused engagement thereof along a second side thereof with said first sealing layer; and an exposed portion of said first sealing layer in between said second sealing layer and said third sealing layer, whereby said rail defines a bumper along said circumferential edge and imparts rigidity to said circumferential edge of said sports board in said inflated configuration.

5. The inflatable water sports board of claim 1 additionally comprising: said fused engagements being formed by a sonic weld or heat fused connection.

6. The inflatable water sports board of claim 2 additionally comprising: said fused engagements being formed by a sonic weld or heat fused connection.

7. A method of manufacture of said inflatable waters sports board of claim 1 comprising: forming said top surface in a shape of said water sports board; forming a bottom surface in said shape of said water sports board; forming a strip of said flexible material to said sealing layer; employing heat or a sonic welder to fuse said first side of said sealing layer to said top surface; employing heat or sonic welding to fuse said second side of said sealing layer to said bottom surface; and positioning said valve in a fused connection with one of said top surface or said bottom surface.

8. A method of manufacture of said inflatable waters sports board of claim 3 with a rail: forming said top surface in a shape of said water sports board; forming a bottom surface in said shape of said water sports board; forming a strip of said flexible material to said sealing layer; employing heat or sonic welding to fuse said first side of said sealing layer to said top surface; employing said heat or said sonic welding to fuse said second side of said sealing layer to said bottom surface; employing said heat or sonic welding to fuse said second sealing layer of flexible material to said first sealed engagement thereof along said first side thereof to said topsurface; employing said heat or sonic welding to fuse said second sealing layer to said second sealed engagement thereof along said second side thereof, to said first sealing layer; employing said heat or sonic welding to fuse said third sealing layer to said first sealed engagement thereof along said first side thereof to said bottom surface; employing said heat or sonic welding to fuse said third sealing layer to said second sealed engagement thereof along said second side thereof to said first sealing layer; and employing said heat or sonic welding to fuse said valve to said sealed connection with either of said top surface or said bottom surface.

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