Composite Hydrofoil Components with Flexible Edge Coating

Solution Overview

Problem

Existing hydrofoil assemblies for surfboards and water skis are heavy due to their rigid, single-material construction, and have sharp edges that can be uncomfortable and increase drag.

Innovation Solution

The hydrofoil assemblies are constructed using a combination of materials, where a stiff and rigid framework made from a first material provides structural strength, and voids within this framework are filled and covered with a softer, more flexible second material, reducing weight and rigidity while minimizing sharp edges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If hydrofoil assemblies are constructed from single-material rigid structures, then strength and rigidity are maintained, but weight increases and edges become sharp

Engineering Contradiction:

Improveweight of hydrofoil assemblyVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining a rigid foam core structure with a flexible rubber or thermoplastic polyurethane outer layer. This composite construction allows the hydrofoil assembly to achieve reduced weight while maintaining structural strength through the rigid core and providing flexible, non-sharp edges through the compliant outer material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by having different materials serve different functions within the same component. The rigid foam core provides structural strength and rigidity where needed, while the flexible rubber or thermoplastic polyurethane coating provides edge softness and comfort where it contacts the rider, allowing each region to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If hydrofoil assemblies use single-material rigid construction, then structural strength is maintained, but edges become sharp causing discomfort and increased drag

Engineering Contradiction:

Improvesharp edges causing discomfort and dragVSAvoidstructural strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent implements local quality by having different materials serve different functions within the same component. The rigid foam core provides structural strength and rigidity where needed, while the flexible rubber or thermoplastic polyurethane coating provides edge softness and comfort where it contacts the rider, allowing each region to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies flexible shells by covering the rigid foam core with a flexible rubber or thermoplastic polyurethane material. This flexible outer layer rounds the edges and creates a smooth, compliant surface that reduces sharp edges and improves rider comfort while maintaining the structural integrity of the underlying rigid core.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If hydrofoil assemblies are constructed as flat rigid plates, then structural rigidity is achieved, but weight increases

Engineering Contradiction:

Improvestructural rigidityVSAvoidweight of hydrofoil assembly

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a rigid foam core structure with a flexible rubber or thermoplastic polyurethane outer layer. This composite construction allows the hydrofoil assembly to achieve reduced weight while maintaining structural strength through the rigid core and providing flexible, non-sharp edges through the compliant outer material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies curvature by replacing the traditional flat rigid plate structure with a contoured, curved hydrofoil blade design. The curved cross-section and streamlined shape reduce drag and improve hydrodynamic performance while the foam core structure provides structural rigidity at reduced weight compared to solid flat plates.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS12263912B2Composite hydrofoil components and systems

Publication Date: 2025.04.01 BI THERMAL ASPEN EARTH LLC

AI summary

This disclosure extends to systems, apparatus, and methods for hydrofoil assemblies with components that may be constructed from multiple materials to achieve reduced weight and/or portion with relatively less rigidity. In one exemplary system, a planing blade has as underlying framework or first structural body including rib elements that define voids. The first structural body may be formed from a relatively stiff and rigid first material to provide strength and rigidity to the component. The voids are filled and at least a portion of the framework covered by a second relatively softer and more flexible material. The second material may cover one or more edges of the planning blade. In some embodiments, a mast member may have a structural member formed from a relatively stiff and rigid first material with at least a portion of the member covered by a second relatively softer and more flexible material.