Fin Plug Assembly with High-Density Foam Cavity
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Solution Overview
Problem
Existing fin plug systems for surfboards are cumbersome to install, prone to deformation under load, and can compromise the structural integrity of the surfboard due to their size and material, leading to alignment issues and performance reduction.
Innovation Solution
A fin plug assembly featuring a high-density foam body with a continuous side wall and a fin plug with a flat upper portion and base portion, where the fin plug is firmly affixed to the foam body, providing enhanced support and allowing for a single-step installation process with improved alignment and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large fin plug with elongated cavity is used to secure the fin, then the fin can be firmly attached to the surfcraft, but the installation process becomes complex requiring two-step cavity routing and the surfcraft structure is compromised
Solution Approach 1:
The fin plug is divided into two separate components: a cavity-forming element that creates the reception space, and a separate fin plug element that secures the fin base. This segmentation allows the cavity to be formed as a simple rounded space without complex routing, while the fin plug element provides the securing function. The installation becomes a single-step process of inserting the assembled fin plug into the pre-formed cavity.
Solution Approach 2:
The cavity is pre-formed in the surfcraft body as a simple rounded space before the fin plug is installed. This preliminary action eliminates the need for complex two-step routing during installation. The fin plug element is then inserted into this pre-prepared cavity, simplifying the overall installation process to a single step.
2Strength
If a large fin plug is used to ensure fin security, then the fin attachment is strong, but the surfcraft maker must compromise fin plug positioning and creates weak points in the surfboard structure
Solution Approach 1:
By separating the cavity formation from the fin plug structure, the cavity can be formed as a simple rounded space that does not require precise positioning. The fin plug element itself is small and compact, allowing it to be accurately positioned without compromising the surfcraft structure. This segmentation eliminates the need to compromise positioning accuracy while maintaining strong fin attachment.
Solution Approach 2:
The complex elongated cavity structure is extracted and replaced with a simple rounded cavity. The fin securing function is extracted into a separate fin plug element that fits into this simple cavity. This extraction allows the fin plug to be small and precisely positionable while maintaining strong attachment capability.
3Ease of manufacture
If a large fin plug cavity is routed into the surfcraft blank, then the fin plug can be installed, but the shapers dot is removed causing alignment doubts
Solution Approach 1:
The cavity is designed as a simple rounded space that does not require deep or extensive routing into the surfcraft blank. This segmented approach separates the cavity formation from the fin plug structure, allowing the cavity to be formed without removing critical alignment markers like the shapers dot. The fin plug element then fits into this shallow cavity, maintaining alignment accuracy while ease of installation.
4Ease of manufacture
If surrounding foam is used to support the fin plug, then the fin plug can be installed, but the foam deforms under load causing fin plug sinking and misalignment
Solution Approach 1:
The fin plug element is made from a rigid material such as plastic or composite that provides structural support and resistance to deformation under load. This rigid fin plug element is inserted into the cavity formed in the foam surfcraft body. The composite construction combines the ease of foam installation with the dimensional stability and load-bearing capacity of rigid materials, preventing foam deformation and fin plug sinking.
Data Source
AI summary
A fin plug assembly, for a surfcraft, including:a fin plug including a flat upper portion having an external perimeter and top and bottom surfaces, at least one fin cavity for receiving a base element of a surfcraft fin extending inwardly from at least one opening in the top surface, a base portion extending from said bottom surface and surrounding said at least one fin cavity; anda high density foam body having an upper surface with a fin plug cavity in said upper surface and a continuous side wall;wherein the base portion of the fin plug is located within said fin plug cavity and said fin plug is firmly affixed to said high density foam body.