A manufacturing method contemplates performing vacuum-assisted resin infusion to enclose an elongated core within a cured composite laminate without employing a mold. Not relying upon an external mold enables the process to be efficiently performed for core shapes that are manufactured in low volumes. Typical resin infusion processes utilize flow media that induces bag bridging during vacuum draw in order to provide gaps facilitating resin flow. However, popular flow media also tends to impart directional aggregate forces during vacuum draw, which forces can deform the core since no mold is being used. To avoid unequal and non-dispersed directional forces from deforming the elongated core, a flow media is employed that is configured to disperse and/or reduce such forces. Some such flow media may be knitted so as to allow overlapping strands to slide over one another. Other flow media may ensure that strands are interleaved so that no one strand or group of strands is disposed outwardly of other strands along a substantial length of the strands, thus dispersing bag bridging forces in several directions and avoiding directional aggregate forces. However, such flow media may have inhibited resin flow relative to popular high-flow flow media, and thus new strategies have been developed to ensure appropriate wetting of fibrous reinforcement. An adjustable brace can also be employed to restrain the elongated core from deflecting during application of vacuum and/or resin infusion.

This disclosure extends to systems, apparatus, and methods for sports board hydrofoil masts and mast-to-fuselage connection assemblies for hydrofoil sports boards. In one exemplary system, a hydrofoil mast formed as an elongated member may include a securing structure disposed in a lower region and a fuselage may include a recess into which the mast is inserted. A securing assembly may be disposed in the fuselage for actuation to secure the mast to the fuselage by interacting with the securing structure on the mast. The securing assembly may include a cam member or locking member and an actuating member. Unique hydrofoil masts constructed from composite materials having reinforcing metal members are disclosed and may be useful in the connection assemblies.

This disclosure extends to systems, apparatus, and methods for sports board hydrofoil masts and mast-to-fuselage connection assemblies for hydrofoil sports boards. In one exemplary system, a hydrofoil mast formed as an elongated member may include a securing structure disposed in a lower region and a fuselage may include a recess into which the mast is inserted. A securing assembly may be disposed in the fuselage for actuation to secure the mast to the fuselage by interacting with the securing structure on the mast. The securing assembly may include a cam member or locking member and an actuating member. Unique hydrofoil masts constructed from composite materials having reinforcing metal members are disclosed and may be useful in the connection assemblies.

Hydrofoil assemblies that can be attached to a board used for watersports are disclosed herein. A hydrofoil assembly may include, for example, a mast a coupleable to a fuselage at a lower portion of the mast and coupleable to a board at an upper portion of the mast, and front and rear wings coupleable to the fuselage. A hydrofoil mast may include, for example, first and second composite sections bonded together to form a hollow load-bearing mast structure. Leading and trailing elements made of a material that is softer than the composite mast structure may be adhered to the mast structure to complete a hydrodynamic profile of the mast.

A fin for a surfboard, having a main body which comprises a first edge which is in contact with the board when the fin is secured to the board, a leading edge at the front and a trailing edge at the rear, a rear curve connecting the leading edge and the trailing edge, the trailing edge comprising a forwardmost front tip. The main body is extended rearwards by an arm which extends from a straight line which is perpendicular to the first edge and passes through the front tip of the trailing edge, as far as the rear curve, the arm having a length greater than approximately 8 cm.

A passively controlled fluid foil has a span; and a rigid spar extending in the spanwise direction, a cellular material and a flexible outer surface defining a profile of the outer surface of the foil and encapsulating the cellular material and the spar.

A method of forming a fin configured for use with a water sports board. The method includes providing a mold having a mold cavity and first and second insert pre-preg sheets each including structural strands respectively bonded by first and second resin materials. The method further includes placing the insert pre-preg sheets within the mold cavity. The method further includes injecting a third resin material under pressure into the mold cavity between the first insert pre-preg sheet and the second insert pre-preg sheet to urge the first insert pre-preg sheet and the second insert pre-preg sheet away from each other and towards respective ones of the pair of mold cavity faces, and dispose the third resin material between the first insert pre-preg sheet and the second insert pre-preg sheet to space at least a portion of the first insert pre-preg sheet from the second insert pre-preg sheet.

A method of forming a fin configured for use with a water sports board. The method includes providing a mold having a mold cavity and first and second insert pre-preg sheets each including structural strands respectively bonded by first and second resin materials. The method further includes placing the insert pre-preg sheets within the mold cavity. The method further includes injecting a third resin material under pressure into the mold cavity between the first insert pre-preg sheet and the second insert pre-preg sheet to urge the first insert pre-preg sheet and the second insert pre-preg sheet away from each other and towards respective ones of the pair of mold cavity faces, and dispose the third resin material between the first insert pre-preg sheet and the second insert pre-preg sheet to space at least a portion of the first insert pre-preg sheet from the second insert pre-preg sheet.

A watercraft manoeuvring device for mounting on a watercraft is disclosed comprising an elongate member having a mounting end and an opposed fin end that is spaced from the mounting end. The device includes a mounting formation on the mounting end for mounting on the watercraft and a fin mounted on the fin end. The fin has a bearing surface for interacting with water and the elongate member is capable of flexing when the fin is subjected to hydrodynamic water forces when travelling through water. The device may be integrally formed from a polymeric material. A watercraft such as a surfboard having the watercraft manoeuvring device is also disclosed.

This disclosure extends to systems, apparatus, and methods for sports board hydrofoil masts and mast-to-fuselage connection assemblies for hydrofoil sports boards. In one exemplary system, a hydrofoil mast formed as an elongated member may include a securing structure disposed in a lower region and a fuselage may include a recess into which the mast is inserted. A securing assembly may be disposed in the fuselage for actuation to secure the mast to the fuselage by interacting with the securing structure on the mast. The securing assembly may include a cam member or locking member and an actuating member. Unique hydrofoil masts constructed from composite materials having reinforcing metal members are disclosed and may be useful in the connection assemblies