Board with board bumper

Abstract

The present invention relates to a method of manufacturing a board for sport equipment and the board for sport equipment thereof. The method comprises the steps of molding a substrate on a first mold; transferring the substrate to a second mold; and injecting a thermoplastic material into a cavity provided between at least a part of an edge side of the substrate and the second mold to form the board with a board bumper on the at least a part of the edge side of the substrate.

Claims

1. A method of manufacturing a board for sport equipment, the method comprising the steps of: forming a substrate on a first mold; transferring the substrate to a second mold; and injecting a material into a cavity provided between at least a part of an edge side of the substrate and the second mold to form the board with a board bumper on the at least a part of the edge side of the substrate.

2. The method of claim 1, further comprising the step of: encompassing, when forming the board with the board bumper, a protrusion formed at the edge side surface of the substrate by the bumper.

3. The method of claim 1, wherein the material comprises a thermoplastic or a thermosetting material.

4. The method of claim 1, wherein forming the substrate on the first mold comprises: placing a shaped core sandwiched between a first layer and a second layer of fiber cloth in the first mold; introducing a resin into the first mold; and bonding the resin to the first and second layers of fiber cloth by curing to form the substrate.

5. The method of claim 4, further comprising the steps of: forming the protrusion by coming together the first layer and second layer at the edge side surface of the substrate and bonding using the resin.

6. The method of claim 4, wherein the shaped core comprises a foam of at least one of polyurethane, polystyrene, polyethylene, and polyethylene terephthalate.

7. The method of claim 4, wherein the fiber cloth comprises at least one of fiberglass, carbon fiber, aramid fiber and natural plant fiber.

8. The method of claim 4, wherein the resin comprises epoxy or polyester.

9. The method of claim 4, wherein molding the substrate on the first mold comprises one of a resin transfer molding (RTM) process, vacuum assisted RTM (VARTM) process, and light RTM process.

10. The method claim 1, wherein the second mold has a profile defining the cavity.

11. The method of claim 1, wherein the method further comprises the step of: selecting at least one portion of the second mold defining a part of the profile of the second mold based on intended behavior properties of the board.

12. A board for sport equipment comprising: a substrate having a first surface, a second surface opposite to the first surface and a side surface connecting the first surface and the second surface; and a board bumper molded on at least a part of the side surface of the substrate.

13. The board of claim 12, wherein the substrate comprises: a shaped core placed in between a first layer and a second layer of fiber cloth and bounded to the layers by a resin.

14. The board of claim 13, wherein the first layer and second layer come together at the edge side surface of the substrate to form a protrusion encompassed by the bumper at the edge of the substrate.

15. The board of claim 16, wherein the board bumper has a shape selectable based on intended behavior properties of the board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The invention will be described further with respect to embodiments shown in the drawings.

[0019] FIG. 1 shows a top view of a board for sport equipment,

[0020] FIG. 2 shows a side view of the board for sport equipment,

[0021] FIG. 3A-3D show a side view of a board with different shapes of bumper, and

[0022] FIG. 4 shows a diagram of a method of manufacturing a board for sport equipment.

DESCRIPTION

[0023] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the figures. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Coordinate axes in the x, y and z direction are shown in each figure to assist in the explanation of the relative arrangement of features of the board.

[0024] In the context of the present application, board for sport equipment means any board suitable for any sport that is played with a board as main equipment, for example skateboards, surfboards, stand-up paddleboards, wind surfboards, kneeboards, kiteboards, and the like.

[0025] FIG. 1 shows a top view of a board 10 for sport equipment, FIG. 2 shows a side view of the board 10 for sport equipment, and FIG. 3A to 3D show a side view of a board for sport equipment having different shapes of bumpers.

[0026] The board 10 comprises a substrate 20 having a first surface 22, a second surface 24 opposite to the first surface 22 and a side surface 26 connecting the first surface 22 and the second surface 24. For example, the first surface can be a top surface and the second surface can be a bottom or rear surface. Boards are usually defined by its parts including a nosethe front tip of the board, a tailthe back part of the boardand a railpart of the side surface of the board. When boards are in use, the nose and tail tend to break due cracks, delamination, buckling, and the like. For example, surfboards tend to crack due to impacting rocks and/or surfers or surfboards. As another example, skateboards tend to delaminate after the nose, tail and/or sides heavily impact curbs or other obstacles. Moreover, skateboards tend to experience a wear which may eventually create a sharp tail or edge on the tail area (also known as razor tail) due to scraping of the tail on a hard surface. This razor tail can leave nasty cuts and cause injuries.

[0027] The substrate 20 comprises a shaped core 40 placed in between a first layer 42 and a second layer 44 of fiber cloth and bounded to the layers by a resin. When the resin is cured, both layers of fiber cloth impregnated with the resin become hard, and form a fiber-reinforced plastic around the shaped core, which allows the shaped core to be water resistant while increasing the strength of the shaped core. As shown in FIG. 3A to 3D, the fiber cloth layers extends further corresponding end of the upper surface and lower surface, respectively. That is, the fiber cloth layers are not wrapped. Then, when resin impregnates the fiber cloth layers, the first layer and second layer come together at the edge side surface of the substrate to form a protrusion (or extension), which later on is encompassed by the bumper.

[0028] In the context of the present application, shaped core refers to a core which has been previously manufactured into the shape of the board. For example, the shaped core can be manufactured by means of molding where foamable material in provided into a mold cavity having a shape corresponding to that of the board, or by means of manual shaping where a shaper cuts and sands raw material into the shaped core, or by means of any combination of them. The shaped core is manufactured into a shape according to any particular desired style to provide a top side (deck) and an under side (bottom) of the board. Alternatively, the shaped core can be previously manufactured into the shape of the board by means of computing numerical control.

[0029] Optionally, the shaped core 40 comprises a foam. Cores made of foam provide lightweight boards due to the low density of foam. The foam can be made of at least one of polyurethane (PU), polyethylene (PE), polystyrene (PS), and polyethylene terephthalate (PET).

[0030] Polyurethane (PU) is a thermoset material, meaning that it can withstand very high temperatures. This means that a polyurethane shaped core will no longer melt when heat is applied. Furthermore, polyurethane (PU) is easy to shape due to its very fine and stiff composition.

[0031] Polyethylene (PE) is a thermoplastic material, meaning that it t has a low melting point. This means that a polyethylene shaped core can be recycled, melted down and reformed into another shape. Thus, polyethylene is environmentally friendly as waste leftover from the cores can be recycled. Furthermore, polyethylene cores are resistant to water, moisture, and chemicals, and extremely durable due to its High impact resistance.

[0032] Polystyrene (PS) is also a thermoplastic material. Furthermore, polystyrene is easier to shape than polyethylene. However, polyethylene (PE) is more lightweight and stronger than polystyrene (PS), thus polyethylene can endure high impact while being less heavy and dense than polystyrene. Polystyrene and polyethylene cores are not as durable as polyurethane cores but usually have a higher density. Examples of polystyrene includes extruded polystyrene (XPS) and expanded polystyrene (EPS).

[0033] Shaped cores comprising foam of at least one of polyurethane (PU), polyethylene (PE) and polystyrene (PS) may not provide the strength to resist breakage required for the corresponding sport. Hence, shaped banks can be strengthen by covering its top side and under side with a fiber cloth with provide high break resistance when a resin impregnating the fiber cloths is cured.

[0034] Optionally, the fiber cloth comprises at least one of fiberglass, carbon fiber, aramid fiber and natural plant fiber. As the names imply, fiberglass is made of small strands of glass that have been melted down, while carbon fiber is made of small strands of carbon atoms. Each of the fiber cloths can then be combined with a resin to create a stiff product (e.g., a fiber-reinforced plastic) that can fit any mold. Further, fiber-reinforced plastics last a long time, are weatherproof and can be colored, shiny or dull. Fiberglass is light, less stiff and less brittle than carbon fiber. In addition to being higher in tensile strength, carbon fiber is also higher in price compared to fiberglass.

[0035] Optionally, the resin comprises epoxy or polyester. Epoxy has low shrinkage during cure and good adhesion to all types of fiber cloths.

[0036] The board 10 also comprises a board bumper 30 molded on at least a part of the side surface 26 of the substrate 20. For example, the board bumper 30 can be molded on the nose of the substrate 20 to protect the nose, and/or on the tail of the substrate 20 to protect the tail, and/or on the rail of the substrate 20 to protect the rail. Optionally, the board bumper 30 has a shape selectable based on intended behavior properties of the board. The intended behavior properties may refer to any characteristic required by the board with board bumper in an specific situation. Some examples of the shape of the board bumper in relation with the intended behavior properties of the board are given in FIG. 3B-3D. It is also to be understood that the shapes used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Furthermore, any combination of shapes as the ones described in relation to 3A-3D are also included in the invention.

[0037] In the example of FIG. 3B, the board bumper has curved up/down shape. A curved up shape bumper molded on the nose of a surfboard allows the surfboard to be faster when there is a cross wind as it lets the water pass underneath. In the example of FIG. 3C, the board bumper has a shape which includes a bulge extending perpendicular to a top/bottom surface of the board. A bulge-shape bumper molded on the rail of a skateboard, and which bulge extends perpendicular to the bottom surface of the skate board, allows the skateboard, and the bottom surface of the skateboard, to be protected against scratches when scraping against road, stairs, etc., protecting as well any aesthetical impression, logo and/or drawing on said bottom surface. In the example of FIG. 3D, the board bumper has a shape which adapts to the contour of the side surface the substrate. This kind of bumpers allows the board to have a uniform outside contour (defined by the outside of the bumper) while core having a larger first surface than second surface.

[0038] FIG. 4 shows a flowchart illustrating a method 100 of manufacturing a board for sport equipment. The board can be the board 40 of any of FIG. 1, FIG. 2 and FIG. 3A to 3D.

[0039] In an initial step 101, the method comprises molding a substrate 20 on a first mold. The first mold may have a first mold cavity having a shape corresponding to that of the substrate 20. For example, the first mold may include a top portion and a bottom portion that when engaged define the first mold cavity, and when a moldable material is provided into the first mold cavity, the moldable material is molded into the substrate.

[0040] Optionally, the molding of the substrate on the first mold can comprise one of a resin transfer molding (RTM) process, vacuum assisted RTM (VARTM) process, and light RTM process. Resin transfer molding (RTM) is a closed molding method in which a pre-formed material (which can be sandwiched between fiber-reinforced layers) is placed between a two-part mold. Once, the two parts of the mold are set to close, resin is pumped under pressure through injection channels into the mold, where it cures under heat and pressure. Vacuum assisted RTM (VARTM) is a variation of RTM in which a top portion of the mold has been replaced with a vacuum bag which assist in resin flow through the mold. The VARTM process involves the use of a vacuum to facilitate resin flow into the fiber layup contained within the mold covered by the vacuum bag. After the impregnation occurs, the composite is allowed to cure at room temperature. Light RTM is also a variation of RTM in which the closed mold consists of an A side mold (base mold) and a semi-rigid B side mold (counter mold) that is sealed to the A side mold using vacuum pressure. Resin is drawn into the resulting cavity under vacuum. After the impregnation occurs, the composite is allowed to cure before demolding. The semi-rigid B mold retains a small amount of flexibility, enabling the B mold to fit perfectly with the A mold.

[0041] Optionally, the step 101 can comprise various steps, as step 102, 103 and 104 defined hereinafter. In step 102, the method comprises placing a shaped core 40 between a first layer 42 and a second layer 44 of fiber cloth in the first mold. For example, in case the first mold may include a top portion and a bottom portion that when engaged define the first mold cavity, the first layer 42 is placed on a surface of the bottom portion defining part of the first mold cavity, the shaped core 40 is then placed over the first layer 42 and, finally the second layer 44 is placed on a surface of the shaped core 40 opposite to the first layer 42. Afterwards, the top portion of the mold is engaged to the bottom portion by, for example, clamps.

[0042] In step 103, the method comprises injecting a resin into the first mold to form the substrate 40 40, and in step 104, the method comprises bonding the resin to the first layer 42 and the second layer 44 of fiber cloth by curing. Optionally, the bonding may comprise heat pressing the resin to the shaped core 40.

[0043] Although, the shaped core 40 has been manufactured by inject molding as described in steps 102, 103 and 104, it should be understood that the shaped back 40 of the invention can be manufactured by any other technique such as compression molding, casting, and the like.

[0044] As shown in FIG. 1, in step 105, the method comprises transferring the substrate 20 to a second mold. The transferring can be performed by a worker manually taken the substrate from the first mold and placing it on the second mold, or by a worker using a machine which transfers the substrate from the first mold to the second mold, or by an automatic machine. transferring the substrate from the first mold to the second mold.

[0045] The second mold has a profile defining the cavity. This cavity defines the shape of the board bumper. Thus, a substrate 20 can be manufactured with different board bumpers depending on the profile of the second mold. For example, a board which may be highly damaged on the nose due to intended use can be manufactured using a second mold where the cavity corresponding to the nose board bumper is big.

[0046] Optionally, in step 106, the method comprises selecting at least one portion of the second mold defining a part of the profile of the second mold based on intended behavior properties of the board. The intended behavior properties of the board may comprise properties of the board that make the board short or long, wide or narrow, different shape of nose, tail and rails board bumpers according to the intended use of the board. For example, a skateboard with a board bumper intended to be used by a kid or unexperienced skater may require of extra rail board bumpers to protect the rail of the board and/or aesthetical impressions on the bottom surface (e.g. the second surface 24) of the substrate compared to an experienced skater.

[0047] In step 107, the method comprises injecting a material into a cavity provided between at least a part of an edge side of the substrate and the second mold to form the board with a board bumper on the at least a part of the edge side of the substrate.

[0048] Optionally, the material can be a thermoplastic or a thermosetting plastic. For example, the thermoplastic material can be thermoplastic polyurethane (TPU), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), and polytetrafluoroethylene (PTFE). comprises polyurethane, polyethylene, polypropylene, and the like. For example, the thermosetting material can be epoxy, polyester, and thermoset urethane.

[0049] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.