Forged Mast Assembly for Hydrofoil Watersports Board System
20260103266 ยท 2026-04-16
Assignee
Inventors
Cpc classification
B63B1/242
PERFORMING OPERATIONS; TRANSPORTING
B63B32/66
PERFORMING OPERATIONS; TRANSPORTING
International classification
B63B32/66
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Systems and methods include a hydrofoil mast for a hydrofoil watersports board system including (I) a first end couplable to a watersports board; (II) a second end couplable to a watersports fuselage; (III) at least one length dimension extending between the first end and the second end; and (IV) at least one deformed mast portion including at least one elastically deformed exterior portion and at least one plastically deformed interior portion coupled with the at least one elastically deformed exterior portion. In addition, other aspects are described in the claims, drawings, and text forming a part of the present disclosure.
Claims
1. A hydrofoil mast for a hydrofoil watersports board system, the hydrofoil mast comprising: (I) a first end couplable to a watersports board; (II) a second end couplable to a watersports fuselage; (III) at least one length dimension extending between the first end and the second end; (IV) at least one leading edge; (V) at least one trailing edge; (VI) at least one width dimension extending between the at least one leading edge and the at least one trailing edge; and (VII) at least one deformed mast portion including at least one exterior portion and at least one plastically deformed interior portion, wherein the at least one exterior portion is coupled with the at least one plastically deformed interior portion.
2. The hydrofoil mast of claim 1, wherein the at least one exterior portion and the at least one plastically deformed interior portion of the at least one deformed mast portion are extruded together before the at least one plastically deformed interior portion is plastically deformed.
3. The hydrofoil mast of claim 1, wherein the at least one exterior portion of the at least one deformed mast portion is elastically deformed.
4. The hydrofoil mast of claim 1, wherein the first end is couplable to a watersports board via a watersports board mount, and wherein the second end is couplable to a watersports fuselage via a watersports fuselage mount.
5. The hydrofoil mast of claim 1, further including at least one undeformed mast portion including at least one undeformed exterior portion and at least one undeformed interior portion, and wherein the at least one undeformed exterior portion is coupled with the at least one undeformed interior portion.
6. The hydrofoil mast of claim 5, wherein the at least one undeformed exterior portion and the at least one undeformed interior portion of the at least one undeformed mast portion are extruded together.
7. The hydrofoil mast of claim 5, wherein the at least one undeformed mast portion includes a first stringer portion and a second stringer portion, the first stringer portion and the second stringer portion including a gap therebetween, wherein the at least one deformed mast portion includes a first stringer portion and a second stringer portion, the first stringer portion and the second stringer portion including a gap therebetween, and wherein the gap of the deformed mast portion is smaller than the gap of the undeformed mast portion.
8. The hydrofoil mast of claim 5, wherein the at least one undeformed mast portion includes at least one thickness, wherein the at least one deformed mast portion includes at least one thickness, and wherein the at least one thickness of the at least one undeformed mast portion is greater than the at least one thickness of the at least one deformed portion.
9. The hydrofoil mast of claim 5, further including at least one progressively deformed mast portion, wherein the at least one undeformed mast portion includes the first end of the hydrofoil mast, wherein the at least one progressively deformed mast portion is coupled to the at least one undeformed mast portion, and wherein the at least one deformed mast portion is coupled with the at least one progressively deformed mast portion.
10. The hydrofoil mast of claim 5, wherein the at least one plastically deformed interior portion includes at least one first spar portion, wherein the at least one undeformed interior portion includes at least one second spar portion, and wherein the at least one first spar portion extends a smaller amount than what the at least one second spar portion extends.
11. The hydrofoil mast of claim 1, wherein the at least one plastically deformed interior portion includes at least one spar portion.
12. The hydrofoil mast of claim 11, wherein the at least one spar portion includes at least one pivot portion.
13. The hydrofoil mast of claim 11, wherein the at least one spar portion includes at least one first portion extending in a first direction, wherein the at least one spar portion includes at least one second portion extending in a second direction, wherein the first direction has a first directional component, wherein the second direction has a second directional component, and wherein the first directional component of the first direction is opposite to the second directional component of the second direction.
14. The hydrofoil mast of claim 11, wherein the at least one spar portion includes at least one anchor portion.
15. A hydrofoil mast for a hydrofoil watersports board system, the hydrofoil mast comprising: (I) a first end couplable to a watersports board; (II) a second end couplable to a watersports fuselage; (III) at least one length dimension extending between the first end and the second end; (IV) at least one leading edge; (V) at least one trailing edge; (VI) at least one width dimension extending between the at least one leading edge and the at least one trailing edge; and (VII) at least one deformed mast portion including at least one elastically deformed exterior portion.
16. The hydrofoil mast of claim 15, wherein the at least one deformed mast portion includes at least one plastically deformed interior portion coupled with the at least one elastically deformed exterior portion.
17. The hydrofoil mast of claim 15, further including at least one undeformed mast portion including at least one undeformed interior portion coupled with at least one undeformed exterior portion, wherein the at least one undeformed mast portion includes at least one first thickness, wherein the at least one deformed mast portion includes at least one second thickness, and wherein the at least one first thickness is greater than the at least one second thickness.
18. A hydrofoil mast for a hydrofoil watersports board system, the hydrofoil mast comprising: (I) a first end couplable to a watersports board; (II) a second end couplable to a watersports fuselage; (III) at least one length dimension extending between the first end and the second end; (IV) at least one leading edge; (V) at least one trailing edge; (VI) at least one width dimension extending between the at least one leading edge and the at least one trailing edge; and (VII) at least one deformed mast portion including at least one elastically deformed exterior portion and at least one plastically deformed interior portion coupled with the at least one elastically deformed exterior portion.
19. The hydrofoil mast of claim 18, wherein the undeformed mast portion includes at least one first thickness, wherein the deformed mast portion includes at least one second thickness, and wherein the at least one first thickness is greater than the at least one second thickness.
20. The hydrofoil mast of claim 18, wherein the at least one undeformed mast portion is adjacent one of the first end or the second end of the hydrofoil mast, and wherein the at least one deformed mast portion is spaced from the first end and the second end of the hydrofoil mast.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0021] For a more complete understanding of implementations, reference now is made to the following descriptions taken in connection with the accompanying drawings. The use of the same symbols in different drawings typically indicates similar or identical items, unless context dictates otherwise.
[0022] With reference now to the figures, shown are one or more examples of a Forged Mast Assembly for Hydrofoil Watersports Board System [0023] , articles of manufacture, compositions of matter for same that may provide context, for instance, in introducing one or more implementations described herein.
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DETAILED DESCRIPTION
[0036] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
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[0038] In implementations, lower assembly 106 is shown to include front wing 106a, fuselage 106b, tail wing 106c. In implementations, front wing 106a is shown to include leading edge 106a1, and trailing edge 106a2. In implementations, fuselage 106b is shown to include upper portion 106b1. In implementations, tail wing 106c is shown to include leading edge 106c1, and trailing edge 106c2.
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[0041] The implementation depicted in
[0042] In implementations extrusion can be a most common process for producing modern aluminum hydrofoil masts since it is an economical and efficient way to achieve a strong, stiff part with constant cross section. In implementations aluminum alloys available are such as including, but not limited to 2000 series, 5000 series (such as 5083, 5086, 5454, 5456, 5754, etc.) series (such as 6061, 6063, 6000s, etc.), 7000 series (such as 7075, etc.) with various heat treatments such O, T4, T6, T7, untreated, etc. (such as 6061-T6, etc.). Other implementations involve other aluminum alloys so these examples are provided without limiting use of other aluminum alloys.
[0043] In implementations drawing is an alternative process to extruding. Instead of pushing material through a die with extrusion, drawing is a process of pulling material through a die. Some metals, such as stainless steel, yield better results (strength, tolerance, surface finish) when drawn through a die as compared to when they are extruded. In other implementations steel alloys (such as stainless steel) can be drawn or extruded; however, wall thicknesses would need to be smaller to keep mast weight reasonable. Steel is much stronger and stiffer than aluminum, so less material may be needed for a drawn steel profile vs. an extruded aluminum profile. However, thin walls can be prone to buckling when subject to compressive loads during forging (explained below). Consequently, implementations using drawn steel can look different from extruded aluminum implementations such as including different internal stiffening features to reinforce the thinner walls of steel hydrofoil mast implementations. In implementations austenitic stainless steel alloys such as 304 and 316 can provide good corrosion resistance and ductility (formability). In other implementations duplex stainless steel alloys can be used.
[0044] It is not possible to fabricate (such as by extrusion) a section with a changing cross-sectional shape, which is why a secondary forging process is used subsequent to fabrication as further explained below. In other implementations hydrofoil mast 12 can first be fabricated as individual components and then assembled, such as through welding. After fabrication of hydrofoil mast 12, regions of hydrofoil mast 12 to be variably deformed mast portion 12b, uniformly deformed mast portion 12c, and variably deformed mast portion 12d can be deformed through use of forging such as shown in
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[0046] In implementations thickness dimension T1 is shown extending the greatest distance between undeformed exterior side portion 12a2 and undeformed exterior side portion 12a4. Thickness substantially affects stiffness of hydrofoil mast 12 on the order of approximately to the third power of thickness. For instance, a 20 mm thick hydrofoil mast is approximately twice as stiff as a 16 mm hydrofoil mast. However, hydrofoil mast thickness also impacts the drag that water has on a hydrofoil mast. Forging of hydrofoil mast portions provide smaller hydrofoil mast thicknesses below the waterline to reduce drag, while providing greater hydrofoil mast thickness above the waterline to provide greater stiffness as a benefit in this area of a hydrofoil mast.
[0047] In implementations gap dimension G1 is shown extending between undeformed interior stringer portion 12a6 and undeformed interior stringer portion 12a7. In implementations undeformed mast portion 12a is shown to have width dimension W1 extending between trailing edge 12a1 and leading edge 12a3.
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[0050] In implementations uniformly plastically deformed interior spar portion 12c5 includes interior portions of which either all or some are uniformly plastically deformed. These interior portions are depicted to include interior anchor portion 12c5a, interior first direction extended portion 12c5b, interior pivot portion 12c5c, interior second direction extended portion 12c5d, and interior anchor portion 12c5e. In implementations uniformly plastically deformed interior spar portion 12c8 includes interior portions of which either all or some are uniformly plastically deformed. These interior portions are depicted to include interior anchor portion 12c8a, interior first direction extended portion 12c8b, interior pivot portion 12c8c, interior second direction extended portion 12c8d, and interior anchor portion 12c8e.
[0051] In implementations thickness dimension T2 is shown extending the greatest distance between uniformly elastically deformed exterior side portion 12c2 and uniformly elastically deformed exterior side portion 12c4. In implementations thickness dimension T2 is less than thickness dimension T1 due at least in part to uniformly plastically deformed interior spar portion 12c5 and uniformly plastically deformed interior spar portion 12c8 not extending as far as undeformed interior spar portion 12a5 and undeformed interior spar portion 12a8 as shown in
[0052] Plastic deformation is the permanent change in shape or size of a solid material when subjected to an applied force, meaning it does not return to its original form after the applied force is removed. Grain structure of plastically deformed materials is also different from undeformed versions of the same materials. Elastic deformation is the temporary change in shape or size of a solid material when subjected to an applied force, meaning it does return to its original form after the applied force is removed. The elastically deformed exterior members are coupled with plastically deformed interior members that provide forces necessary to keep the elastically deformed exterior members elastically deformed. In implementations uniformly plastically deformed interior spar portion 12c5 and uniformly plastically deformed interior spar portion 12c8 can have at least thirty percent of their structures being uniformly plastically deformed in a predictable manner without experiencing buckling of portions of their structures. In implementations, such as depicted, interior anchor portion 12c5a and interior anchor portion 12c8a are shown to be perpendicularly coupled to reduce strain on uniformly elastically deformed exterior side portion 12c2 and uniformly elastically deformed exterior side portion 12c4, respectively.
[0053] As depicted, interior anchor portion 12c5a, interior first direction extended portion 12c5b, interior pivot portion 12c5c, interior second direction extended portion 12c5d, and interior anchor portion 12c5e of uniformly plastically deformed interior spar portion 12c5 are shown to be linearly shaped components, however, in other implementations interior spar portions can be curved shaped components or a combination of linearly shaped and curved shaped components. As depicted, interior anchor portion 12c8a, interior first direction extended portion 12c8b, interior pivot portion 12c8c, interior second direction extended portion 12c8d, and interior anchor portion 12c8e of uniformly plastically deformed interior spar portion 12c8 are shown to be linearly shaped components, however, in other implementations interior spar portions can be curved shaped components or a combination of linearly shaped and curved shaped components.
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[0060] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as open terms (e.g., the term including should be interpreted as including but not limited to, the term having should be interpreted as having at least, the term includes should be interpreted as includes but is not limited to, etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases at least one and one or more to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles a or an limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases one or more or at least one and indefinite articles such as a or an (e.g., a and/or an should typically be interpreted to mean at least one or one or more); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of two recitations, without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to at least one of A, B, and C, etc. is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., a system having at least one of A, B, and C would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to at least one of A, B, or C, etc. is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., a system having at least one of A, B, or C would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase A or B will be typically understood to include the possibilities of A or B or A and B.
[0061] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like responsive to, related to, or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.