Shape-adjustable mold, skin and interior-core structures for custom board production
First Claim
1. An aquatic sports board having broad generally planar top and bottom surfaces and curved edge portions comprising:
- a structural exterior skin covering the surface of the board and defining an interior, said structural exterior skin being formed with a layer of thermoformed plastic, with said layer of thermoformed plastic covering a board substrate, and further with a division in the board substrate creating right and left sides;
said layer of thermoformed plastic being further characterized by having a single continuous surface on both sides of the point of greatest breadth of the board and through the area of sharpest curvature of the board surface, thereby forming a perimeter rail intermediately connecting the top and bottom surfaces of the board.
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Abstract
A mold and construction method for forming aquatic sports boards is provided. The method and molds provide skin and interior core structures made shape-adjustable by a pre-molded perimeter rail. Division(s) in the structural exterior skin allow the skin core to be trimmed and bonded to a variety of convex, shape-defining core structures to produce a plurality of different shapes. A reusable shape-defining mold allows the board structure to be modified in shape. The mold is reversible and male/female configurations produce convex, shape-defining board substrates for a wide array of custom designs.
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Citations
20 Claims
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1. An aquatic sports board having broad generally planar top and bottom surfaces and curved edge portions comprising:
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a structural exterior skin covering the surface of the board and defining an interior, said structural exterior skin being formed with a layer of thermoformed plastic, with said layer of thermoformed plastic covering a board substrate, and further with a division in the board substrate creating right and left sides;
said layer of thermoformed plastic being further characterized by having a single continuous surface on both sides of the point of greatest breadth of the board and through the area of sharpest curvature of the board surface, thereby forming a perimeter rail intermediately connecting the top and bottom surfaces of the board. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A mold system for fabricating an aquatic sports board comprising:
a shape-defining mold including a first shape-defining component adapted to define the shape of a board substrate, said board substrate being removable from said shape-defining mold subsequent to formation, the surface of said shape-defining mold further characterized as having the capacity to produce a plurality of different board shapes. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
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16. A mold system for fabricating an aquatic sports board having an exterior skin formed with at least one layer of thermoformed plastic, with the thermoformed layer characterized as having a continuous surface on both sides of the point of greatest breadth and through the area of sharpest curvature, and having a perimeter rail connecting the broad, generally planar top and bottom surfaces of the board, the mold system comprising:
a first shape-defining mold component for defining the shape of the board layer, with said shape-defining mold having a continuous surface on both sides of the point of greatest breadth and through the area of sharpest curvature, thereby forming a shape-defining surface corresponding to the perimeter rail, with the surface of the shape-defining mold being further characterized by having the capacity to produce a plurality of different board shapes. - View Dependent Claims (17, 18, 19, 20)
Specification