BRPI0809075A2 - SPORT BOARD, SURF BOARD, AND, SURF PIECE OF SURF BOARD - Google Patents

Description

“SPORT BOARD, SURF BOARD, AND, GROSS PART OF THE SURF BOARD”

BACKGROUND OF THE INVENTION

1. Field of the invention

The present invention relates to unpublished sports boards that can be used for various sporting activities.

2. Description of the Prior Art

Modified boards and boards are used for various sporting and / or athletic activities, such as, for example, surfing, riding waves, sailing surfing, being towed by a boat, water skiing, snow surfing, sledding, snow skiing and skate.

Surfboards are narrow or slightly curved floating bodies that are suitable for use by one or more individuals to move with them or ride a wave or wave of water as they approach land, shore or a beach.

Sailing boards may be similar to surfboards, but may be fitted with a sail, which captures the available wind currents to propel the board, and thus does not rely solely on the available water currents and / or waves to provide the impetus to surf. move forward.

Often, in order to stabilize the direction, surfboards and sailing boards require a keel, i.e. a triangular design plate, whose plane is arranged essentially parallel to the plane of the direction of travel.

Surfboards and sailing boards are generally made of wood, or a plastics material, for example, epoxy resin, acrylonitrile butadiene styrene (ABS) resin or similar materials, which form the back and surrounding body and surround it. a core made of expanded material such as polystyrene or polyurethane. Since, for various reasons, the boards must be designed to be as light as possible, the plastic film is not very thick.

U.S. Patent No. 5,928,045 describes a sports board having a foam core, and a non-slip platform layer, a base layer and an outer rail covering the foam core.

U.S. Patent No. 3,337,886 describes a surfboard that has a foam material core and an outer skin or shell.

GB 961,612 describes surfboards composed of an expanded polystyrene plate with a plastic cover. The material of

Polystyrene used for this surfboard is "water repellent". The expanded polystyrene plate is plastic coated. Although this combination provides a surfboard with water repellent features and an outer surface to support users, the combination is not impact resistant.

EP 224 023 describes a surfboard that has a

Composite structure where the foam core is coated with a synthetic resin and a thermoplastic material with a silver weft fabric fitted between them. Silver weft fabric provides a stiffer foam structure.

FR 2,787,088 describes a sandwich structure for a

surf board. This surfboard includes a soft foam core, such as polystyrene and polyurethane, between fiberglass and carbon. The frame is assembled with an adhesive such as epoxy resin and laminated polymers.

U.S. Patent No. 5,275,860 describes surfboards and

Chest surfboards where the board includes a core foam which is a closed pore or closed cell foam that is directly attached to an upper and lower film. To achieve a substantially high integrity bond, an intermediate layer is composed of a mixture of the foam polymeric material and the different polymeric material of the films. The foam is an expanded polypropylene microsphere foam, while the films are high density polyethylene.

U.S. Patent No. 5,944,570 discloses a surfboard 5 having a pre-tensioned central spar with a foam core element located on either side of the spar to form a center core element.

US Patent No. 4,798,549 discloses a surfboard including an elongate spar with upper and lower surfaces 10 generally curved in the longitudinal profile of the surfboard, a passage formed at and extending along the length of the spar; spaced exit doors along the stringer, a keel box formed on the stringer at its rear end. The keel case and passage doors are constructed and arranged for introducing at least one of 15 foam and steam into them for introduction into a space adjacent to said stringer.

US Patent No. 4,850,913 describes a surfboard, snow sledge and other sports board having a molded polyethylene foam core in which a polyethylene film / polyethylene foam sheet laminate is hot-rolled substantially over all core surfaces.

U.S. Patent No. 4,887,986 describes surfboards and sailing boards that include an inflexible floating body having a stern and a nipple; two flexible side portions attached to the inflexible floating body 25, one on each side thereof; and a mast foot located on the rigid floating body, where the flexible side portions are incorporated into the flexible floating stern body up to approximately the mast foot range, and the rigid floating body tapers between the flexible lateral parts toward the stern. which is narrower than each of the flexible side parts.

U.S. Patent No. 6,712,657 describes breast surfboards and surfboards that have a bearing element mounted longitudinally between the two halves of the board. Reinforcing elements 5 are mounted longitudinally and transversely along the board blanks.

U.S. Patent Application 2006/0270288 describes a process of covering a foam core surfboard shape with 1/4 ”(6.25 mm) smooth foam films by heat transfer. The heat transfer from the “foam stacked parapet configurations” allows “scratches” to delineate the outer edges of the board.

A chest surfboard is used by a sportsman to maneuver in waves in the ocean. The athlete typically holds one or both sides of the chest surfboard, while the athlete's hip, chest, knee and / or feet are positioned on the upper non-slip platform of the chest surfboard. The combination of ocean surfing, the athlete's weight and the direction of the athlete's chest surfboard with his hands, elbows, torso, knee and / or feet exerts tremendous bending and twisting tension on the chest surfboard. Bending and torsional tension tends to distort the chest surfboard and is generally an undesirable result because successful maneuvering requires the chest surfboard to respond properly to the sportsman's command. The force applied to the chest surfboard that only distorts the board does not assist the surfer in redirecting the board. Thus, a high degree of rigidity of the breast surfboard is desirable.

On the other hand, simply taking the very rigid chest surfboard is not a practical solution because of weight concerns and because bending in the chest surfboard may be desirable along certain sections of the board. For example, it may be desirable for the board to be more flexible in a transverse line about a quarter toward the nose and front corners. Such flexibility allows the athlete to pull the nozzle upwards by distorting it above the plane of the main non-slip surfboard platform to prevent the nozzle and front edges from falling into the water surface in a dynamic situation where the nozzle is tipped. forced down. However, in the fore quarter of the board, it is generally considered desirable that the board be very hard along a transverse line such that the surfer's steering commands on one side of the board are effectively transmitted to the opposite side of the board and redirect the opposite side. Notwithstanding these generalizations, variations in individual surfer's styles and preferences for performance characteristics of the surfboard, as well as variations in the surf conditions, complicate the task of providing proper rigidity to a surfboard.

In general, chest surfboards may include a variable bending feature, for example, required bending in the nozzle area which is known as “power turns” and resistance in the middle and tail sections, which may be required for speed. . The nozzle section can be configured to allow corner flexibility or flexibility throughout the nozzle section. In general, the base film is soft, firm and tear resistant for water speed. The non-slip platform film or top surface of the board is textured to provide relative slip resistance.

In addition to the above, there is a characteristic of a

breast surfing known as the "curve." This usually refers to the upward folding of the centerline of the chest surfboard. There is general bottom curvature, beak bottom curvature, and tail bottom curvature. Background curvature usually affects the ability of the board to glide above the uneven surface of the water. There is no “perfect” background curvature, but there is general consent to what constitutes good background curvature. Typically, a good bottom bend encloses a gentle upward bend of about 1/3 of the back of the nozzle with a resulting increase in the base of the board to about 11 inches (3.8 cm) in the nozzle. The other 2/3 of the board should be flat or have a very small increase of about 1/3 of the nozzle.

Chest surfboards are typically constructed of a floating foam core to which an upper film, a lower film and side side portions are attached. The added films and side parts provide durable outer surfaces, and the bottom film typically has a smooth outer surface for speeding the board in water.

U.S. Patent Application 2003/0008575 describes a breast surfboard that includes a buoyant foam core to support a surfer in the water. A substantially solid and generally flat rigid reinforcing member is coupled to the core, for example, seated thereon, and the member provides a flexural strength in response to a bending force applied by the surfer to the core. The reinforcing member may include a support oriented in a direction generally perpendicular to the longitudinal axis of the core, a support oriented in a direction generally parallel to the longitudinal axis and / or a support oriented in an oblique direction to the longitudinal axis. The flexural strength provided by the reinforcing member may be increased by a continuously varying amount over at least a portion of the foam core. The element can provide resistance over a first selected vector and a second selected vector, where the second selected vector is not parallel to the first.

A sled is a sliding device that includes an elongate element configured to slide on any sufficiently downward sloping surface, such as snow, ice, grass, metal, or water on a slide with one or more surfers in a seated position, genuflection, or face down.

U.S. Patent Applications 2003/0205872 and 2005/0035564

describe a soft foam sled board prepared from a molded polyethylene foam core and at least the bottom surface of the core is lined with a polyethylene film / flat sheet laminate polyethylene foam that provides little frictional resistance between the Sledge board and sliding surface.

A snow board is a gliding device that includes an elongate element configured to slide on a snow-covered downward sloping surface with one or more surfers in a standing position.

U.S. Patent No. 5,865,446 describes a snow board

which includes a first section having an upper surface, a lower surface, an outer end and an inner end, the outer end being curved upward to facilitate movement of the first section over a surface in a first direction; a second section having an upper surface, a lower surface, an outer end and an inner end, the outer end being curved upward to facilitate movement of the second section on the surface in a second direction; a flexible connector for connecting the inner end of the first section to the inner end of the second section, the flexible connector being rotatable and flexible in both a horizontal and vertical direction; a first link to secure one of the user's feet to the upper surface of the first section, the first link to be securely held in the first section: and a second link to attach the other user's foot to the upper surface of the second section, the second link to be fixed secure in the second section; wherein the user is able to facilitate snowboard movement in both the first and second directions. The first and second sections of the snowboard may each have a middle section positioned between the inner and outer ends and the middle 5 sections may be constructed of foam core or solid polymer resins.

A skate board is a narrow elongated wheeled platform for a surfer to be carried in a standing position.

U.S. Patent No. 5,716,562 describes a method for preparing an injection molded expanded composite skate board. The body of the skateboard is formed of a composite material including a structural foam plastics mass including a plurality of elongated ribbons of carbon fiber material distributed within the masses. The body of the skateboard is formed by injection molding 15 using a thermoplastic such as nylon, polypropylene and polyethylene.

Lightweight sports boards are advantageous, as in most cases, and it is desirable that the surfer does not have to carry any weight more than necessary. Additionally, in water applications, the weight of the board may adversely affect the buoyancy of the board.

Unfortunately, foam core boards that use

Polyurethane, expanded polystyrene and / or expanded polypropylene tend to acquire moisture when exposed to water, making them heavier and less desirable.

Additionally, in many sports board applications, it is desirable for the board to have good flexibility, the ability of a board to "return" to its original shape when deformed. Flexibility can provide, for example, acceleration while surfing and better turning radius and acceleration during snow surfing.

While flexibility is a desirable attribute, it has proven difficult to build on a sports board, and typically requires time consuming and expensive construction methods.

Thus, there is a need in the art for lightweight, water-free sports boards that can provide good flexibility characteristics in an economical manner.

SUMMARY OF THE INVENTION The present invention provides a sports board including a water-impermeable elongated thermoplastic foam core having an upper surface and a lower surface; an upper layer covering at least a portion of the upper surface; and a lower layer covering at least a portion of the lower surface. The foam core is made of an expanded material that has a water absorption (measured according to ASTM C-272) of less than 2 percent by volume.

The present invention also provides a surfboard 15 that includes a water impermeable elongated foam core comprising an interpenetrating web of one or more polyolefins and one or more vinyl aromatic monomer polymers having an upper surface and a lower surface; an upper layer covering at least a portion of the upper surface; and a lower layer covering at least a portion of the lower surface. The foam core is made of an expanded material that has a water absorption (measured according to ASTM C-272) of less than 2 percent by volume.

A surfboard blank comprising a first, water-resistant elongate portion comprising an expandable polymeric matrix 25 having an inner edge, a front end and a rear end; a second elongate, water resistant portion comprising an expandable polymeric matrix having an inner edge, a front end and a rear end; and a stringer disposed along and between the inner edges of the first part and the second part and attached thereto. The expandable polymer matrix contains one or more resins selected from polyolefin interpolymers and in situ polymerized aromatic vinyl monomers, rubber modified polystyrene, polyolefins, polystyrene modified rubber, polyphenylene oxide, and combinations and mixtures thereof.

DESCRIPTION OF DRAWINGS

Figure 1 shows a top plan view of a surfboard according to embodiments of the invention;

Figure 2 shows a bottom plan view of a surfboard according to embodiments of the invention;

Figure 3 shows a side elevation view of a surfboard according to embodiments of the invention;

Figure 4 shows a cross-sectional view of a surfboard according to embodiments of the invention;

Figure 5 shows a cross-sectional view of a surfboard.

surfing according to embodiments of the invention;

Figure 6 shows a top plan view of a surfboard according to embodiments of the invention;

Figure 7 shows a bottom plan view of a surfboard according to embodiments of the invention;

Figure 8 shows a side elevation view of a surfboard according to embodiments of the invention;

Figure 9 shows a cross-sectional view of a surfboard according to embodiments of the invention;

Figure 10 shows a cross-sectional view of a surfboard.

surfing according to embodiments of the invention;

Figure 11 is a top plan view of a breast surfboard according to embodiments of the invention;

Figure 12 is a side elevational view of a breast surfboard according to embodiments of the invention;

Figure 13 is a cross-sectional view of a chest surfboard according to embodiments of the invention;

Figure 14 is a cross-sectional view of a breast surfboard according to embodiments of the invention;

Figure 15 is a top plan view of a water ski according to embodiments of the invention;

Figure 16 is a side elevation view of a water ski according to embodiments of the invention;

Figure 17 is a cross-sectional view of a water ski from

according to embodiments of the invention;

Figure 18 is a cross-sectional view of a water ski according to embodiments of the invention;

Figure 19 is a top plan view of a snow board according to embodiments of the invention;

Figure 20 is a side elevation view of a snow board according to embodiments of the invention;

Fig. 21 is a cross-sectional view of a snow board according to embodiments of the invention;

Figure 22 is a cross-sectional view of a snow board of

according to embodiments of the invention;

Figure 23 is a top plan view of a snow ski according to embodiments of the invention;

Fig. 24 is a side elevation view of a snow ski according to embodiments of the invention;

Figure 25 is a cross-sectional view of a snow ski according to embodiments of the invention;

Fig. 26 is a cross-sectional view of a snow ski according to embodiments of the invention; Fig. 27 is a top plan view of a sleigh according to embodiments of the invention;

Figure 28 is a bottom plan view of a sleigh according to embodiments of the invention;

Figure 29 is a side elevational view of a sledge of

according to embodiments of the invention;

Fig. 30 is a cross-sectional view of a sleigh according to embodiments of the invention;

Figure 31 is a top plan view of a surfboard blank according to embodiments of the invention;

Figure 32 is a side elevational view of the surfboard blank of Figure 31;

Fig. 33 is a top plan view of a surfboard blank according to embodiments of the invention;

Figure 34 is a side elevational view of the blank

the surfboard of figure 33;

Figure 35 is a top plan view of a surfboard blank according to embodiments of the invention; and

Figure 36 is a side elevational view of the surfboard blank of Figure 35.

DETAILED DESCRIPTION OF THE INVENTION For purposes of description hereinafter, the terms "upper", "lower", "internal", "external", "right", "left", "vertical", "horizontal", "top" , "Base", and derivatives thereof, should relate to the invention oriented in the drawings of the figures. However, it should be understood that the invention may assume alternative variations and sequence of steps, except where expressly specified otherwise. Specific devices and processes, illustrated in the accompanying drawings and described in the following specification, are also understood to be an exemplary embodiment of the present invention. Thus, specific dimensions and other physical characteristics related to the embodiment described herein should not be considered as limiting the invention. In describing embodiments of the present invention, reference will be made herein to drawings wherein like numerals 5 refer to like resources of the invention.

Except in the operating examples or where otherwise indicated, all numbers or expressions referring to ingredient quantities, reaction conditions, etc. used in the specification claims are to be understood as modified in all examples by the term "about". Thus, unless otherwise indicated, the numerical parameters set forth in the following specification and the appended claims are approximations which may vary depending upon the desired properties which the present invention wishes to obtain. Finally, and not as an attempt to limit the application of the equivalent doctrine to the scope of the claims, each numerical parameter must be at least constructed in light of the number of significant digits reported and applying common rounding techniques.

Although numerical ranges and parameters having the broad scope of the invention are approximations, the numerical values presented in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective test measurements.

Also, it should be understood that any numeric range stated herein must include all sub-ranges here sub-summed. For example, a range of “1 to 10” is intended to include all sub-ranges comprised and including the minimum quoted value of 1 and the maximum quoted value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Because the described numeric ranges are continuous, they include each value between the minimum and maximum values. Unless expressly stated otherwise, the various numeric ranges specified in this patent application are approximations.

As used herein, the term "surfboard" refers to an elongate element configured to float that is suitable for one or more surfers to use a standing position for surfing.

As used herein, the term "sailing board" refers to an elongated element configured to float, which is or can be adjusted with a sail and is suitable for one or more surfers to use in a standing position for sailing boards. and the like.

As used herein, the term "chest surfboard" refers to an elongated element configured to float, which is used by a surfer to maneuver on ocean waves in a seated, knee or prone position.

As used herein, the term "wave board" refers to a roughly small rectangular element configured to float, which is used by a surfer to maneuver on ocean waves in a prone position.

As used herein, the term "sledge board" refers to a sliding device that includes an elongate member configured to slide on any sufficiently sloping downward sliding surface, such as snow, ice, grass, metal, or water on a slippery surface of water with one or more surfers in a sitting, kneeling or prone position.

As used herein, the term "snow board" refers to a sliding device that includes an elongate member configured to slide on a downwardly deflected snow-covered surface with one or more surfers in a standing position.

As used herein, the term "skate board" refers to a narrow elongated wheeled platform adapted for one or more surfers to be carried in a standing position.

As used herein, the term "snow skiing" refers to a generally rectangular narrow gliding device used in pairs to slide a snow-covered downward sloping surface to a surfer in a standing position with one foot attached to each device.

As used herein, the term "water skiing" refers to a generally rectangular narrow sliding device that can optionally be used in pairs to slide along the water surface being pulled by a motorized water craft with a surfer. in a standing position with feet attached to one or two of such devices.

As used herein, the term "kart" refers to a rectangular wheeled platform adapted for one or more surfers to be carried in a sitting, kneeling or prone position.

As used herein, the term "expandable polymer matrix"

refers to a polymeric material in a particulate or microsphere form that is impregnated with a blowing agent such that when the particulates and / or microspheres are exposed to heat, evaporation of the blowing agent (as described below) following) affects the formation of a cell structure and / or a cell structure that expands into the particulates and / or microspheres causing the microsphere to expand and, when the expanded microspheres are placed in a mold and further exposed to heat, microspheres may further expand and the outer surfaces of the particulates and / or microspheres may fuse to form a continuous mass of polymeric material according to the shape of the mold.

As used herein, the terms "expanded plastics", "pre-expanded", "expanded resin microspheres" and "pre-foam" refer to expanded thermoplastic particles that have been impregnated with a blowing agent, at least some of which have been subsequently removed (as a heated and expanded non-limiting example followed by evaporation and diffusion of the microsphere) in a manner that increases the volume of the particles and thereby decreases their apparent density.

As used herein, the term "thermoplastic" refers to

materials that are capable of softening, melting and / or changing their shape when heated and hardening again when cooled.

As used herein, the term "polymer" embraces, without limitation, grafted homopolymers, copolymers and copolymers.

As used herein, the term "polyolefin" refers to a

A polymer prepared from at least one olefin monomer such as C2 -C32 unsaturated straight or branched alkenes, non-limiting examples of which include ethylene, propylene, 1-butene, 1-hexene and 1-octene. As used herein, the term "polyethylene" refers to and includes not only an ethylene homopolymer, but also an ethylene copolymer containing units of at least 50 mol%, in some cases at least 70 mol%, and in others at least 80 mole% of an ethylene unit and a corresponding proportion of units of an ethylene copolymerizable monomer, and combinations containing at least 50% by weight, in some cases at least 60% by weight, and in other cases at least at least 75% by weight of an ethylene homopolymer or copolymer with another polymer.

Non-limiting examples of monomers that may be copolymerized with ethylene include vinyl acetate, vinyl chloride, propylene, 1-butene, 1-hexene, 1-octene, and met (acrylic) acid and their esters. Polymers that can be combined with homopolymers or

Ethylene copolymers include any polymer compatible with ethylene homopolymers or copolymers. Non-limiting examples of polymers that may be mixed with ethylene homopolymers or copolymers include polypropylene, polybutadiene, polyisoprene, polychloroprene, chlorinated polyethylene, polyvinyl chloride, styrene / butadiene copolymers, vinyl acetate / ethylene copolymers, styrene polymers, acrylonitrile copolymers butadiene, styrene / butadiene / acrylonitrile copolymers, and vinyl chloride / vinyl acetate copolymer.

As used herein, the term "styrenic polymers" refers to

homopolymers of styrenic monomers and copolymers of styrenic monomers and another copolymerizable monomer, wherein the styrenic monomers constitute at least 50 mol percent of the monomeric units in the copolymer. Nonlimiting examples of styrenic monomers include styrene, p-methyl styrene, [alpha] methyl styrene, tertiary butyl styrene, dimethyl styrene, dibrostyrene, brominated or chlorinated nuclear derivatives thereof and combinations thereof. Non-limiting examples of suitable copolymerizable monomers include straight, cyclic or branched C1-C32 alkyl met (acrylate) 1,3-butadiene (specific non-limiting examples include butyl (meth) acrylate, (meth) ethyl acrylate, ( methyl) acrylate, and (2-ethylhexyl) (meth) acrylate, butyl acrylate, acrylonitrile, vinyl acetate, alpha-methylethylene, divinyl benzene, maleic anhydride, maleic acid, fumaric acid, C1- and mono-dialkyl esters. Straight, branched or cyclic C12 maleic acid, mono and dialkyl esters 20 Ci-C 12 straight, branched or cyclic fumaric acid, itaconic acid, straight, branched or cyclic esters of itaconic acid, anhydride itaconic and combinations thereof.

As used herein, the terms "(meth) acrylic" and "(meth) acrylate" include both acrylic and methacrylic acid derivatives, such as the corresponding alkyl esters often referred to as acrylates and (meth) acrylates, the term of which (( meth) acrylate ”encompasses.

As used herein, the term "molding" refers to the modeling of a flexible material to take on a new desired shape. Molding may terminate the use of specific molding tools such as male and female molding tools, carving press plates, and the like. It may also include the use of specifically molded core elements including compressible core elements that are used to shape a desired shape of at least a portion of a thermoplastic material.

As used herein, the term "rubber" refers to natural or synthetic polymeric substances which have the ability to undergo deformation under the influence of a force and to resume its original form once the force is removed.

As used herein, the term "polystyrene modified with

"rubber" refers to styrenic polymers where styrenic polymers are a continuous phase and rubber is a dispersed phase in the resin.

As used herein, the term "polystyrene modified rubber" refers to resins where rubber is a continuous phase and styrenic polymers are a dispersed phase in the resin as described in copending patent application US No. 2006-0276558 Al , the relevant portions of which are incorporated herein by reference.

The present invention provides a sports board comprising a water-resistant or water-resistant elongated thermoplastic foam core having an upper surface and a lower surface; an upper layer covering at least a portion of the upper surface; and a lower layer covering at least a portion of the lower surface.

The thermoplastic foam core contains a foamed expandable polymeric matrix that is at least water resistant or impervious. The expandable polymer matrix contains one or more thermoplastic resins. Suitable thermoplastic resins include, but are not limited to, a polyolefin interpolymer and in situ polymerized aromatic vinyl monomers, rubber modified polystyrene, polystyrene modified rubber, polyphenylene oxide, mixtures of polyolefins and at least one other polymer, and combinations thereof. mixtures thereof.

Thermoplastic resins may be in the form of microspheres, pellets, granules, or other particles suitable for use in expansion and molding operations.

In one embodiment of the invention, the above thermoplastic resins may be mixed and may include one or more polymers selected from vinyl aromatic monomer homopolymers; copolymers of at least one vinyl aromatic monomer with one or more divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile and / or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.

In a particular embodiment of the invention, the thermoplastic resins indicated above are a mixture of one or more polyolefins and one or more polymers selected from vinyl aromatic monomer homopolymers; copolymers of at least one vinyl aromatic monomer with one or more divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile and / or maleic anhydride; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.

In a particular aspect of this embodiment of the invention, expandable thermoplastics may include thermoplastic homopolymers or copolymers selected from homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the like. as copolymers prepared by copolymerizing at least one vinyl aromatic monomer described with one or more other monomers, non-limiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer. In one embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers may be included, such as polyolefins (e.g., polyethylene, polypropylene), polycarbonates, polyphenylene oxide and mixtures thereof. In embodiments of the invention, mixtures of the aforementioned polymers may be used.

As indicated above, the polymer matrix

The expandable polyolefin may include an interpolymer of a polyolefin and in situ polymerized aromatic vinyl monomers and optionally other expandable polymers.

In embodiments of the invention, the interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers may be one or more of those described in U.S. Pat. 3,959,189; 4,168,353; 4,303,756. Nos. 4,303,757 and 6,908,949, the relevant portions of which are incorporated herein by reference. A non-limiting example of such interpolymers that may be used in the present invention includes those available under the trade name ARCEL®, available from NOVA Chemicals Inc., Pittsburgh, PA and PIOCELAN®, available from Sekisui Plastics Co., Ltd., Tokyo , Japan.

In embodiments of the invention, the polyolefin interpolymer and in situ polymerized aromatic vinyl monomers are a resin particle or microsphere, which is subsequently processed to form the foam core of a sports board in accordance with the present invention. The interpolymer particles used in the invention include a polyolefin and an in situ polymerized aromatic vinyl resin forming an interpenetrating polyolefin network and aromatic vinyl resin particles. The interpolymer particles are impregnated with a blowing agent and optionally a plasticizer.

Such interpolymer particles may be obtained by processes including suspending polyolefin particles and vinyl aromatic monomer or monomer mixture in an aqueous suspension and polymerizing the monomer or monomer mixture within the polyolefin particles. Non-limiting examples of such processes are described in U.S. Patent Nos. 3,959,189, 4,168,353 and 6,908,949.

In one embodiment of the invention, the polyolefin may include one or more selected low, medium and high density polyethylene resins; an ethylene vinyl acetate copolymer; an ethylene / propylene copolymer; a mixture of polyethylene and polypropylene; a mixture of polyethylene and an ethylene / vinyl acetate copolymer; and a mixture of polyethylene and an ethylene / propylene copolymer. Ethylene butyl acrylate copolymer and ethylene methyl methacrylate copolymer may also be used.

As indicated above, the thermoplastic polymer matrix resin may include a polystyrene modified rubber where the rubber constitutes a continuous phase and the styrenic polymers 20 constitute a dispersed phase in the resin as described in copending patent application US No. 2006-0276558 , the relevant portions of which are incorporated herein by reference.

In some embodiments of the invention, the expandable polymer matrix may include mixtures and combinations of the thermoplastic resins 25 described above. In other embodiments, the thermoplastic resins described above or combinations of thermoplastic resins may be used in blends and combinations with other polymers. The mixtures and combinations may be used to provide particular properties for the expandable polymer matrix and / or foam core, such as water tightness, flexural strength, elastic modulus, toughness and / or tear strength.

In particular embodiments of the invention, the expandable polymeric matrix may contain 100% interpolymers of a polyolefin and in situ polymerized aromatic vinyl monomers, but may also contain up to 99%, in some cases up to 95%, in other cases up to 90%, in some examples up to 80% and in other examples up to 75% based on the weight of the expandable polymeric matrix of interpolymers of a polyolefin and in situ polymerized aromatic vinyl monomers. Also, the expandable polymer matrix may contain at least 25%, in some cases at least 30%, in other cases at least 40% and in some examples at least 50% based on the weight of the expandable polymeric matrix of interpolymers of a polyolefin and in situ polymerized vinyl aromatic monomers. The amount of interpolymers of a polyolefin and in situ polymerized vinyl aromatic monomers in the expandable polymer matrix may be any value or range between any of the aforementioned values.

When other expandable polymers are included in the expandable polymer matrix with the interpolymers, the other expandable polymers 20 may be present at a level of at least 1%, in some cases at least 5%, in other cases at least 10%, in some examples. at least 20% and in other examples at least 25% based on the weight of the expandable polymer matrix. Also, the other expandable polymers may be present in the expandable polymer matrix at a level of up to 75%, in some cases up to 70%, in some cases up to 60% and in some examples up to 50% based on the weight of the expandable polymer matrix. . The other expandable polymers may be included in the expandable polymer matrix at any level or range between any of the aforementioned values. In other particular embodiments of the invention, the expandable polymer matrix may contain 100% polystyrene modified rubber, but may also contain up to 99%, in some cases up to 95%, in other cases up to 90%, in some instances up to 80% and in another 5 examples up to 75% based on the weight of the polystyrene modified rubber expandable polymer matrix. Also, the expandable polymer matrix may contain at least 25%, in some cases at least 30%, in other cases at least 40% and in some instances at least 50% based on the weight of the polystyrene modified rubber expandable polymer matrix 10. . The amount of polystyrene modified rubber in the expandable polymer matrix may be any value or range between any of the above values.

When other expandable polymers are included in the expandable polymer matrix with polystyrene modified rubber, the other 15 expandable polymers may be present at a level of at least 1%, in some cases at least 5%, in other cases at least 10%, in some examples at least 20% and in other examples at least 25% based on the weight of the expandable polymer matrix. Also, the other expandable polymers may be present in the expandable polymer matrix 20 at a level of up to 75%, in some cases up to 70%, in some cases up to 60% and in some examples up to 50% based on the weight of the expandable polymer matrix. . The other expandable polymers may be included in the expandable polymer matrix at any level or range between any of the aforementioned values.

In the present invention, thermoplastic resins may be

polymerized particles in a suspension process, which are essentially spherical resin microspheres used to prepare expandable thermoplastic particles. However, polymers derived from solution and bulk polymerization techniques that are extruded and cut into particles classified into resin microsphere sections can also be used.

In one embodiment of the invention, (non-expanded) thermoplastic resin microspheres containing any of the resins, polymers 5 and / or polymer compositions described herein may have a particle size of at least 0.2, in some situations at least 0; 33, in some cases at least 0.35, in other cases at least 0.4, in some instances at least 0.45 and in other instances at least 0.5 mm. Also, resin microspheres may have a particle size of up to 10 3, in some instances up to 2, in other instances up to 2.5, in some cases up to 2.25, in other cases up to 2, in some situations up to 1 , 5 and in other situations up to 1 mm. The resin microspheres used in this embodiment may be any value or range between any of the values cited above.

The impregnated thermoplastic resin microspheres

The expanded materials may be expanded, pre-expanded plastics and / or expanded resin microspheres used in the present invention.

Expandable thermoplastic particles or resin microspheres may optionally be impregnated using any conventional method with a suitable blowing agent. As a non-limiting example, impregnation may be achieved by adding the blowing agent to the aqueous suspension during polymerization of the polymer, or alternatively resuspending the polymer particles in an aqueous medium and then incorporating the blowing agent of US Patent No. 2,983. .692. Any gaseous material or material that will produce gases on heating may be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and halogenated hydrocarbons, for example CFCs and HCFCs, which boil at a temperature below the softening point of the chosen polymer. . Mixtures of these aliphatic hydrocarbon blowing agents may also be used.

Alternatively, water may be combined with these aliphatic hydrocarbon blowing agents or water may be used as the sole blowing agent of U.S. Pat. 6,127,439; 6,160,027; and 6,242,540 in these patents, water retaining agents are used. The weight percentage of water for use as the blowing agent may range from 1 to 20%. U.S. Patent Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein by reference.

The impregnated thermoplastic resin microspheres are

The

optionally expanded to an apparent density of at least 0.5 lb / ft

J -J

(0.008 g / cm), in some cases at least 1.25 lb / ft (0.02 g / cm), in some cases

Λ the

other cases at least 1.5 lb / ft (0.024 g / cm), in some situations at least

3 3

1.75 lb / ft (0.028 g / cm3), in some circumstances at least 2 lb / ft3 (0.032 g / cm3) in other circumstances at least 3 lb / ft3 (0.048

3 3 3

g / cm), and in particular circumstances at least 3.25 lb / ft (0.052 g / cm)

3 3

or 3.5 lb / ft (0.056 g / cm) thus forming pre-expanded thermoplastic microspheres or particles. When unexpanded resin microspheres are used, higher apparent density microspheres may be used. As such, bulk density can be up to 40 lb / ft (0.64 g / cm) and

Λ Λ

when only slightly expanded to 30 lb / ft (0.48 g / cm3), in some cases up to 20 lb / ft3 (0.32 g / cm3), in other cases up to 10 lb / ft3 (0.16 g / cm3) cm3) and

λ λ

in some examples up to 7.5 lb / ft (0.12 g / cm). The apparent density of the thermoplastic particles may be any value or range between any of the above values.

The expansion step is conventionally performed by heating the impregnated microspheres by any conventional heating means such as steam, hot air, hot water or radiant heat. A generally accepted method for pre-expanding impregnated thermoplastic particles is provided in U.S. Patent No. 3,023,175.

Resin impregnated microspheres may be foamed cellular polymer particles as set forth in U.S. Patent Application No.

2002-0117769, the precepts of which are incorporated herein by reference. The foamed cell particles may be any of the above-described expandable resins and / or polymers and contain a volatile blowing agent at a level of less than 14 wt%, in some situations less than 6 wt%, in some cases ranging from about 2 wt% to about 5 wt%, and in other cases ranging from about 2.5 wt% to about 3.5 wt% based on the weight of the polymer.

When interpolymer resins are included in the expandable polymer matrix, the amount of polyolefin in the interpolymer resin of the invention may be at least 20%, in some cases at least 25%, and in other cases at least 30% and may be up to 80%. %, in some cases up to 70%, in other cases up to 60% and in some instances up to 55% by weight based on the weight of the interpolymer resin particles. The amount of polyolefin in the interpolymer resin may be any value or range between any of the above values.

The amount of polymerized vinyl aromatic resin in the

The interpolymer resin of the invention may be at least 20%, in some cases at least 30%, in other cases at least 40% and in some instances at least 45% and may be up to 80%, in some cases up to 75% and in others. other cases up to 70% by weight based on the weight of the interpolymer resin particles. The amount of polymerized vinyl aromatic resin of the interpolymer resin may be any value or range between any of the aforementioned values.

The vinyl aromatic resin in the interpolymer resin may be made of polymerized vinyl aromatic monomers or the resin may be a copolymer containing monomeric units of vinyl aromatic monomers and copolymerizable comonomers. Non-limiting examples of vinyl aromatic monomers that may be used in the invention include styrene, alpha-methylstyrene, ethylstyrene, chlorostyrene, bromostyrene, vinyl toluene, vinylbenzene and isopropylxylene. These monomers can be used either alone or in admixture.

Non-limiting examples of copolymerizable comonomers include straight, cyclic or branched C1-C32 alkyl (meth) acrylates (specific non-limiting examples include 10-butyl (meth) acrylate, (meth) ethyl acrylate and (meth) ) 2-ethylhexyl acrylate), acrylonitrile, vinyl acetate, alpha-methylethylene, divinyl benzene, maleic anhydride, itaconic anhydride, dimethyl maleate and diethyl maleate.

Non-limiting examples of vinyl aromatic copolymers that may be used in the interpolymer resin of the invention include those described in patent No. 4,049,594. Specific non-limiting examples of suitable vinyl aromatic copolymers include copolymers containing repeated polymerization styrene units and repeated polymerization units of one or more selected 1,3-butadiene monomers, straight, cyclic or branched C 1 -C 32 alkyl (acrylates) (non-limiting specific examples including butyl (meth) acrylate, ethyl (meth) acrylate and 2-ethylhexyl (meth) acrylate, acrylonitrile, vinyl acetate, alpha-methylethylene, divinyl benzene, maleic anhydride, itaconic anhydride, dimethyl maleate and diethyl maleate.

In particular embodiments of the invention, the aromatic vinyl resin in the interpolymer resin includes polystyrene or styrene butyl acrylate copolymers.

In embodiments of the invention, the interpolymer resin particles are formed as follows: Polyolefin particles are dispersed in an aqueous medium prepared by adding 0.01 to 5%, in some cases 2 to 3% by weight based on the weight of the polyolefin. water of a suspending agent, such as water-soluble high molecular weight materials, for example, polyvinyl alcohol or methyl cellulose or slightly water-soluble inorganic materials, for example, calcium phosphate or magnesium pyrophosphate and soap, such as sodium dodecyl benzene sulfonate, and the vinyl aromatic monomers are added to the suspension and polymerized within the polyolefin particles.

Any conventionally known suspending agent commonly used for polymerization of vinyl aromatic monomers 10 may be employed. These agents are well known in the art and can be freely selected by one of skill in the art. Initially, water is in an amount generally from 0.7 to 5, preferably 3 to 5 times that of the starting polyolefin particles employed in the aqueous suspension, on a weight basis, and gradually the ratio of polymer particles to water. 15 can reach around 1: 1. The polymerization of vinyl aromatic monomers, which are absorbed into polyolefin particles, is performed using primers.

Suitable initiators for suspension polymerization of vinyl aromatic monomers are generally used in an amount of from about 0.05 to 2 weight percent, in some cases 0.1 to 1 weight percent, based on the weight of the aromatic monomer. Vinyl Non-limiting examples of suitable initiators include organic peroxides such as benzoyl peroxide, lauroyl peroxide, t-butyl perbenzoate and t-butyl perpivalate and azo compounds such as azobisobutyl nitrile and azobidimethylvaleronitrile.

These primers may be used alone or two or more primers may be used in combination. In many cases, the initiators are dissolved in the vinyl aromatic monomers, which are absorbed in the polyolefin particles. In other cases, the initiator may be dissolved in a solvent, such as toluene, benzene, and 1,2-dichloropropane.

When in situ polymerization of vinyl aromatic monomers is complete, the polymerized vinyl aromatic resin is uniformly dispersed within the polyolefin particles.

In many cases, polyolefin particles are crosslinked.

Crosslinking may be performed simultaneously with the polymerization of the vinyl aromatic monomer into the polyolefin particles, and prior to the impregnation of the blowing agent and / or plasticizer. For this purpose, crosslinking agents are used. Such crosslinking agents include, but are not limited to, di-t-butyl peroxide, t-butyl cumyl peroxide, dicumyl peroxide, [alpha], [alpha] bis (t-butylperoxy) -p-diisopropylbenzene 2,5-dimethyl

2,5-di- (t-butylperoxy) -hexine-3,2,5-dimethyl-2,5-di- (benzoylperoxy) -hexane and t-butyl peroxyisopropyl carbonate. These crosslinking agents are absorbed into the polyolefin particles together with the vinyl aromatic monomers 15 by dissolving the crosslinking agent in an amount of about 0.1 to 2 wt.% And in some cases 0.5 to 1 wt.%. based on the weight of the polyolefin particles suspended in water. Additional details of crosslinking agents and the manner in which crosslinking agents are absorbed in polyolefin particles are provided in U.S. Patent No. 3,959,189. The interpolymer particles are acidified, dehydrated, screened and subsequently loaded into a second reactor where the particles are impregnated with blowing agent and / or plasticizer.

The impregnation step may be performed by suspending the interpolymer particles in an aqueous medium, adding the blowing agent and / or plasticizer to the resulting suspension, and stirring at a temperature, preferably from about 40 ° C to 80 ° C. The blowing and / or plasticizing agent may be mixed together and then added to the interpolymer particles or may be added to the interpolymer particles separately. Alternatively, the blowing and / or plasticizing agent may be added to the first reactor during or after the polymerization process.

The foregoing processes describe a wet process for impregnating interpolymer particles. Alternatively, the interpolymer particles may be impregnated by an anhydrous process similar to that provided in column 4, lines 20-36 of U.S. Patent No. 4,429,059.

When polystyrene modified rubber resins are included in the expandable polymer matrix, these resins may be made by forming a dispersion of organic droplets by pressure atomization of an organic liquid mixture below the free surface of an aqueous phase, which may be stationary or fluid. or by applying mechanical agitation. The organic mixture typically contains an organic solution comprising one or more elastomer polymers and / or one or more polyolefins dissolved without a monomer solution containing one or more styrenic monomers. Dispersed organic droplets typically have an average diameter of about 0.001 mm to about 10 mm. Monomers are typically polymerized, using primers as described above, into the organic droplets dispersed in a low shear flow pattern to form unexpanded polymer microspheres. In many cases, the organic mixture has a density of ± 20% of the density of the aqueous phase and the dispersed organic droplets constitute from 0.01 to 60 percent by volume of the total volume of organic and aqueous liquids.

In some embodiments, the low flow pattern

Shear is a controlled low turbulence flow pattern created without mechanical agitation by continuously or periodically injecting up to 15 bar gauge pressure into selected parts of the reactor one or more streams of an inert gas in the reactor contents and immiscible with the reactor contents. . The gas may be injected into the aqueous phase at a gauge pressure of less than 3 bar and may form one or more bubble streams having diameters substantially larger than the average size of atomized organic droplets.

In some embodiments, the low flow pattern

Shear is provided by mechanical agitation.

Typically, unexpanded polystyrene modified rubber resin microspheres have a continuous phase and a dispersed phase and the continuous phase includes the elastomeric polymers and / or polyolefins in a crosslinked mesh morphology. The continuous phase may also include elastomeric polymers and / or polyolefins in a line morphology having a large aspect ratio, which are optionally at least partially cross-linked and / or connected via locally formed branches and / or an interconnected mesh structure.

In many embodiments, the organic mixture contains about

from 5 to about 50% by weight based on the weight of the organic mixture of one or more elastomer polymers and / or one or more polyolefins and from about 95 to about 50% by weight of a monomer solution comprising one or more styrenic monomers, wherein the elastomer polymers and / or one or more polyolefins are soluble in the monomer solution. In embodiments of the invention, elastomer polymers may be selected from butadiene or isoprene homopolymers, and random, block, diblock AB or triblock ABA copolymers of a diene conjugated to an aryl monomer and / or (meth) acrylonitrile and ethylene and copolymers. 25 random vinyl acetate, altemantes or in block.

In some embodiments of the invention, elastomeric polymers include one or more block copolymers selected from styrene-butadiene diblock and triblock copolymers, styrene-butadiene styrene, styrene-isoprene, styrene-isoprene-styrene, ethylene-vinyl acetate, styrene-isoprene. partially hydrogenated styrene and combinations thereof. In other embodiments of the invention, elastomeric polymers include one or more copolymers containing repeated polymerization units of one or more conjugated dienes and at least one unsaturated nitrile selected from acrylonitrile and methacrylonitrile.

In one embodiment of the invention, the blowing agent may be metered into the expandable polymer matrix in an extruder to produce resin pellets or microspheres. The extruder acts to blend the blowing agent into the expandable polymer matrix before extruding a shaft from the mixture. The shaft may be cut to microsphere or pellet lengths using a suitable device, a non-limiting example being an underwater end mill.

The expandable polymeric matrix particles and / or microspheres according to the invention may also contain other additives known in the art, non-limiting examples including nucleating agents, antistatic additives; flame retardants; dyes or inks; loading materials and combinations thereof. Other additives may also include chain transfer agents, non-limiting examples including C 2-15 alkyl mercaptans such as n-dodecyl mercaptan, t-dodecyl mercaptan, t-butyl mercaptan and n-butyl mercaptan, and other agents such as pentaphenyl ethane and the alpha-methyl styrene dimer. Other additives may further include nucleating agents, non-limiting examples including polyolefin waxes, i.e. polyethylene waxes.

The resulting expandable polymer matrix is used as a raw material in the production of foam core and / or blanks on the present sports boards. The blowing agent and / or plasticizers are introduced into the expandable polymeric matrix resin particles to form friable or expandable resin particles or microspheres which in turn are used to shape foam cores. The blowing agent should have a boiling point lower than the polyolefin softening point and should be gaseous or liquid at room temperature (about 20 to 30 ° C) and normal pressure (about atmospheric). Blowing agents are well known in the art and generally have boiling points ranging from -42 ° C to 80 ° C, more generally from 10 ° C to 36 ° C. Suitable hydrocarbon blowing agents include, but are not limited to, aliphatic hydrocarbons such as n-propane, n-butane, iso-butane, n-pentane, isopentane, n-hexane, and neopentane, cycloaliphatic hydrocarbons such as cyclobutane and cyclopentane, and halogenated hydrocarbons such as methyl chloride, ethyl chloride, methylene chloride, trichlorofluoromethane, dichlorofluoromethane, dichlorodifluoromethane,

chlorodifluoromethane and dichlorotetrafluoroethane, etc. These blowing agents may be used alone or as mixtures. If n-butane, ethyl chloride, and dichlorotetrafluoroethane, which are gaseous at room temperature and normal pressure, are used as a mixture it is possible to achieve foaming at a low apparent density. Specific types of volatile blowing agents are set forth in U.S. Patent No. 3,959,180. In particular embodiments of the invention, the blowing agent is selected from npentane, iso-pentane, neopentane, cyclopentane, and mixtures thereof.

The amount of blowing agent ranges from about 1.5% to

about 20% by weight, in some cases from about 1.5% to 15% by weight, and in other cases from 5% to 15% by weight, based on the weight of the expandable polymer matrix.

A plasticizer may be used in combination with the blowing agent and as set forth hereinbefore and acts as a blowing aid in the invention.

Suitable plasticizers include, but are not limited to, straight, branched or cyclic C 5 to C 20 alkanes, benzene, toluene, limonene, white oil, straight, branched or cyclic C 1 to C 20 dialkylphthalates, styrene, styrene oligomers, (meth) acrylate oligomers having a glass transition temperature lower than polystyrene, and combinations thereof.

In a particular embodiment of the invention, the plasticizer includes limonene, a mono-terpene hydrocarbon that exists widely in the plant world. Known types are d-limonene, 1-limonene, and dllimonene. D-limonene is contained in the citrus fruit film and is used in food additives as a fragrance agent; its boiling point is about 176 ° C; and its flammability is low. D-Limonene is a colorless liquid, has a pleasant orange aroma, is approved as a food additive and is widely used as a perfume raw material. Limonene is not a harmful air pollutant.

The amount of plasticizer may range from about 0.1 to about 5 parts and in some cases from about 0.1 to about 1 parts by weight per 100 parts by weight of the expandable polymer matrix.

In many embodiments of the invention, microspheres or

Pre-expanded particles containing the expandable polymer matrix are molded into a foam core shape of desired size by adding pre-expanded particles or microspheres after four to 48 hours of aging to completely fill a mold of the desired shape and size and mold into a steam molding press. When steam is uniformly applied to the pre-expanded particles or microspheres, good fusion between the microspheres is performed. When heat is also applied from the mold and / or mold press, a film may be formed on the outer surface of the molded foam core.

The film that is formed during molding provides a

surface that readily accepts paint as well as lamination resins.

In prior art methods, the pre-expanded microspheres or particles are molded into a mold of generally rectangular shape. The foam core is then prepared by cutting the general foam core shape into the block molded foam and then shaping the desired curvature to provide the foam core. This method is typically used in the prior art and causes any film of the molded part to be removed and the molten cell structure of the foam core to be severely ruptured. This method results in significantly higher water absorption in the foam core as well as incompatibility with paint and laminating resins. The latter typically results in a non-uniform or wavy surface on the sports board, which is aesthetically undesirable and makes the sports board less aerodynamic.

In embodiments of the invention, these problems have been

overlapping directly molding the foam core into its desired shape as described above to form a film and / or applying a sealant to the damaged surface created by cutting into the foam core shape.

Any sealer coating can be used which provides water repellent properties to the foam core surface and provides a surface that accepts lamination resins with little or no wrinkling or other surface deformation. Suitable sealants are formulations which include, but are not limited to, ethylene vinyl acetate copolymers, ethylene vinyl alcohol copolymers, ethylene acrylic acid copolymers, styrene butadiene polymers, styrene isoprene polymers; styrene-butadiene-styrene block polymers; styrene-isoprene-styrene block polymers; and hydrogenated resins thereof and combinations thereof.

Other materials that may be used as or as part of the sealant, in some examples, include joint compound, plaster paste, polyurethanes, styrenic block copolymers, polypropylene and polyethylene.

In some embodiments, the sealant may be multilayer, including layers containing any of the above materials. Having one or more layers and the composition of these layers being determined based on the composition of the foam core and the composition of the upper covering layer and the coating of the lower layer. As a non-limiting example, sealant may include three components, a thermoplastic polyolefin; thermoplastic styrene polymers; and a styrenic block copolymer.

5 In some examples, the sealant includes film structures.

containing from 35 to 65% by weight of thermoplastic olefin, in some cases from 55 to 60% by weight; from 10 to 30% by weight of thermoplastic styrene polymers, in some cases from 15 to 20% by weight with the equilibrium being a styrene block copolymer.

In particular examples, the sealant may include from 20 to 60%

by weight polypropylene, in some cases 40 to 50% by weight; from 20 to 60% by weight polystyrene, in some cases from 40 to 50% by weight with the equilibrium being a styrene block copolymer.

The styrenic block copolymer used in the sealant may be a copolymer of at least one vinyl aromatic monomer and at least one other olefin, diolefin and / or diene monomer. In particular embodiments, styrene block copolymers may contain styrene blocks and butadiene blocks with from about 35 to 55% by weight of bound styrene and an average molecular weight (determined using polystyrene standard gel permeation chromatography) from about 50,000 to about 100,000. Non-limiting example of suitable styrenic block copolymers are those available under the trademark KRATON® from KRATON Polymers U.S. L.L.C. of Houston, TX.

In some embodiments, the sealant includes multilayer structures containing at least three layers, a thermoplastic polyolefin (TPO) layer; a layer of thermoplastic aromatic vinyl (TVA); and a loop layer (TL) that is located between the TLO layer and the TVA layer. This can be described as a TPO / TL / TVA structure. In some specific embodiments, the sealant may include five layer film structures, with the TVA layer being the core layer, as a non-limiting example, a five layer structure may be described as TPO / TL / TVA / TL / TPO

When the sealant includes multilayer films, in many cases the sealant contains about 5 to 25% by weight of the loop layer material (based on the total weight of the multilayer structure). Loop layers may be used in amounts of 5 to 10% by weight in the preparation of lamina structures, although useful structures may be prepared which contain less than 1% of loop layer material. The amount of material used in the other layers can be widely varied to suit different end uses. As a non-limiting example, a multilayer film containing similar amounts of polyolefin and thermoplastic styrenic polymers (for example, from 10 to 20 wt% "loop layer" and 40-50 wt% in each of the TPO layers and TVA.

It is also within the scope of the invention to premix the loop layer material with a portion of the material used for one of the films. This method can be used when only a very small weight% of the overall structure is contained in both the TPO layer and the TVA layer. In embodiments of the invention, the foam cores herein

described have a water absorption measurement (measured according to ASTM C-272) of less than 2, in some cases less than 1, and in other cases less than 0.5 percent by volume determined in a sample molded to a density of 1.5 to 2.5 lb / ft3 (0.024 to 0.04 g / cm3).

In other embodiments of the invention, foam cores

described herein are made of materials that have a 5% bending strength (measured according to ASTM C-203) of at least 20 psi (0.14 MPa), in some cases at least 25 psi (0, 17 MPa) and in other cases at least 30 psi (0.21 MPa) at a molding density of about 1.5 lb / ft3 (0.024 g / cm3); at least 30 psi (0.21 MPa), in some cases at least 35 psi (0.24 MPa) and in other cases at least 40 psi (0.27 MPa) at a molding density of about 1 , 75 lb / ft (0.028 g / cm); at least 40 psi (0.27 MPa), in some cases at least 45 psi (0.31 MPa) and in other cases at least 50 psi (0.34 MPa) at a molding density of about 2 1b / ft3 (0.032g / cm3); and at least 60 psi (0.41 MPa), in some cases at least 65 psi (0.41 Pa) and in other cases at least 70 psi (0.48 MPa) at a molding density of about 2.25 lb / ft (0.036 g / cm3).

As a further embodiment of the invention, the foam cores described herein are made of materials that have a tensile strength (measured according to ASTM D-3575-T) of at least 25 psi (0.17 MPa), in some cases. at least 30 psi (0.21 MPa) and in other cases at least psi (0.24 MPa) at a mold density of about 1.5 lb / ft3 (0.024

The

g / cm); at least 40 psi (0.27 MPa), in some cases at least 45 psi (0.31 MPa) and in other cases at least 50 psi (0.34 MPa) in a

• 3 Λ

mold density about 1.75 lb / ft (0.028 g / cm); at least 55 psi, in some cases at least 60 psi (0.41 MPa) and in other cases at least

• 3

65 psi (0.41 Pa) at a molding density of about 2 lb / ft

The

(0.032 g / cm); and at least 75 psi (0.52 MPa), in some cases at least 80 psi (0.55 MPa) and in other cases at least 85 psi (0.59 MPa) at a molding density of about 2.25 lb / ft3 (0.036 g / cm3).

As a further embodiment of the invention, the foam cores described herein are made of materials that have a foam tear strength (measured according to ASTM D-3575-G) of at least 5 lb / in (89.5 g / mm ) in some cases at least 5.5 lb / in (89.5 g / mm) and in other cases at least 6 lb / in (107.4 g / mm) at a molding density of

-3 * 3

about 1.2 lb / ft (0.019 g / cm); at least 9 lb / in (161.1 g / mm), in some cases at least 10 lb / in (179 g / mm) and in other cases at least 11 β ^ lb / in (196.9 g / mm) at a molding density of about 1.5 lb / ft (0.024 g / cm3); at least 12 lb / in (214.8 g / mm), in some cases at least 13 lb / in (232.7 g / mm) and in other cases at least 14 lb / in (250.6

3 3

g / mm) at a molding density of about 1.75 lb / ft (0.028 g / cm); at least 15 lb / in (89.5 g / mm), in some cases at least 17 lb / in (304.3 g / mm) and in other cases at least 18 lb / in (322.2 g / mm) in one

• λ λ

mold density about 2 lb / ft (0.032 g / cm); and at least 19 lb / in (161.1 g / mm), in some cases at least 20 lb / in (358 g / mm) and in other cases at least 22 lb / in (393.8 g / mm) mm) at a molding density of about 2.25 lb / ft3 (0.036 g / cm3).

Advantageously, the foam cores described herein have better water repellent properties compared to prior art expanded polystyrene foam cores in that they absorb much less moisture and thus do not absorb undesirable weight when exposed to water.

Additionally, the foam cores described herein have greater tensile strength compared to expanded polyethylene or expanded polystyrene foam cores of the same density, and thus the present foam cores are less likely to break during use.

Once the foam core has been prepared, an upper layer covering at least a portion of the upper surface of the foam core and a lower layer covering at least a portion of the lower surface of the foam core are applied.

In embodiments of the invention, the upper covering layer and the lower covering layer include fibrous webs or fibrous fabrics. The webs or fabrics may be conventional and contain fibers such as glass fibers, aramid fibers, polyamide fibers, carbon fibers, silicon carbide fibers, composite fibers, metal fibers, glass fibers, and combinations of the same. as well as fabric containing the aforementioned fibers and fabric containing combinations of the aforementioned fibers.

When the prefabricated foam core has had one or more fibrous layers applied as the top covering layer and / or the lower covering layer 5, a lamination resin is poured into the fibrous webs on the top and / or bottom surfaces of the foam core. . The lamination resin can then naturally cure and harden by grasping the fibrous layer (s) of the upper covering layer and / or the lower covering layer of the foam core.

In embodiments of the invention, after the resin of

lamination has been applied, the foam core or void thus treated is inserted into a lower mold segment of a mold press where the fibrous lamination resin layer (s) is held by vacuum, and the mold press is closed. The pressure of the press causes the laminating resin 15 to be completely distributed in the space between the foam core and the fibrous layer (s) and cures to form a closed fiber reinforced shell, which intimate with the foam core. . The curing step may take place at a molding tool temperature of at least about 80 ° C and for at least about 5 minutes.

After curing, the edges of the projection core projection film

Laminated foam can be trimmed. Thereafter, the cut faces can be optionally sealed. The lamination resin used to saturate the fibrous layer (s) is typically a resin catalyst system component system that includes a resin system, a curing catalyst, and optionally filler materials.

In embodiments of the invention, the lamination resin may be a polyurethane formulation comprising a polyalcohol component and an isocyanate component; an epoxy formulation comprising an epoxy containing component and a reactive component, such as a polyalcohol component; a curable polyester formulation comprising an unsaturated polyester resin component and a peroxide component, non-limiting examples of suitable peroxides include methyl ethyl ketone peroxide, hydrogen peroxide, benzoyl peroxide, lauroyl peroxide, t-perbenzoate. butyl, t-butyl perpivalate, di-t-butyl peroxide, t-butyl cumyl peroxide, dicumyl peroxide, [alpha], [alpha] bis (t-butylperoxy) -p-diisopropylbenzene, 2,5- dimethyl-2,5-di- (t-butylperoxy) hexane

3,2,5-dimethyl-2,5-di (benzoylperoxy) hexane and t-butylperoxyisopropyl carbonate; a mixture of dimethyl phthalate and a 10 ester plasticizer and second component of methyl ethyl ketone peroxide; acrylic unsaturated polyester resins as described in U.S. Patent No. 5,395,866; vinyl ester epoxide resins as described in U.S. Patent No. 4,595,734; and combinations thereof. The relevant portions of U.S. Patent Nos. 5,395,866 and 4,595,734 are incorporated herein by reference.

In embodiments of the invention the resin resin system

Lamination includes a curable unsaturated polyester resin and optionally a co-curable unsaturated monomer.

Curable unsaturated polyester resins are known in the art and are generally prepared in a non-limiting sense by esterifying or transesterifying one or more unsaturated dicarboxylic acids or reactive derivatives thereof with one or more aliphatic or cycloaliphatic diols. Saturated dicarboxylic acids, aromatic dicarboxylic acids, or their reactive derivatives may be used in conjunction with unsaturated dicarboxylic acid (s) to decrease crosslinking density. Curable polyester resins are commercially available and examples thereof are described, as non-limiting examples, in U.S. Pat. 3,969,560, 4,172,059, 4,491,642, 4,626,570 and 6,226,958 which are incorporated herein by reference.

Curable unsaturated polyester resins may be a high reactivity polyester resin. Nonlimiting examples of suitable high reactivity polyester resins include, but are not limited to, high reactivity orthophthalic polyester resins, high reactivity isophthalic polyester resins, and high reactivity dicyclopentadiene modified polyester (DCPD) resins. A particular non-limiting example of a curable unsaturated high reactivity polyester resin is a dicyclopentadiene modified propylene glycol polyester resin.

Co-curable unsaturated monomers are also well known in the art and include, by way of non-limiting examples, the various alkyl acrylates and alkyl methacrylates, as well as vinyl toluene. alpha. methylstyrene, p-methylstyrene and styrene. By the term "co-cure," it is meant that the monomer contains unsaturation capable of reacting with itself and / or unsaturated sites of curable polyesters under curing conditions. Additional co-curable monomers are identified in previously referenced patents 15. A non-limiting example of a co-curable monomer is styrene.

Non-limiting examples of suitable lamination resins include SILMAR® and CoREZYN® products available from Interplastic Corporation, Saint Paul, MN, HI-POINT resins available from Crompton 20 Corporation, Middlebury, CT and polyester resins, a non-limiting example. Polyester Resin 30P-105, available from Dura Technologies, Inc., Bloomington, CA.

Suitable fibrous layer fabric which may be used in the invention includes, but is not limited to, the fibers described above in the following forms: flat weave, 14 mil (0.36 mm) thick cloth; flat weaving, 11 mil (0.28 mm) thick cloth; flat weaving cloth of thickness 10 mil (0.25 mm); flat weaving, 8 mil thick (0.20 mm) cloth; flat weaving, 5.5 mil (0.14 mm) thick cloth; four-satin satin weaving, thickness 3.5 mil (0.09 mm); 2/2 twill weft cloth, thickness 9.3 mil (0.24 mm); modified flat weaving, thickness 7.7 mil (0.20 mm); eight-lath satin weaving, thickness 8 mil (0.20 mm); eight-satin satin weaving, thickness 9 mil (0.23 mm); and layers of combinations of such fabrics.

Sports boards using foam cores or construction methods according to the invention provide boards that have a fast "flexible memory", the ability of a board to "return" to its original shape very quickly when deformed. . Flexible memory can provide, for example, better surfing acceleration and better turning radius and snowboard acceleration. Thus, flexible memory is a desirable attribute that has shown elusive on prior art sports boards.

Sports boards constructed in accordance with the invention may be evaluated using an Emerson 8510 Compression Tester (Emerson Apparatus Company, Inc., Portland, ME) designed to meet ASTM D642 and TAPPI T804 equipment specifications. In these assessments, a programmable reel is adjusted at a rate of 0.5 inches (1.27 cm) per minute using a position of the type used in the alpine skis test protocols, a three-point folding test described in ASTM Standard 780. -93a.

In this assessment, the sports board is supported near each end by a 1.5 ”(38.1 mm) diameter free-floating steel rebar so as not to apply any friction to the base of the board as it is deflected from the top using a laminated structure that includes a flexible rubber accessory (19 inches (48 cm) long x 1.5 inches (3.81 cm wide)) that follows the contour of the non-skid sports platform apply the same amount of force to its width.

The amount of deflection that sports boards according to the invention can resist without breaking is greater than that observed when compared to prior art sports boards.

Additionally, where prior art sports boards fail catastrophically and are no longer capable of withstanding a load, sports boards constructed in accordance with the invention are able to continue to carry a load even after failure. In other words, where prior art sports boards break down, sports boards constructed in accordance with the invention fold and are hard enough to maintain the same structural integrity.

A mode of sports boards according to the

The invention is a surfboard as shown in Figures 1-4. Surfboard 10 has foam core elements 12 and 14 as described above separated by stringer 16 where foam core elements 12 and 14 are located on either side of stringer 16. Stringer 16

It may be made of wood, carbon / graphite reinforced material, composite material, metal and / or combinations of such materials.

During manufacture, the stringer 16 may be arched in a smooth downward curve to its full length to form a shape from the bottom curvature of the nozzle 18 to the tail 20. The stringer 16 may first be formed with an approximately upward curve. from center to end, and a relatively thicker structure in half of spar 18 of spar 16 relative to shank 20. Half of shank 20 of spar 16 is approximately straight at this stage of manufacture. The stringer 16 may then be further bent downward by pressing 25 into a shape of a stringer curve to produce a smooth downward curve approximately at half its length from the tail 20 to complete the shape of the overall bottom curvature. The relatively thinner end of the tail 20 folds into the curved shape compared to the tip end 18. Thus, a tail 20 with a curved shape of the concave top 22 and convex base 23 longitudinally is created. What's more, the stringer

16 thus becomes in a condition of tension or predisposition with energy and tends to return to its original straight form. Thus, any force tending the end of the curved upward tail 20 must act against this elastic force, thus providing a great resistance to bending in an upward direction and a great force to return to the original shape. Unique to the present invention is the extra tensile force provided by the foam core that acts to restore the surfboard to its original shape.

The upper cover layer 24 and the lower cover layer

The cover 26, described in more detail above, are joined to cover the foam core elements 12 and 14 and the spar 16 to form the surfboard film 28. The film 28 includes two components, a laminated resin with loads. optionally added and a fabric as described above.

Epoxy-reinforced metal or fiber-reinforced wooden-framed keel 30 may be attached to base 23 near tail 20.

The use of the present foam core elements 12 and 14 provides a flexible reinforced construction with respect to the nozzle 18 and the tail 20 20 on this part of the surfboard 10. This, in combination with the spar 16, allows flexing in the middle section of the surfboard. surfboard 10 which is twisted around the spar 16. In addition, the density of the foam core elements 12 and 14 may be higher at the ends of the nozzle 18 and the tail 20 and lower in the areas between them to further allow flexing in the end. middle section of the surfboard 10. Put differently, the more the foam core elements 12 and 14 allow the nozzle 18 and tail 20 parts to twist around the stringer 16 when under pressure, or bending force. When folding, when used in water surfing while the nozzle 18 and tail 20 parts tend to remain rigid, the greater the resulting bounce force will be. Optionally, in order to construct differences in bending in the surfboard 10, the upper cover layer 24 and the lower cover layer 26 may vary in stiffness, varying their respective thickness and / or composition. As a non-limiting example, the nozzle area 18 may be relatively rigid, the area of the tail 20 may be relatively rigid, and the area between them may be relatively flexible.

This design allows for additional surfing or gliding speed due to resilient and torsional action, or quick flexible memory of tail 20 in water. This feature provides stability and ease of turn due to the flexibility and relative shape between the flexible area and the relatively rigid ends of the surfboard nozzle 18 and tail 20.

The embodiments shown in Figure 4 utilize foam core elements 12 and 14 either molded directly into their final shape or molded into nearly the final shape cut in half. As described above, directly shaping the foam core into its final form allows a film to form on the core elements that is not damaged by the lamination resin. Figure 5 shows an embodiment of the invention where the foam core elements have been molded and then cut to their final shape. In this embodiment, the outer surfaces of the 20 foam core elements 12 and 14 and optionally spar 16 are coated with sealer 32 before the upper cover layer 24 and lower cover layer 26 are affixed to the foam core elements 12 and 14. 14 and the stringer 16.

One embodiment of the sports boards according to the invention is a surfboard shown in figures 6-9. The surfboard 110 has a foam core 112 as described above and a parabolic stringer 116 attached to the outer circumference of the foam core 112. The parabolic stringer 116 may be made of wood, carbon / graphite reinforced material, composite material or metal. In embodiments of the invention, the parabolic stringer 116 may be made of two elements which are constructed such that the ends of each element accept and / or attach to each other. As a non-limiting example, at nozzle 118 and tail 120, the ends of each parabolic stringer member 116 may be attached to each other.

During manufacture, the parabolic stringer 116, or its individual elements, may be arched in a smooth downward curve along its entire length to form a shape from the bottom curvature of the nozzle 118 to the tail 120. The parabolic stringer 116 may first be formed with an upward curve approximately from the center to the ends, and a relatively thicker structure in the beak 118 at half of the parabolic stringer 116 relative to the tail 120. The tail 120, half of the parabolic stringer 116, or its elements is approximately straight at this stage of manufacture. The parabolic stringer 116, or elements thereof, may then be further bent downward under pressure in the form of the stringer curvature to produce a smooth downward curve approximately at half its length from the tail 120 to complete the shape of the stringer curvature. General background. The end of the tail 120 being relatively thinner, bends into the curved shape compared to the end of the nozzle 118.

Thus, a tail 120 is created with a curved shape of the concave top 122 and longitudinally convex base 123. Moreover, the parabolic stringer 116 is thus in a condition of tension or predisposition with energy and tends to return to its original straight form. Thus, any force that tends to bend the end of the tail 120 upward must act against this elastic force, thus providing a great resistance to bending in an upward direction and a great force to return to the original shape. Unique to the present invention is the added tensile strength provided by the foam core 112 which acts to restore the surfboard to its original shape.

Upper cover layer 124 and lower cover layer 126, as described in more detail above, are joined to cover foam 112 and parabolic stringer 116 to form surfboard film 128 of 128. Film 128 includes two components, a laminating resin with optionally added fillers and a fabric as described above.

Wood-molded metal or fiber-reinforced epoxy frame fins 130 may be attached to base 123 near tail 120.

In embodiments of the invention, the cross section of the parabolic stringer 116 or its members may have an inner surface 114 which is concave as shown in Figure 9, or approximately perpendicular to the top 122 and base 123, or straight as shown in the figure. 10

Use of the present foam core 112 provides a

Flexible reinforced construction with respect to nozzle 118 and tail 120 on the surfboard part 110. This, in combination with the parabolic spar 116, prevents flexing in the middle section of the surfboard 110, which is torsional around the parabolic spar 116 Additionally, the density of foam core 20 may be higher at the ends of nozzle 118 and tail 120 and lower in the areas therebetween, to further provide bending in the middle section of the surfboard 110. Put another way, the more foam core 112 allows nozzle 118 and tail portion 120 to rotate relative to parabolic stringer 116 when under pressure or bending force 25 when used for surfing in water while nozzle 118 and tail member 120 tend to remain rigid, the greater will be the resulting tensile force of return. Optionally, in order to construct differences in bending of the surfboard 110, the upper cover layer 124 and the lower cover layer 126 may vary in stiffness, varying their respective thickness and / or composition. As a non-limiting example, the nozzle area 118 may be relatively rigid, the area of the tail 120 may be relatively rigid, and the area between them may be relatively flexible.

This design allows for additional surfing or gliding speed 5 due to the take-back and twisting action, or quick flexible memory of the tail 120 in the water. This feature provides stability and ease of turn due to the relative flexibility and shape between the flexible area and the relatively rigid ends of the surfboard nozzle 118 and tail 120. The present foam core and design allow surfers to use 10 boards. according to the invention cross even the most twisted waves.

The embodiments shown in Figure 9 utilize foam core 112 molded directly into its final shape or molded close to the final shape and parabolic stringer 116 either attached to it or placed 15 in a mold while foam core 112 is being molded. As previously described, directly molding the foam core 112 into its final form allows a film to form on the foam core that is not damaged by the lamination resin. Figure 10 shows an embodiment of the invention where the foam core has been molded and then cut into its final shape. In this embodiment, the outer surfaces of the foam core 112 and optionally the stringer 116 are covered with sealer 132 before the upper cover layer 124 and lower cover layer 126 are attached to the foam core 112 and stringer 116.

In embodiments of the present invention, surfboards

The foregoing described include an elongate, water-resistant or impermeable foam core containing an interpenetrating web of one or more polyolefins and one or more vinyl aromatic monomer polymers having an upper surface and a lower surface; an upper layer covering at least a portion of the upper surface; and a lower layer covering at least a portion of the lower surface, wherein the foam core is made of a foam material having a water absorption (measured according to ASTM C-272) of less than 2 percent by volume in 5 a density of 1.5 to 2.5 lb / ft3 (0.024 to 0.04 g / cm3).

Surfboards according to the invention may be provided in any suitable length, such as large wave boards (9 feet or more), long board (8-10 feet long) or short board (less than 8 feet) of lenght. In the surf, the 10 present surfboards give a surfer the ability to pull off and launch at the epicenter of the most overwhelming or powerful wave in a quasimoto or any other position and ride the board or perform cutting, chaining maneuvers, going to the crest. the wave and back, go to the crest of the wave and follow, exit the wave and / or re-enter the wave easily. Most importantly, while using the present surfboards, a surfer boy or boy may catch a wave, get caught in the tunnel while shouting “banzai”, “cowabunga” or other appropriate explosives while enjoying a surf totally excellent twisted.

Figure 11 shows a chest surfboard 210 configured to support a water surfer having an overall elongate shape defining a longitudinal axis A, a nozzle end 212, and a tail end 214. An elongated foam core 216, as described above, provides the main mass of the breast surfboard 210, and the foam core 216 is surrounded by an upper layer 218 and a lower layer 220, as well as side layers 222 and 226 all attached to the core. 216 as described above.

Upper layer 218, lower layer 220 and side layers 222 and 226, as more fully described above, are bonded to cover foam core 216 and to form film 228 of breast surfboard 210. Film 228 includes two components. , a laminating resin with optionally added fillers and a fabric as described above.

Use of the present foam core 216 provides a flexible reinforced construction with respect to nozzle 212 and tail 214 on the part of breast surfboard 210. This, in combination with upper layer 218, lower layer 220 and side layers 222 and 226 provides flexion in the middle section of the breast surfboard 210 which is torsional about the longitudinal axis A. In addition, the density of the foam core 216 is higher at the ends of the nozzle 212 and the tail 214 and lower in the areas between they further provide flexion in the middle section of the breast surfboard 210. In other words, the more the foam core 216 allows the nozzle 212 and tail 214 parts to rotate relative to the longitudinal axis A when under pressure. , or bending force when used in water wave surfing while the nozzle 212 and tail 214 parts tend to remain rigid, the greater the resulting return force. Optionally, in order to construct differences in flexion in the breast surfboard 210, upper layer 218, lower layer 220 and side layers 222 and 226 may vary in stiffness, varying their respective thickness and / or composition. As a non-limiting example, the nozzle area 212 may be relatively rigid, the area of the tail 214 may be relatively rigid and the side layers 222 and 226 may be relatively flexible.

This design provides additional gliding speed due to the elastic and torsional action, or the fast flexible memory of tail 214 in the water. This feature provides stability and ease of rotation. The present foam core and design allows surfers using surfboards according to the invention to cross even the most twisted waves.

The embodiments shown in Figure 13 utilize foam core 216 molded directly into its final form or molded near the final form. As described above, directly shaping the foam core 216 into its final form allows a film to form on the foam core that is not damaged by the lamination resin. Figure 14 shows an embodiment of the invention where the foam core has been molded and then cut into its final shape. In this embodiment, the outer surfaces of the foam core 216 are covered with sealing coating 230 before the upper layer 218, lower layer 220 and side layers 222 and 226 are attached to the foam core 216.

Chest surfboards according to the present invention are not distorted by bending and twisting tension and readily allow successful completion of the maneuvers responding to the surfer's command. External forces do not tend to distort this chest surfboard, making it easier for a surfer to redirect the board. Thus proper and properly placed stiffness is provided in the present chest surfboard. Additionally, sufficient bending is also provided in the present chest surfboard, allowing the surfer to pull the nozzle upwards, distorting it above the plane of the main non-slip chest surfboard platform to prevent the nozzle and front corner. fall on the water surface in a dynamic situation where the nozzle is forced down. Thus, the flexibility for “powerful turns” and resistance in the middle and speed spindle sections can be readily provided on the present chest surfboard.

Figure 15 shows water skiing 310 configured to support a surfer in a standing position while being towed by a motorized watercraft having a generally elongated shape along a longitudinal axis A, a beak end 312, and an end. 314. An elongated foam core 316, as described above, provides the main water skiing mass 310, and foam core 316 is surrounded by an upper layer 318 and a lower layer 320, as well as side layers 322 and 326. all attached to core 316 as described above.

Upper layer 318, lower layer 320 and side layers 322 and 326, as described in more detail above, are connected to cover foam core 316 and to form water ski film 328. Film 328 includes two components. , a laminating resin with optionally added fillers and a fabric as described above.

Front foot socket 332 and rear foot socket 334 10 may be attached to the top 321 approximately midway between the end of the nozzle 312 and the end of the tail 314, or adjusted as desired. When two water skis 310 are used by a surfer, each ski has front foot socket 332 and rear foot socket 334, and the skier may insert one foot into each of them and ski conventionally. 15 When zigzagging is desired, the second foot support 336 may be attached to the top 321 between the rear foot socket 334 and the tail 314. Front foot socket 332, rear foot socket 334 and second foot holder 336 They may be constructed of a generally elastomeric material and attached to the top 321 as known in the art.

Wooden frame or epoxy frame keel

reinforced fiber 333 may be attached to base 323 next to tail 120.

Use of the present foam core 316 provides a flexible reinforced construction with respect to nozzle 312 and tail 314 in part 25 of water skiing 310. This, in combination with upper layer 318, lower layer 320 and side layers 322 and 326, provides flexion in the middle section of water ski 310 which is twisting around the longitudinal axis A. In addition, the density of foam core 316 may be higher at the ends of nozzle 312 and tail 314 and lower in the areas between them to further provide flexion. otherwise, the more the foam core 316 allows the nozzle parts 312 and the tail 314 to tend to rotate relative to the longitudinal axis A at bending pressure or force when used in skiing. while the 5 parts of nozzle 312 and tail 314 tend to remain rigid, the greater the resulting return force. Optionally, in order to construct differences in bending in water skiing 310, upper layer 318, lower layer 320 and side layers 322 and 326 may vary in stiffness, varying their respective thickness and / or composition. As a non-limiting example, the nozzle area 10 312 may be relatively rigid, the tail area 314 may be relatively rigid and side layers 322 and 326 may be relatively flexible.

This design provides additional gliding speed due to elastic and torsional action, or fast flexible memory of the 314 in water. This feature provides stability and ease of rotation.

The embodiments shown in Figure 17 utilize the core of

foam 316 molded directly into its final shape, or molded close to the final shape. As described above, directly shaping the foam core 316 into its final form allows a film to form on the foam core that is not damaged by the lamination resin. Figure 18 shows an embodiment of the invention where the foam core has been molded and then cut to its final shape. In this embodiment, the outer surfaces of the foam core 316 are covered with sealing coating 330 before the upper layer 318, lower layer 320 and side layers 322 and 326 being affixed to the foam core 316.

Figures 19 and 20 show the snowboard assembly

410 including snow board 412 to which a pair of links 414 is mounted to the top side 416 of snow board 412. Links 414 may be conventionally mounted to a center portion of snow board 412. Figure 21 is a cross section through the snow board 412 of figures 19 and 20. The snow board 412 includes the foam core 418 completely surrounded by a film 420 including the upper layer 422, lower layer 424 and side layers 426 and 428. A 5 Film 420 of the shape described in more detail above is bonded to cover foam core 418 and includes two components, a laminating resin with optionally added fillers and a fabric of the shape described above.

The density of the foam core 418 may vary along the length of the snow board 412. As an example, the density of the foam core 412 may be lower at the tip portion 430 and the tail portion 432 compared to the middle portion 436. .

The currently constructed snowboard assembly 410 has a moment of inertia, also called pivot weight, which is reduced while maintaining a desired shear strength and compressive strength of the snowboard. The lower articulation weight makes snowboards easier to perform many maneuvers, especially turns.

In embodiments of the invention, the shear strength and crush strength (compression) of the foam core 418 between the top surface 416 and the bottom surface 417 are sufficiently high to provide the desired pivot weight. In embodiments of the invention, the density of foam core 418 is no more than about 33% of the density of foam core 418 in middle part 436.

Use of the present 418 foam core provides a

Flexible reinforced construction with respect to the tip portion 430 and the tail portion 432 on the snowboard portion 412. This, in combination with the upper layer 422, lower layer 424 and side layers 426 and 428, can provide bending in the middle section. of the snow plank 412 which can be torsional about the longitudinal axis A. As a non-limiting example, the more the foam core 418 allows the tip portion 430 and the tail portion 432 to tend to rotate relative to the longitudinal axis. The pressure or bending force when used on the snowboard, although the tip portion 430 and the tail portion 432 tend to remain rigid, the greater the resulting return force. Optionally, in order to construct differences in bending in the snowboard 412, upper layer 422, lower layer 424 and side layers 426 and 428 may vary in hardness by varying their respective thickness and / or composition.

This design provides stability and ease of rotation.

The embodiments shown in Fig. 21 utilize foam core 418 molded directly into its final shape, or molded near the final shape. As previously described, directly shaping foam core 418 into its final form allows a film to form on foam core 15 that is not damaged by lamination resin. Figure 22 shows an embodiment of the invention where foam core 418 has been molded and then cut to its final shape. In this embodiment, the outer surfaces of foam core 418 are covered with sealing liner 440 before upper layer 422, lower layer 424 and side layers 426 and 428 are affixed to foam core 418.

Figures 23 and 24 show snow skiing 500 according to the invention having a front part 510, an intermediate part 508 and a rear part 512. The ski is provided with a connection including a first part 514 which is intended for coercing with the toe portion of a ski boot 25 and a second portion 516 for coercing with the heel of the boot.

Figure 25 is a cross-section through the snow ski 500 of figures 23 and 24. Snow ski 500 includes the foam core 520 completely surrounded by a film 522 including the top layer 523, the bottom layer 524 and the side layers. 526 and 528. Film 522, as described in more detail above, is bonded to cover foam core 520 and includes two components, an optionally added filler laminating resin and a fabric as described above.

The density of foam core 520 may vary over the length of snow skiing 500. As an example, the density of foam core 520 may be lower at front 510 and rear 512 compared to intermediate 508.

Use of the present foam core 520 provides a

flexible reinforced construction with respect to the front 510 and the back 512 on the snow ski part 500. This, in combination with the top layer 523, bottom layer 524 and side layers 526 and 528 can provide bending at the intermediate part of the As a non-limiting example, the more foam core 520 allows the front 510 and the rear 512 to deflect under pressure or bending force when used in the snow ski 500 while the front 510 and back 512 tend to remain rigid, the greater the resulting return force. Optionally, in order to construct bending differences in snow skiing 500, the upper layer 523, lower layer 524 and side layers 526 and 528 may vary in stiffness, their thickness and / or composition varying.

This design provides stability and ease of rotation.

The embodiments shown in Figure 25 utilize foam core 520 molded directly into its final shape or molded near the final shape. As described above, directly shaping foam core 520 into its final form allows a film to form on the foam core that is not damaged by lamination resin. Figure 26 shows an embodiment of the invention where foam core 520 has been molded and then cut to its final shape. In this embodiment, the outer surfaces of foam core 520 are covered with sealing coating 540 before upper layer 523, lower layer 524 and side layers 526 and 528 are attached to foam core 520.

Figures 27-30 generally describe a device for

sliding or sledding according to the present invention. Sled 600 typically includes elongate member 602, configured to slide on any sufficiently slippery surface, such as snow, ice, grass, metal, or water on a slippery water surface. 10 The surface is often covered with snow or ice and has a downward slope.

As shown in Figures 27-29, elongate member 602 includes a substantially straight or planar body part 604, and a front end portion 606. In use, a surfer sits or kneels on body part 604. The body 604 may include one or more grip handles 608, posterior to the front end portion 606 and anterior to the rear edge 610. Front end portion 606 has an inner end that is positioned to connect or continuous with the front end of the front end. The front end portion 606 typically extends outwardly from the upwardly shaped body portion 604 to prevent digging in the sliding surface as the sled 600 moves forward.

The rear edge 610 may be straight, may have a convex curve, or may have two or more convex curves known in the art as bat wings.

Figure 30 is a cross section of sled 600 on elongate member 602. Sled 600 includes foam core 620 completely surrounded by a film 622 including top layer 623, bottom layer 624 and side layers 626 and 628. The shape described in more detail above is bonded to cover the foam core 620 and includes two components, a laminate resin with optionally added fillers and a fabric as described above.

The density of the foam core 620 may vary over the length of the sled 600. As an example, the density of the foam core 620 may be lower at the front end portion 606 compared to the body portion 604.

Use of the present foam core 620 provides a flexible reinforced construction with respect to front end portion 10 606 and body portion 604 on sled portion 600. This, in combination with upper layer 623, lower layer 624 and side layers 626 and 628, may provide bending on sled 600. As a non-limiting example, the more foam core 620 allows front end portion 606 to deviate in bending pressure or force when used on sled 600, although 15 the body part 604 remains rigid, the greater the resulting return force. Optionally, in order to construct differences in bending in sled 600, the upper layer 623, lower layer 624 and side layers 626 and 628 may vary in stiffness, varying their respective thickness and / or composition.

This design provides stability and ease of rotation.

In Figure 25, foam core 620 may be molded directly into its final form, or molded near the final form. As described above, directly shaping the foam core 620 into its final form allows a film to form on the foam core that is not damaged by the lamination resin. In one embodiment of the invention, the foam core 620 may be molded and then cut to its final shape. In this embodiment, the outer surfaces of foam core 620 are covered with sealing liner 640 before upper layer 623, lower layer 624 and side layers 626 and 628 are attached to foam core 620.

One or more hand grips or handles 608 may be attached to the sled 600 for a surfer to catch during use. Often the sled 600 has a pair of handles 608 on opposite sides of the sled 600.

As described above, a blank or

Foam core element including the expanded and molded expandable polymer matrix described above is a key component in the sports boards of the present invention. In various embodiments of the invention, the blank or foam core element may be particularly used to prepare surfboards.

Figures 31 and 32 show particular non-limiting embodiments of surfboard foam core or member according to the invention. The blank 700 includes front end 702, rear end 704, bottom curvature portion 706, and stringer 708 extending from front end 702 to rear end 704.

Front end 702 is generally straight, perpendicular and centered around spar 708. Depending on intended use and desired performance characteristics, front end 702 may have a width 710 of at least about 2 "(50.8 mm), in some cases at least about 2.5 "(63.5 mm), and in other cases at least about 3 inches (76.2 mm) and may be up to about 6" (152.4 mm) ), in some cases up to about 5 "(127.0 mm) and in other cases up to about 4 inches (101.6 mm). Width 710 can be any value or range between any of the 25 values cited above.

Rear end 704 is generally straight, perpendicular, and centered around spar 708. Depending on intended use and desired performance characteristics, rear end 704 may have a width 712 of at least about 3 "(76.2 mm). ), in some cases at least about 4 "(101.6 mm), and in other cases at least about 5 inches (127.0 mm) and may be up to about 12" (304.8 mm), in some cases up to about 10 "(254.0 mm) and in other cases up to about 9 inches (228.6 mm). Width 712 can be any value or range between any of the aforementioned values.

Depending on intended use and desired performance characteristics, blank 700 may have a length 714 measured from front end 710 to rear end 712 of at least about 4 feet (1.2 m), in some cases at least about 5 feet (1.5 m) and in other cases at least about 6 feet (1.8 m) and can be up to 10 feet (3.0 m), in some cases up to 9 (2, 7 m) and in other cases up to about 8 feet (2.4 m). The length 714 can be any value or range between any of the values cited above.

The bottom curvature portion 706 of the blank 700 is generally upwardly curved from a lower surface of the blank 700. The bottom curvature portion 706 constitutes the portion of the blank 700 near the front end 702 and may be characterized in terms of the upwardly curved length portion 714 to form the bottom curvature portion 706. The size of the bottom curvature portion 708 will vary depending upon the intended use and desired performance characteristics of the surfboards made. 700. Typically, the bottom curvature portion 706 may include at least the 10% length difference 714, in some cases at least the 15% length difference 714, and in other cases at least the 10% length difference. 25% length 714 and may be up to 50% length 714, in some cases up to 40% length 714, and in other cases up to 30% length 714 Part of the bottom curvature 706 of the blank 700 may be any value or range between any of the aforementioned values. The bottom curvature portion 706 of blank 700 may be characterized by the amount that the upward curve moves away from the bottom surface of blank 700 (deflection 718). Deflection 718 represents the vertical distance from the bottom surface plane of the blank 700 to the front end 702. The length of the deflection 718 at the bottom curvature portion 708 will vary depending upon the intended use and desired performance characteristics of the surfboards. made of blank 700. The deflection 718 may be at least about 3 inches (76.2 mm), in some cases at least about 4 inches (101.6 mm) and in other cases at least about 4 inches. Inches (114.3 mm) and can be up to about 10 inches (254.0 mm), in some cases at least about 8 inches (203.2 mm), and in other cases at least about 6 inches (152.4 mm). The length of the deflection 718 may be any value or range between any of the aforementioned values.

The stringer 708 extends from the rear end 704 to the

front end 702 of blank 700 and is positioned between first part 720 and second part 722 of blank 700. Stringer 708 generally corresponds to the shape and curvature of blank 700 and in particular to the curvature portion background 706.

In many aspects of this modality, first part 720 and

second part 722 are approximately equivalent in size, shape, weight and dimension. As indicated above, the stringer 708 may be made of wood, carbon / graphite reinforced material, composite material, metal and / or combinations of such materials. Stringer 708 may be incorporated into blank 700 by cutting a molded blank of the two-part expanded polymer die, first part 720 and second part 722, and subsequently using a suitable adhesive to attach first part 720 and second part 722 on opposite sides of the stringer 708. Alternatively, the expansion holes may be placed on the stringer 718 and then placed in a mold to mold the blank 700 as described above. During the molding / microsphere process, the expandable polymer matrix pre-expandable expands and melts, in particular, expanding through the expansion holes to provide a one-piece blank 5 of first part 720, spar 708 and second part 722.

The width and composition of the 708 spar are selected to provide desirable combinations of stiffness, response and flexibility. As such, the width of the spar 708, measured as the distance between the first part 720 and the second part 722, may be at least about 0.1 inch (2.54 mm), in some cases at least about 0. .2 inch (50.8 mm) and in other cases at least about 0.25 inch (6.35 mm) and may be up to about 2 inches (50.8 mm), in some cases up to about 1, 5 inches (38.1 mm) and in other cases up to about 1 inch (25.4 mm). The width of the stringer 708 may be any value or range between any of the aforementioned values.

Figures 33 and 34 show particular non-limiting additional blanks or foam core embodiments for surfboards according to the invention.

Bulk 750 includes front end 752,

rear end 754, part of bottom curvature 756, and stringer 758 extending from front end 752 to rear end 754.

Front end 752 is generally straight, perpendicular and centered around spar 758 and bends to sides of blank 25 750. Depending on intended use and desired performance characteristics, front end 752 may have a width of 760 at least about 1 "(25.4 mm), in some cases at least about 1.5" (38.1 mm), and in other cases at least about 2 inches (50.8 mm) and may be up to about 5 "(127.0 mm), in some cases up to about 4.5" (114.3 mm) and in other cases up to about 4 inches (101.6 mm). Width 760 can be any value or range between any of the values cited above.

The rear end 754 is generally straight, perpendicular and centered around the spar 758 and bends to the sides of the blank 750. Depending on the intended use and desired performance characteristics, the rear end 754 may be 762 wide. at least about 4 "(101.6 mm), in some cases at least about 5" (127.0 mm), and in other cases at least about 6 inches (152.4 mm) and may be up to 10 about 14 "(355.6 mm), in some cases up to about 12" (304.8 mm) and in other cases up to about 11 inches (279.4 mm). Width 762 can be any value or range between any of the values cited above.

Depending on the intended use and desired performance characteristics, the blank 750 may have a length 764 from the front end 752 to the rear end 754 of at least about 4 "(101.6 mm), in some cases by about 5 "(127.0 mm), and in other cases at least about 6 feet (1.8 m) and can be up to 10 (3.0 m), in some cases up to about 9 (2, 7 m) and in other cases up to about 8 feet (2.4 m). The length 764 may be any value or range 20 between any of the values cited above.

The end bend portion 756 of blank 750 generally curves upwardly from a lower surface of the blank 750. The bottom bend portion 756 forms the portion of blank 750 near the front end 752 and may be characterized in terms of which the length portion 764 curves upward to form the bottom curvature portion 756. The size of the bottom curvature portion 758 will vary depending upon the intended use and desired performance characteristics of the piece surfboards. 750. Typically, the bottom curvature portion 756 may include at least the 10% difference in length 764, in some cases at least the 12.5% difference in length 764, and in other cases at least 10%. 15% difference in length 764 and may be up to 40% difference in length 764, in some cases up to 30% difference in length 764, and in other cases 5 up to 25% difference in length 764. The bottom curvature portion 756 of blank 750 may be any value or range between any of the values cited above.

The bottom curvature portion 756 of blank 750 may be characterized by the amount of upward curve exiting the lower surface of blank 750 (offset 768). The offset 768 represents the vertical distance from the bottom surface plane of the blank 750 to the front end 752. The length of the offset 768 at the bottom curvature portion 758 will vary depending on the intended use and desired performance characteristics of the surfboards made. 750. The offset 768 may be at least about 2 inches (50.8 mm), in some cases at least about 2.5 inches (63.5 mm) and in other cases at least about 3 inches. inches (76.2 mm) and can be up to about 8 inches (203.2 mm), in some cases at least about 7 inches (177.8 mm), and in other cases at least about 6 inches (152.2 mm). , 4 mm). The deviation length 768 may be any value or range between any of the values cited above.

The stringer 758 extends from the rear end 754 to the front end 752 of blank 750 and is positioned between first part 770 and second part 772 of blank 750. Generally 757 corresponds to the shape and curvature of the blank. 750 and in particular apart from the bottom curvature 756.

In many aspects of this embodiment, first part 770 and second part 772 are approximately equivalent in size, shape, weight and dimension. The stringer 758 may be made of materials as described above, dimensionally similar and incorporated into blank 750 using the methods described with respect to blank 700.

Figures 35 and 36 show particular non-limiting additional embodiments of the surfboard foam core or member according to the invention. The blank 800 includes front end 802, rear end 804, bottom curvature portion 806, and stringer 808 extending from front end 802 to rear end 804.

Front end 802 is generally straight, perpendicular and

centered around the stringer 808 and bends to the sides of the blank 800. Depending on the intended use and desired performance characteristics, the front end 802 may have a width 810 of at least about 3, in some cases at least about 4 "(101.6 mm), and in 15 other cases at least about 5 inches (127.0 mm) and can be up to about 10 (254.0 mm), in some cases up to about 9 ( 228.6 mm) and in other cases up to about 8 inches (203.2 mm) .The width 810 can be any value or range between any of the aforementioned values.

The rear end 804 is generally straight, perpendicular and centered around the stringer 808 and bends to the sides of the blank 800. Depending on the intended use and desired performance characteristics, the rear end 804 may be 812 in width. of at least about 4 "(101.6 mm), in some cases at least about 6 (152.4 mm), and in other cases at least about 8 inches (203.2 mm) and may be up to 25". about 20 (508.0 mm), in some cases up to about 18 (457.2 mm) and in others up to about 16 inches (406.4 mm) .The width 812 can be any value or range between any one of the values mentioned above.

Depending on intended use and desired performance characteristics, blank 800 may have a length 814 measured from front end 802 to rear end 804 of at least about 4 "(101.6 mm), in some cases at least about 5 "(127.0 mm), and in other cases at least about 6 feet (1.8 m) and can be up to 10 (3.0 m), in some cases up to 9 (2.7 m) ) and in other cases up to about 8 feet (2.4 m). The length 814 can be any value or range between any of the values cited above.

The bottom curvature portion 806 of blank 800 generally curves upwardly from a lower surface of blank 800. The bottom curvature portion 806 constitutes the portion of blank 800 10 near the front end 802 and may be characterized in that the length portion 814 curves upwardly to form the bottom curvature portion 806. The size of the bottom curvature portion 808 will vary depending upon the intended use and desired performance characteristics of the part surfboards. 800. Typically, the portion of bottom curvature 806 may include at least the 10% difference in length 814, in some cases at least the 12.5% difference in length 814, and in other cases at least the difference of 15% in length 814 and may be up to 40% in length 814, in some cases up to 30% in length 814, and in other cases 20 up to 25% in length 8 14. The bottom curvature portion 806 of blank 800 may be any value or range between any of the values cited above.

The bottom curvature portion 806 of blank 800 may be characterized by the amount of upward curve exiting lower surface 25 of blank 800 (offset 818). The offset 818 represents the vertical distance from the bottom surface plane of the blank 800 to the front end 802. The length of the offset 818 at the bottom curvature portion 808 will vary depending on the intended use and desired performance characteristics of the surfboards made. 800. The offset 818 may be at least about 2 inches (50.8 mm), in some cases at least about 2.5 inches (63.5 mm) and in other cases at least about 3 inches. (76.2 mm) and may be up to about 9 inches (228.6 mm), in some cases at least about 8 inches (203.2 mm), and 5 in other cases at least about 7 inches ( 177.8 mm). The deviation length 818 can be any value or range between any of the values cited above.

The stringer 808 extends from the rear end 804 to the front end 802 of blank 800 and is positioned between first part 820 and second part 822 of blank 800. Generally 808 corresponds to the shape and curvature of the blank. 800 and in particular apart from the bottom curvature 806.

In many aspects of this embodiment, first part 820 and second part 822 are approximately equivalent in size, shape, weight and dimension.

The stringer 808 may be made of materials as described above, be dimensionally similar and incorporated into blank 800 using the methods described with respect to blank 700.

In embodiments of the invention, surfboards made according to the invention using the cores or blanks described in Figures 31-36 may be deflected using the Emerson 8510 Compression Testing Equipment as described 0.75 inch (1.9 inches). cm), in some cases 0.79 inch (2 cm) and in particular examples 0.83 inch (2.1 cm) without demonstrating a deflection in the stress-strain curve. Additionally, the present surfboards do not cease to function when deflected 0.87 inch (2.2 cm), in some cases 0.91 inch (2.3 cm) and in particular examples 0.94 inch (2.4 cm). cm). After such deflections, the present surfboards are able to resume their original form. The particular properties of a particular board will depend on the composition of the blank or core and the lamination resin used to reflect on the surfboard.

Additionally, even after the failure of the present surfboards using the Emerson 8510 compression tester 5 as described above, the present surfboards are capable of withstanding a load of at least 100 pounds (45.4 kg), in some cases at least 150 pounds (68 kg) and in other cases at least 200 pounds (91 kg). The particular properties of a particular board will depend upon the composition of the blank or core and the laminating resin used to vitrify the surfboard.

Because the sports boards of the present invention are made from the expanded polymeric matrix described above, they are generally lighter than conventional sports boards, but can be handled in the same way by virtue of the physical characteristics of the foam core and sports boards. described above. As such, these sport boards are ideally suited for use in various sporting activities.

Various embodiments and structures have been described herein which should not be limited to one application. Various designs and structures of one type of sports board may be incorporated into other types of sports boards to achieve desired characteristics, as readily apparent to those skilled in the art.

The present invention will further be described by reference to the following examples. The following examples are merely illustrative of the invention and are not intended to be limiting.

EXAMPLES

Example 1

This example demonstrates the superior flexibility of surfboards made in accordance with the invention. Tester

The test was conducted on an Emerson 8510 Compression Test Equipment (Emerson Apparatus Company, Inc., Portland, ME) designed in accordance with the requirements of ASTM D642 and TAPPI T804 equipment specifications 5. The programmable press plate was set at a rate of 0.5 inches (1.27 cm) per minute. The accessory used was a modified design of the general test protocol for alpine skis, a three-point folding test for ASTM 780-93a standard.

Each surfboard was placed on the accessory, which was installed on the Emerson device aligned to the same center point. The base of each surfboard was supported by a 1.5 ”(38.1 mm) diameter freely floating steel rod so as not to apply any friction to the surfboard base as it deflected from the top. The spacing between the sides of the base is 28 inches (71.1 cm) and the spacing selection 15 was determined by observing the rear and front end main compression points typically encountered during surfing.

The upper force accessory exerted a downward force at the center of the surfboard, measured 38 inches (96.5 cm) from the front end of the surfboard. The laminate structure includes a flexible rubber fitting (19 inches (48.3 cm) long x 1.5 inches (3.8 cm wide)) that followed the outline of the surfboard's non-slip platform to apply an equal amount of force in the width of the surfboard.

Sample Description Sample surfboards were similar to those shown

31 and 32, approximately 70 inches (178 cm) long. The blanks for each sample were shaped and cut in half length and a wooden spar attached to each half with an adhesive. The blanks were vitrified using a polyester laminate. All ingredients and construction were identical except for the foam material for the blanks, which were as follows:

Sample 1: 2.5 lb / ft3 (40 kg / m3) polyurethane density Sample 2: 2.5 lb / ft3 (40 kg / m3) resin density

Expanded ARCEL® 730 (NOVA Chemicals Inc., Pittsburgh, PA)

Each surfboard was placed in the test apparatus and the press plate was lowered until a break in the stress-strain curve indicated a failure. Sample 1 indicated a 0.71 inch (1.8 cm) deflection failure and sample 2 a 0.79 inch (2.0 cm) deflection failure.

The performance of foam compression after the structural failure of each surfboard was evident in the formation of a downward slope in the stress-strain curve. The compressive assembly observed in samples 1 was much smaller than in sample 2, in which the foam appeared to store a degree of latent energy during compression.

The data demonstrate the superior flexibility of the surfboard made according to the invention.

Example 2

This example demonstrates the superior flexibility of surfboards made in accordance with the invention. The test apparatus described in example 1 was also used in this example.

Sample Description

The sample surfboards were similar to those shown in Figures 31 and 32, approximately 70 inches (178 cm) long. The blanks for each sample were shaped and cut in half to length and a wooden spar attached to each half with an adhesive. The blanks were vitrified using an epoxy laminate. All ingredients and construction were identical except for the foam material for the blanks, which were as follows: Sample 3: 2.5 lb / ft3 (40 kg / m3) expanded polystyrene density

Sample 4: 2.5 lb / ft3 (40 kg / m3) expanded ARCEL® 730 resin density

Each surfboard was placed in the test apparatus and the press plate was lowered until a break in the stress-strain curve indicated a failure. Sample 3 indicated a 0.71 inch (1.8 cm) failure and sample 4 at 0.85 inch (2.2 cm) deflection. The performance of foam compression after the structural failure of each surfboard was evident in the formation of a downward trend in the stress-strain curve. The compression set observed in samples 3 was much smaller than that of sample 4, in which the foam appeared to store a degree of latent energy during compression. The data demonstrate the superior flexibility of the surfboard made according to the invention.

Example 3

This example demonstrates the effect of the laminate on the flexibility of surfboards made in accordance with the invention. The test apparatus described in example 1 was also used in this example.

The sample surfboards were similar to those shown in Figures 31 and 32, approximately 70 inches (178 cm) long. The blanks for each sample were shaped and cut to half length and a wooden stringer attached to each half with an adhesive. The foam used for the blanks was 2.5 lb / ft3 (40 kg / m3) expanded ARCEL ® 730 expanded resin. All ingredients and construction were identical except for the laminate resin used to glaze the blanks, which were as follows:

Sample 5: Glazed blank using a laminate of

epoxy

Sample 6: Glazed blank using a polyester laminate

Each surfboard was placed on the test apparatus and the press plate was lowered at a rate of 0.5 inches (1.27 cm) per minute for a 1 inch (2.54 cm) deflection. Deflection and load where a break in the stress-strain curve was observed as a point of deflection. The deflection point for sample 5 was 0.85 inch (2.2 cm) at a load of 886 lb (402 kg) and for sample 6 was 0.79 inch (2.0 cm) at a load of 728 Ib (330 kg) ·

The previous test was repeated on the same boards except that the press plate was lowered at a rate of 0.5 inch (1.27 cm) per minute to a 1.5 inch (3.8 cm) deflection. Deflection and load where a break in the stress-strain curve was again observed as a point of deflection. The deflection point for sample 5 was 0.99 inch (2.5 cm) at a load of 687 Ib (312 kg) and for sample 6 was 0.95 inch (2.4 cm) at a load of 15 lbs. 525 Ib (238 kg). Although both surfboards had a deflection point, complete failure was not observed and the foam blank of each surfboard continued to withstand a deflection load of 1.5 inches (510 cm), 510 Ib. (231 kg) for sample 5 and 490 Ib (222 kg) for sample 6.

A test comparable to the sample 1 polyurethane surfboard demonstrated complete failure and no 1.2 inch (3 cm) deflection load support. A test comparable to the expanded polystyrene surfboard of sample 3 demonstrated complete failure and no load support at the 1.35 inch (3.4 cm) deflection.

A 2 inch (5 cm) diameter plug with a round top 25 is designed and fixed to a rigid base to support the plug. This accessory has been attached with clamps to the upper movable press plate of the Emerson compression testing equipment. The test fixture faceplate was driven down at a rate of 0.5 inch (1.27 cm) per minute. The base of each surfboard was fixed to a solid steel table below the movable press plate. Sample 4 film (epoxy laminate) provided a more durable shell demonstrating a peak load at 430 pounds (190 kg) with a peak deflection at 0.0456 inch (0.12 cm). Sample 5 demonstrated a peak load of 245 pounds (111 kg) at a break deflection of 0.315 inches (0.8 cm).

The data demonstrate the toughness and durability properties of surfboards made in accordance with the present invention and also highlight the best safety characteristics of such a board, since a degree of safety integrity is maintained even under conditions where Prior art surfboards fail catastrophically.

The present invention has been described with reference to specific details of particular embodiments thereof. Such details are not intended to be related to limitations on the scope of the invention except to the extent and to the extent that they are included in the appended claims.

Claims (26)

1. Sports board, characterized in that it comprises: (a) an elongated, water-resistant thermoplastic foam core having an upper surface and a lower surface; (b) an upper layer covering at least a portion of the upper surface; and (c) a lower layer covering at least a portion of the lower surface; wherein the foam core is made of a foam material having a water absorption (measured according to ASTM C-272) of less than 2 percent by volume. Sports board according to claim 1, characterized in that the foam core comprises an expandable polymeric matrix comprising interpolymers of a polyolefin and in situ polymerized aromatic vinyl monomers, rubber modified polystyrene, polystyrene modified rubber, oxide polyphenylene, mixtures of polyolefins and at least one other polymer, and combinations and mixtures thereof. Sports board according to claim 1, characterized in that the foam core comprises an interpenetrating network of one or more polyolefins and one or more vinyl aromatic monomer polymers. Sports board according to claim 1, characterized in that the foam core comprises a molded part with a film formed of at least a part of an outer surface of the molded part. Sports board according to claim 1, characterized in that a sealant is applied to at least a portion of an outer surface of the foam core. Sports board according to claim 5, characterized in that the sealant is selected from the group consisting of ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, ethylene-acrylic acid copolymers, styrene-butadiene polymers, polymers styrene-isoprene; styrene-butadiene-styrene block polymers; styrene-isoprene-styrene block polymers; and hydrogenated resins thereof and combinations thereof. Sports board according to claim 1, characterized in that the foam core has a flexural strength at 5% deformation, measured according to ASTM C-203, of at least 60 psi (0.41 MPa ) at a mold density of about 2.25 lb / ft3 (0.036 g / cm3). Sports board according to claim 1, characterized in that the foam core has a tensile strength (measured according to ASTM D-3575-T) of at least 75 psi (0.52 MPa) on a mold density is about 2.25 lb / ft3 (0.036 g / cm 3). Sports board according to claim 1, characterized in that at least one of the upper and lower layer cover comprises a fabric comprising one or more fibers selected from the group consisting of carbon fibers, graphite fibers, aramid fibers, metal fibers, glass fibers, silicon carbide fibers, polyester fibers, composite fibers, glass fibers and combinations thereof. Sports board according to claim 9, characterized in that the fabric is attached to the upper surface by a laminating resin, which encloses the fabric and forms a bond to the thermoplastic foam core. Sports board according to claim 10, characterized in that the lamination resin is selected from the group consisting of unsaturated polyester resins, saturated polyester resins, epoxy resins, phenol formaldehyde resins, melamine formaldehyde resins, Urea formaldehyde resins, unsaturated polyesteramide resins, vinyl ester resins, polyimide resins, polyamide imide resins, unsaturated (meth) acrylic resins, acrylic urethane resins and combinations thereof. Sports board according to claim 1, characterized in that the cover of the upper cover layer and / or the lower layer comprises one or more polyolefins. Sports board according to claim 1, characterized in that it comprises one or more axial and / or parabolic stringers. Sports board according to claim 1, characterized in that it comprises one or more fins attached to and extending from the underside of the sports board. Sports board according to claim 1, characterized in that it comprises one or more safety devices attached to and extending from the top of the sports board. Sports board according to claim 1, characterized in that it comprises one or more wheels attached to and extending from the underside of the sports board. Sports board according to claim 1, characterized in that the sports board is selected from the group consisting of a surfboard, a breast surfboard, a sailing board, a waveboard, a surfboard. a trailer, a water ski, a snow board, a sled, a toboggan run, a snow ski, a go-kart and a skate board. 18. Sports board, characterized in that it comprises (a) an elongated, water-resistant thermoplastic foam core having an upper surface and a lower surface; (b) one or more axial and / or parabolic stringers; (c) an upper fabric layer covering at least a portion of the upper surface; (d) a lower fabric layer covering at least a portion of the lower surface; and (e) a laminating resin enclosing the upper fabric layer and the lower fabric layer bonded to the thermoplastic foam core; wherein the foam core is made of a foam material having a water absorption (measured according to ASTM C-272) of less than 2 percent by volume. Sports board according to claim 18, characterized in that the sports board is selected from the group consisting of a surfboard, a breast surfboard, a sailing board, a waveboard, a surfboard. a trailer, a water ski, a snow board, a sled, a toboggan run, a snow ski, a go-kart, and a skate board. Sports board according to claim 19, characterized in that the sports board is a surfboard. Sports board according to claim 20, characterized in that the surfboard can be deflected using a 0.75 inch (1.9 cm) Emerson 8510 compression tester without demonstrating a deflection in the stress curve. -deformation. Sports board according to claim 20, characterized in that the surfboard does not fail when deflected to 0.87 inch (2.2 cm). Surfboard, characterized in that it comprises: (a) an elongated, water-resistant foam core comprising an interpenetrating web of one or more polyolefins and one or more vinyl aromatic monomer polymers having an upper surface and a lower surface; (b) an upper layer covering at least a portion of the upper surface; and (c) a lower layer covering at least a portion of the lower surface; wherein the foam core is made of a foam material having a water absorption (measured according to ASTM C-272) of less than 2 percent by volume. Surfboard according to Claim 23, characterized in that the surfboard can be deflected using an Emerson 8510 compression tester at 0.75 inches (1.9 cm) without demonstrating a curve deflection. stress-strain. 25. A surfboard blank comprising: (a) a first elongate, water resistant portion comprising an expandable polymeric matrix having an inner edge, a front end and a rear end; (b) a second elongate, water resistant portion comprising an expandable polymer matrix having an inner edge, a front end and a rear end; (c) a stringer disposed along and between the inner edges of and secured to the first part and the second part; wherein the expandable polymeric matrix comprises one or more resins selected from the group consisting of polyolefin interpolymers and in situ polymerized aromatic vinyl monomers, rubber modified polystyrene, polyolefins, polystyrene modified rubber, polyphenylene oxide, and combinations and mixtures. of the same. Surfboard, characterized in that it comprises the surfboard blank as defined in claim 25, wrapped in one or more layers of the fabric, which are enclosed with a laminating resin attached to the expandable polymer matrix.