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Filled shell devices and methods of manufacturingRelated Patent Categories: Buoys, Rafts, And Aquatic Devices, Water Skimming Or Walking DeviceFilled shell devices and methods of manufacturing description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060063447, Filled shell devices and methods of manufacturing. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] This is continuation-in-part of prior application Ser. No. 10/781,320, filed Feb. 18, 2004, which is hereby incorporated herein by reference in its entirety, and which claims the benefit of U.S. Provisional Application No. 60/448,218, filed Feb. 18, 2003, which is also hereby incorporated herein by reference in its entirety. FIELD [0002] The apparatus and methods described herein relate to generally to devices having a shell filled with a core produced using plastic thermal forming techniques, and in particular to a board, such as a surfboard. BACKGROUND [0003] Surfboards and other types of boards are made from a variety of materials using different methods. Initially, surfboards were made by hand carving wood boards. Another way of manufacturing a surfboard involves the use of foam reinforced with fiberglass. Both wood and foam and fiberglass surfboards have durability problems. Another type of surfboard was developed using an epoxy and PVC and EPS core foam sandwiched between fiberglass matting. Although more durable and lighter than wood or foam reinforced fiberglass boards, such boards still have durability problems along with intensive and costly labor necessary to manufacture the boards. [0004] Manufacturing a foam surfboard having fiberglass matting involves multiple steps, such as those illustrated in FIG. 12. The first step is to purchase a foam blank. The blank is a large piece of foam that has yet to be cut to the precise dimensions of the surfboard. There are a variety of different types of blanks for use and manufacturing different types of surfboards. For example, there are blanks for short and long surfboards. [0005] The next step is to cut the blank down to the desired shape. This task involves selecting a template and attaching the template to the blank. The template is a standardized design according to the particular desirability of the surfboard parameters, such as the weight, shape, and width which contribute to the overall balance and feel of the surfboard. The blank is routed or cut with a saw and shaped by hand to correspond to the perimeter of the template. The blank must also be planed to the appropriate thickness. The rails of the surfboard must also be foiled. The surfboard blank is then hand sanded and shaped into the finished design shape. [0006] Once the surfboard blank has been converted into the appropriate form, multiple finishing steps must be performed. One of the first finishing steps is to remove a portion of the blank corresponding to a fin box. A fin box includes attachment means for attaching fins relative to the fin box which in turn is attached to the surfboard. A leash plug is also inserted into the foam board. The leash plug allows for the attachment of a surfboard leash, which is used to tether the surfboard to a rider. Graphics and other artwork may be applied to the foam board. [0007] Fiberglass matting or fiberglass weave is then applied around the entire surfboard. Resin is applied over the fiberglass matting and cured using hot coating techniques. After curing, the resin coated board is sanded to remove any ridges or bumps. [0008] After the surfboard has been coated with fiberglass, striping and other exterior artwork may be applied. The surfboard is typically prepared for a gloss coat of resin. The gloss coat must be allowed to cure prior to hand polishing. Lastly, the surfboard must be cleaned to remove any dust resulting from polishing of the gloss coat. [0009] Many of the typical steps described above requires skilled technicians adding to the increased cost of labor, resulting in a costly surfboard. A typical surfboard made using the above process will take up to ninety-six hours, including drying and curing time. Moreover, many of the functions involve subjective shaping decisions and techniques, which can result in non-uniform surfboards, even when made using identical templates. SUMMARY [0010] A method of manufacturing an apparatus or device, such as a floatable board, is provided where a shell is formed in a mold cavity and the shell is filled with a core in a mold cavity that substantially prevents distortion of the shell during filling. [0011] The method of manufacturing the device includes providing upper and lower sheets of material. The upper and lower sheets of material may be inserted into an interior of a mold cavity. The upper and lower sheets of material may be formed to the interior of the mold cavity to form a shell. After forming the shell, the shell is filled with an expandable material. During filling of the shell with the expandable material, the shell is prevented from substantially deforming by a mold cavity. [0012] The method of manufacturing a device may include positioning the upper sheet of material above the lower sheet of material within the mold cavity. A perimeter of the upper sheet of material and a perimeter of the lower sheet of material may be clamped relative to each other in the mold cavity, either prior to insertion within the mold cavity or once within the mold cavity. A sealing gasket may be provided between the perimeter of the upper sheet and the perimeter of the lower sheet and clamped therebetween. [0013] Within the mold cavity, at least a portion of the upper and lower sheets of material may be spaced apart. To space the upper and lower sheets of material apart, fluid may be blown between the upper and lower sheets of material. If a gasket is provided between the perimeters of the upper and lower sheets, a fluid inlet tube may be passed through the gasket to allow fluid to space at least a portion of the upper and lower sheets of material apart. [0014] The method of manufacturing a device may include heating the upper and lower sheets of material within the mold cavity and forcing the upper and lower sheets of material against interior walls of the mold cavity to form the shell. Forcing the upper and lower sheets of material against interior walls of the mold cavity may include drawing the upper and lower sheets of material against the interior walls and may be accomplished with a vacuum. Alternatively, or in conjunction with the vacuum, pressure between the upper and lower sheets may be used to force the sheets against the interior walls of the mold cavity. For example, one or more needles may be inserted through one or both of the upper and lower sheets, such as on the sheet where fins will eventually be attached, and compressed air injected between the sheets to force the sheets against the interior cavity walls. During the forming of the shell, the perimeters of the upper and lower sheets may become bonded to each other. Once the shell has been formed within the mold cavity, excess portions of the first and second sheets of material, along with any gasket, may be removed. [0015] The method of manufacturing a device may include forming an aperture in the shell to allow for filling of the shell with the expandable material. To assist in filling of the shell, a filling device may be passed though the aperture and into the shell. The expandable material may then flow through the filling device and into the shell. During filling of the shell with the expandable material, the filling device may be withdrawn from within the shell in a controlled manner. [0016] To prevent the shell from substantially deforming during filling with the expandable material, the shell may be placed within a mold cavity having internal dimensions substantially similar to external dimensions of the shell. The mold cavity for substantially preventing deforming during filling may be a different mold cavity than the mold cavity used for forming the shell. However, the filling mold cavity may be the same mold cavity as the forming mold cavity. To provide added structural rigidity to the device, the filling mold cavity may be heated while the expandable material is filling the shell to allow the expandable material to at least partially bond to the shell. [0017] The method of manufacturing a device may include applying graphics to at least one of first and second sheets of material prior to inserting the upper and lower sheets of material into the interior of the forming mold cavity. The graphics may be disposed on the interior of the shell. Once the shell is filled with the expandable material to form the device, any graphics are on the interior of the shell may be protected from marring, such as by scratching. [0018] The expandable material may comprise polyurethane, and in particular may comprise a rigid polyurethane. The expandable material may also comprise an expanded polystyrene, or other suitable materials. The upper and lower sheets of material forming the shell may comprise polycarbonate, and in particular a weatherable polycarbonate. The sheets may also comprise other suitable materials, such as acrylonitrile butadiene styrene (ABS) and thermal-plastic poly-olethin (TPO). The sheets may be multi-layered, such as having protective film on their outer surfaces, or a metallic or colored graphic film on their inner surfaces. [0019] A method of manufacturing a device, such as a floatable board, is provided, where means are provided for forming at least two sheets of material to the interior of a mold cavity to form a shell. Means may also be provided for filling the shell with an expandable material. Means may further be provided for preventing the shell from substantially deforming during filling with the expandable material. [0020] A device, such as a board or surfboard, made in accordance with the methods of manufacturing a device may comprise a polymer shell having first and second sheets of material. The first and second sheets of material may each have a perimeter, and the perimeters of the first and second sheets of material may be bonded together. A core of a material different than the material of the first and second sheets may substantially fill the interior of the shell. The core may have residual compressive stresses to provide structural rigidity to the shell. [0021] The apparatus and methods for producing the apparatus described herein are not limited to boards or surfboards, and are applicable to other types of devices. For example, the methods described herein can be used to produce floatable boards, such as knee boards, kite surfing boards, body boards, wake boards, skim boards, and wind surfing boards. The methods can also be used to produce other devices, such as ocean kayaks and paddle boats. The methods can also be used to produce non-aquatic devices, such as highway barrier panels and saddle trees for saddles. Continue reading about Filled shell devices and methods of manufacturing... 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