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  Flex and resonance controlled watercraftUSPTO Application #: 20060178061Title: Flex and resonance controlled watercraft Abstract: A subassembly structurally engineered and manufactured in an aquatic watercraft. The subassembly includes hollow cored or foam filled tube-like structures incased in a foam core blank. The foam core blank containing the subassembly is subsequently to be manually or machined shaped. The invention relates to methods for making the craft produced from subassembly foam blank and surfacing the craft with combinations of curable resins and structural fibers such as fiberglass or carbon, and/or thermoplastics. (end of abstract) Agent: J. Michael Caldwell - Cardiff, CA, US Inventor: James Michael Caldwell USPTO Applicaton #: 20060178061 - Class: 441074000 (USPTO) Related Patent Categories: Buoys, Rafts, And Aquatic Devices, Water Skimming Or Walking Device, Surfboard The Patent Description & Claims data below is from USPTO Patent Application 20060178061. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This patent application claims the benefit of provisional patent APPL NO. 60/642,927 Title: Flex and Resonance Controlled Watercraft, filed by this inventor on Jan. 10, 2005 BACKGROUND OF THE INVENTION [0002] A subassembly structurally engineered and manufactured in an aquatic watercraft. The subassembly includes hollow cored or foam filled tube-like structures incased in a foam core blank. The foam core blank containing the subassembly is subsequently to be manually or machined shaped. The invention relates to methods for making the craft produced from subassembly foam blank and surfacing the craft with combinations of curable resins and structural fibers such as fiberglass or carbon, and/or thermoplastics. FIELD OF THE INVENTION [0003] The invention relates to the fabrication of wave riding or paddled aquatic boards, and particularly to the use of structural subassemblies incorporated into a surfboard. The method additionally relates to a method for the manufacture of these subassemblies and to a board manufactured using the subassemblies. [0004] Most surfboards presently consist of a foam core that is shaped to produce the desired final shape of the board. Furthermore, in most traditional surfboards (but not all surfboards) have one or more stringers. These typically consist of a vertically oriented strip of wood that runs along the centerline of the longitudinal axis of the board and is exposed on the top and bottom faces of the shaped blank. Other materials, such as dense PVC foam, SphereTex.RTM., micro spheres, and various types of honeycomb are sometimes used in place of wood. The stringer stiffens up the board and the increased rigidity assists in the shaping of the board, as well as contributing to the stiffness of the completed board and the strength of the board. [0005] The surface of this core and the exposed strips of the stringer are then covered by a structural skin. This typically consists of a matrix composed of a structural reinforcement such as fiberglass or carbon fiber and a curable resin such as epoxy or polyester. Alternative skins may consist of wood or other fibrous material, or a thermoplastic. [0006] In related U.S. Pat. No. 6,736,689 a structural subassembly is provided to produce an aquatic gliding board. The subassembly includes a hollow inner shell which is covered with a casing made of foam capable of being machined. The invention also relates to a method of making such a subassembly and to a board made by covering the preceding subassembly with a layer of resin-coated fibers. [0007] There have been a number of efforts at changing the base foam blank for the surfboard industry. The current invention provides the option for the use of engineered composite structures and through their use achieving reproducible flex and strength properties [0008] Virtually all surfboards incorporate one or more fins extending downward from the bottom of the rear area of the board. These may be bonded to the bottom surface, or fin boxes (receptacles to hold and support the base of a fin) may be placed into the foam core prior to the skinning operation. [0009] There are a number of alternative or modified methods of surfboard construction. For example, the foam core may be skinned with some intermediate material, such as a denser foam, before glassing to increase the compressive strength. Alternatively, composite sandwich skins may be molded for the upper and lower portions of the board, and then joined at their perimeter. In another alternative, a mold and an inflatable bladder may be used in combination with composite sandwich construction methods to form the complete board in a single step. These latter two methods result in a hollow board. [0010] The construction method, the type of materials used, and the specific design details (e.g. type, weight, and weave of fibrous reinforcing material, type of resin, type and density of foam, stringer width and composition, etc.), when combined with the physical dimensions of the board, determine its weight, flexural properties, and strength in the presence of various types of loadings. [0011] The experienced surfer develops preferences for certain characteristics in his boards. In general, these preferences will be related to his skill level, his physical characteristics, and the type and size waves he wishes to surf with the board. The hydrodynamic design of the board is one variable affecting these characteristics, other variables include the weight of the board, its moment of inertia (particularly about the yaw axis), the flexural characteristics of the board, and its durability. In general, a change in any one of these properties (e.g. due to dimensional changes, compositional changes, or construction method) will simultaneously change many of the board's characteristics. [0012] Current surfboard construction techniques tend to strongly couple these board characteristics together. For example, increasing the strength against breakage typically increases the weight of the board and the moment of inertia, and reduces flexibility. The usual consequence for most types of waves is a reduction in maneuverability and a reduction in flotation. On occasion, all of these factors come together to produce a board that meets or exceeds the rider's preference desires and expectations. But these boards, frequently referred to as "magic" boards, are rare and, given typical manufacturing tolerances, difficult or nearly impossible to reproduce. BRIEF SUMMARY OF THE INVENTION [0013] An objective of this invention is to incorporate one or more subassemblies into the construction of a surfboard which will provide the surfboard designer and builder more degrees of freedom in the design and construction so as to assist him in manufacturing a board that can better match the board characteristics with the rider's preferences. The flexural properties include not only the degree of flex as a function of loading, but also the temporal response of the flexed system to intermittent loading and unloading by the surfer and the hydrodynamic pressures on the surface of the board. For example, flexural response can be expected to be most rapid and require the least effort when the frequency of loading and unloading by the rider matches the natural frequency of that mode of vibration of the board (i.e. the loading and response are in, or close to, resonance). Flexural motions affect not only the "feel" of the board, but also its hydrodynamic performance and, in some instances, the structural strength (e.g. structural failure due to buckling). Controlled flexural movements can also provide new hydrodynamic means of controlling the board and increasing its performance, such as the addition of hydrofoils. [0014] The predominant method for manufacturing surfboards is using molded polyurethane foam blanks. The foam blank is generally molded and then structurally reinforced with a wood stringer that is glued into the foam along the centerline of the blank. This wood stringer is installed for a number of reasons that include structural reinforcement and rocker or longitudinal curvature correction. The foam blank is molded to the approximate size required for the finish or custom shape dimensional requirements. The remaining removal and shaping and sanding are then completed by either a computer controlled shaping machine and/or by the individual. An outside covering lamination of a curable resin combined with fiberglass is then applied, sanded, and reapplied to produce a structurally and exterior visually acceptable product. [0015] Alternatively a foam core like polystyrene can be used and can alternatively be covered with higher density foam and either covered with fiberglass and a curable resin or a combination of epoxy resins and fiberglass and/or plastic outer covers. [0016] A number of construction methods are now being used to manufacture hollow boards. Composite foam sandwich or honeycomb core skin methods are combined with a mold and an internal pressure bladder to form, and cure top and bottom sections combined together to produce the shaped board. An alternative product combines pre-formed and cured sections that are then combined in a perimeter assembling ring mold for joining, sealing and finishing of the final board. [0017] A molded surfboard can be manufactured in a variety of ways. One manufacturing method is to form combinations of one or more materials such as plastics or composites such as fiberglass, carbon fiber, Kevlar, micro sphere materials such as Sphere-a-tex, Nomex.RTM. honeycomb, aluminum honeycomb, foams cores and sheets made from polyurethanes and polystyrenes and foam or materials chemistries. This construction method can form laminates consisting of an outer skin and a center core with an inner skin to create a three dimensional structural laminate that forms the top and bottom surface of the craft. Alternatively boards can be molded by placing an uncured polymer resinous gel coating material on a preformed mold cavity and then placing on top of the gel coat an uncured polymeric resinous saturated substrate fibrous layer, and then onto the previous layers a resinous saturated substrate fibrous three dimensional layer. This muti-layer composite can then be cured under pressure employing a process such as vacuum bagging. Other molded craft construction methods include solid polystyrene foam cores with outer layers and or laminates of plastics and or composites such as those listed above. [0018] These molding construction methods can incorporate some stringer or reinforcement elements inside the boards. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0019] The invention will be better understood from the description that follows, with reference to the drawings, in which: Continue reading... Full patent description for Flex and resonance controlled watercraft Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Flex and resonance controlled watercraft patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Flex and resonance controlled watercraft or other areas of interest. ### Previous Patent Application: Propeller shaft apparatus Next Patent Application: Multifunctional hydrofoil surfboard Industry Class: Buoys, rafts, and aquatic devices ### FreshPatents.com Support Thank you for viewing the Flex and resonance controlled watercraft patent info. 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