Surfboard and method of manufacturing

Abstract

A surfboard includes a core covered with a laminate and having perforations where the user places his feet, in order to prevent air blisters from forming between the core and laminate. The core is formed from an extruded closed-cell polystyrene foam block which has been shaped by restraining it against a shaped form using shaped restraining tools and straps, and heating it; and by cutting using a hot wire. The core is laminated with FIBERGLAS® and epoxy resin, and the perforations are formed using a perforating tool that has a planar or curved working surface and one or more heated needles extending perpendicularly from the working surface.

1 . A method of manufacturing a surfboard, comprising the steps of: 
 providing a core covered by a laminate; and    forming at least one perforation in said laminate.    
     
     
         2 . A method of manufacturing as in  claim 1 , wherein: 
 said step of forming at least one perforation in said laminate, comprises the steps of 
 providing a perforating tool having a working surface and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface;  
 manipulating said perforating tool such that said at least one needle is translated substantially in the direction that said at least one needle points, such that said at least one needle penetrates said laminate; and  
 manipulating said perforating tool such that said at least one needle is translated substantially opposite the direction that said at least one needle points, such that said at least one needle is withdrawn from said laminate.  
   
     
     
         3 . A method of manufacturing as in  claim 2 , wherein: 
 said at least one needle is heated.    
     
     
         4 . A method of manufacturing as in  claim 2 , wherein: 
 said working surface is substantially planar.    
     
     
         5 . A method of manufacturing as in  claim 1 , wherein: 
 said step of forming at least one perforation in said laminate, comprises the steps of 
 providing a perforating tool having a working surface curved in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface;  
 rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.  
   
     
     
         6 . A method of manufacturing as in  claim 5 , wherein: 
 said at least one needle is heated.    
     
     
         7 . A method of manufacturing as in  claim 1 , wherein: 
 said step of forming at least one perforation in said laminate, comprises the steps of 
 providing a perforating tool having a working surface having substantially the shape of an arc of a circle in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface;  
 rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.  
   
     
     
         8 . A method of manufacturing as in  claim 7 , wherein: 
 said at least one needle is heated.    
     
     
         9 . A method of manufacturing as in  claim 1 , wherein: 
 said step of providing a core covered by a laminate, comprises the steps of: 
 extruding closed-cell foam into a blank;  
 shaping said blank into a core; and  
 covering said core with a laminate.  
   
     
     
         10 . A method of manufacturing as in  claim 9 , wherein: 
 said step of covering said core with a laminate, comprises the steps of 
 covering said core with FIBERGLAS®; and  
 covering said core with epoxy resin.  
   
     
     
         11 . A method of perforating a laminate, comprising the steps of: 
 providing a laminate;    providing a perforating tool having at least one needle; and    manipulating said perforating tool such that said at least one needle perforates said laminate.    
     
     
         12 . A method as in  claim 11 , wherein: 
 said at least one needle is heated.    
     
     
         13 . A method as in  claim 11 , wherein: 
 said step of providing a perforating tool having at least one needle, comprises the step of 
 providing a perforating tool having a working surface and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where  
 said at least one needle intersects said working surface.  
   
     
     
         14 . A method as in  claim 11 , wherein: 
 said step of manipulating said perforating tool such that said at least one needle perforates said laminate, comprises the steps of 
 manipulating said perforating tool such that said at least one needle is translated in the direction that said at least one needle points, such that said at least one needle perforates said laminate; and  
 manipulating said perforating tool such that said at least one needle is translated opposite the direction that said at least one needle points, such that said at least one needle is withdrawn from said laminate.  
   
     
     
         15 . A method as in  claim 11 , wherein: 
 said step of forming at least one perforation in said laminate, comprises the steps of: 
 providing a perforating tool having a working surface having substantially the shape of an arc of a circle in at least one dimension, and at least one needle extending from said working surface at an angle substantially perpendicular to said working surface at the point where said at least one needle intersects said working surface;  
 rolling said working surface along said laminate such that each said at least one needle successively penetrates and is then withdrawn from said laminate.  
   
     
     
         16 . A perforating tool, comprising: 
 a perforating tool body having a working surface; and    at least one needle extending from said working surface.    
     
     
         17 . A perforating tool as in  claim 16 , wherein: 
 said working surface is substantially planar.    
     
     
         18 . A perforating tool as in  claim 16 , wherein: 
 said working surface is substantially curved in at least one dimension of said working surface.    
     
     
         19 . A perforating tool as in  claim 16 , wherein: 
 said working surface substantially has the shape of an arc of a circle in at least one dimension of said working surface.    
     
     
         20 . A perforating tool as in  claim 16 , wherein: 
 each said at least one needle is substantially parallel to each other said at least one needle.    
     
     
         21 . A perforating tool as in  claim 16 , wherein: 
 each said at least one needle is substantially at an angle to each other said at least one needle.    
     
     
         22 . A perforating tool as in  claim 16 , wherein: 
 said at least one needle is substantially perpendicular to said working surface at the point where said at least one needle extends from said working surface.    
     
     
         23 . A perforating tool as in  claim 16 , wherein: 
 said at least one needle can be heated.