Surfboard and method and apparatus of manufacture

Abstract

A method of forming a surfboard includes using a press to bend a flexible mold that contains a surfboard core, layed up with resin and reinforcing material. The layed up surfboard core is allowed to cure in the mold/press, at least partially, to set a desired degree of rocker to the surfboard. Common surfboard core blanks may be used to form surfboards with different degrees of rocker, and in this sense, may allow surfboard manufacturers to provide a greater variety of surfboard choices and/or to manufacture surfboards more efficiently. A surfboard may be formed with a core that includes a central portion and a separate rail portion. The rail portion may placed inside of a braided sleeve or reinforcing material and assembled to the central portion of the surfboard core to provide desired structure characteristics to the surfboard.

1 . A method of manufacturing a surfboard, the method comprising:
 positioning a surfboard core and hardenable material in a mold cavity of a flexible mold;   bending the flexible mold and surfboard core to a curvature;   curing the hardenable material to set the surfboard core and hardenable material to the curvature.   
   
   
       2 . The method of  claim 1 , wherein positioning the surfboard core and hardenable material in the mold cavity comprises applying reinforcing sheets and hardenable resin to surfaces of the surfboard core. 
   
   
       3 . The method of  claim 2 , wherein the reinforcing sheets comprise woven fiberglass sheets. 
   
   
       4 . The method of  claim 1 , further comprising:
 wrapping a rail portion of the surfboard core with the reinforcing sheets.   
   
   
       5 . The method of  claim 4 , wherein wrapping the rail portion of the surfboard comprises cutting the rail portion from the surfboard core, wrapping the rail portion with the reinforcing sheets, and then reassembling the rail portion to the surfboard core. 
   
   
       6 . The method of  claim 4 , wherein wrapping the rail portion comprises positioning a braided reinforcing sleeve about the rail portion. 
   
   
       7 . The method of  claim 6 , wherein wrapping the rail portion comprises wrapping an entire perimeter of the surfboard rail with the braided reinforcing sleeve. 
   
   
       8 . The method of  claim 7 , wherein the braided reinforcing sleeve includes carbon fiber material. 
   
   
       9 . The method of  claim 8 , wherein the braided reinforcing sleeve includes fiberglass material. 
   
   
       10 . The method of  claim 1 , wherein the surfboard core comprises a foam surfboard core, the method further comprising:
 foaming the foam surfboard core in a foaming mold to a shape that conforms substantially to the mold cavity of the flexible mold.   
   
   
       11 . A method of forming a surfboard, comprising:
 providing a surfboard core that includes a central portion and a separate rail portion;   positioning a reinforcement about the rail portion of the surfboard core;   positioning the surfboard core, including the central portion and the separate rail portion, reinforcement, and hardenable material together in a flexible mold;   bending the flexible mold, the surfboard core, including the central portion and the separate rail portion, and reinforcement to a curvature;   curing the hardenable material so that the surfboard core retains the curvature.   
   
   
       12 . The method of  claim 11 , further comprising:
 applying reinforcing sheets and hardenable resin to surfaces of the surfboard core prior to curing the hardenable material.   
   
   
       13 . The method of  claim 12 , wherein the reinforcing sheets comprise woven fiberglass sheets. 
   
   
       14 . The method of  claim 11 , further comprising:
 cutting the separate rail portion from the central portion of the surfboard core.   
   
   
       15 . The method of  claim 14 , wherein cutting the separate rail portion comprises cutting the separate rail portion from an entire perimeter of the surfboard core. 
   
   
       16 . The method of  claim 11 , wherein positioning reinforcement about the rail portion comprises positioning the rail portion in a braided sleeve of reinforcing material. 
   
   
       17 . The method of  claim 16 , wherein the braided reinforcing sleeve includes carbon fiber material. 
   
   
       18 . The method of  claim 17 , wherein the braided reinforcing sleeve includes fiberglass material. 
   
   
       19 . The method of  claim 11 , wherein the surfboard core comprises a foam surfboard core, the method further comprising:
 foaming the foam surfboard core in a foaming mold to a shape that conforms substantially to the to a mold cavity of the flexible mold.   
   
   
       20 . A method of designing a flexible mold for imparting rocker to a surfboard, the method comprising:
 constructing a surfboard, at least partially, to a first shape that includes a first rocker;   measuring the first shape;   creating a model having the first shape;   bending the model to a second shape;   constructing a flexible mold with a mold cavity that conforms substantially to the first shape when in a first flexed position and the second shape when in a second unflexed position.   
   
   
       21 . The method of  claim 20 , wherein creating the model comprises creating an electronic model. 
   
   
       22 . The method of  claim 20 , wherein constructing the flexible mold comprises constructing a flexible mold that includes first and second mold halves that engage one another along a parting line. 
   
   
       23 . A method of forming a surfboard, the method comprising:
 providing a surfboard core with a top surface and a bottom surface, the surfboard core including a main core portion and a rail portion, separate from the main core portion;   positioning a reinforcing sleeve about the rail portion;   applying hardenable material to at least a portion of the reinforcing sleeve;   assembling the rail portion and reinforcing sleeve to the main core portion;   curing the hardenable material to join the main core portion and rail portion of the surfboard core.   
   
   
       24 . The method of  claim 23 , wherein positioning the sleeve comprises positioning a braided sleeve of fiberglass and/or carbon fiber about the rail portion. 
   
   
       25 . The method of  claim 23 , wherein the rail portion of the surfboard core is cut from the main portion of the surfboard core. 
   
   
       26 . The method of  claim 23 , wherein the rail portion comprises a ring that is positioned about the main portion of the surfboard core. 
   
   
       27 . The method of  claim 23 , further comprising:
 laminating the top surface of the surfboard core with one or more reinforcing sheets that extend partially over the rail portion.   
   
   
       28 . The method of  claim 27 , further comprising:
 laminating the bottom surface of the surfboard core with one or more reinforcing sheets that extend partially over the rail portion.   
   
   
       29 . The method of  claim 28 , wherein laminating the top surface and laminating the bottom surface occur in a flexible mold. 
   
   
       30 . A surfboard comprising:
 a surfboard core defining top and bottom surfaces, the surfboard core including a central core portion and a separate rail portion;   a reinforcing sleeve positioned about the separate rail portion;   one or more reinforcing layers positioned over at least portions of the top and bottom surfaces.   
   
   
       31 . The surfboard of  claim 30 , wherein the separate rail portion includes a complete perimeter of the surfboard core. 
   
   
       32 . The surfboard of  claim 30 , wherein the surfboard core is cut to provide the separate rail portion and the central core portion. 
   
   
       33 . The surfboard of  claim 30 , wherein the reinforcing sleeve comprises a braided sleeve of fiberglass and/or carbon fiber material. 
   
   
       34 . The surfboard of  claim 30 , wherein the one or more reinforcing layers extend over at least a portion of the reinforcing sleeve. 
   
   
       35 . A flexible mold for forming a surfboard with a shape that has a desired rocker, the flexible mold comprising:
 a first mold portion having a first parting line;   a second mold having a second parting line configured to mate with the first parting line of the first mold portion to define a mold cavity between the first and second mold portions, wherein at least portions of the first parting line move relative to the second parting line as the flexible mold is flexed between a first position for receiving a layed up surfboard core and a second position that conforms substantially to the shape of the surfboard with the desired rocker.