Surfboard layup system and method

Abstract

A surfboard includes a first layer and a second layer. The first layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover a rocker and rails and wherein the first layer extends onto a deck at a middle portion of the surfboard and tapers toward a tip and tail so that the first layer does not extend onto the deck at the tip and the tail. The second layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover the deck and wherein the second layer extends to cover the rails at the middle portion of the surfboard and tapers toward the tip and tail so that the second layer covers less than half of the rails at the tip and the tail.

What is claimed is: 
     
         1 . A surfboard comprising:
 a rocker defining a bottom surface of the surfboard;   a deck defining a top surface of the surfboard;   a pair of rails disposed on opposite sides of the surfboard, each rail defining a side surface of the surfboard and connecting the rocker to the deck;   a pair of edges defined by an interface between the rocker and the corresponding rail;   a tip disposed at a front of the surfboard;   a tail disposed at a rear of the surfboard;   a first layer, the first layer being defined by epoxy impregnated fiber reinforcement fabric configured to cover the rocker and the rails and wherein the first layer extends onto the deck at a middle portion of the surfboard and tapers toward the tip and tail so that the first layer does not extend onto the deck at the tip and the tail; and   a second layer, the second layer being defined by epoxy impregnated fiber reinforcement fabric configured to cover the deck and wherein the second layer extends to cover the rails at the middle portion of the surfboard and tapers toward the tip and tail so that the second layer covers less than half of the rails at the tip and the tail.   
     
     
         2 . The surfboard according to  claim 1 , wherein an overlap of the first layer and the second layer is about 110% to about 120% of a width of the rails at the middle portion of the surfboard and tapers to about 10% to about 20% of the width of the rails at the tip and the tail. 
     
     
         3 . The surfboard according to  claim 1 , wherein the first layer and the second layer are carbon fiber fabric. 
     
     
         4 . The surfboard according to  claim 3 , wherein the carbon fiber fabric is 3K 94.8 grams/meter 2  (“g/m 2 ”) (4 oz/square yard) plain weave carbon fiber fabric. 
     
     
         5 . The surfboard according to  claim 1 , further comprising one or more fin boxes disposed in the rocker proximal to the tail. 
     
     
         6 . The surfboard according to  claim 5 , further comprising one or more fins disposed in respective fin boxes. 
     
     
         7 . The surfboard according to  claim 1 , further comprising a dent cloth disposed below the second layer. 
     
     
         8 . The surfboard according to  claim 7 , wherein the dent cloth is fiberglass. 
     
     
         9 . The surfboard according to  claim 1 , further comprising a leash plug disposed in the deck proximal to the tail. 
     
     
         10 . A method of fabricating a surfboard, the method comprising:
 applying a first layer to a foam blank, the foam blank having:
 a rocker defining a bottom surface of the foam blank; 
 a deck defining a top surface of the foam blank; 
 a pair of rails disposed on opposite sides of the foam blank, each rail defining a side surface of the foam blank and connecting the rocker to the deck; 
 a pair of edges defined by an interface between the rocker and the corresponding rail; 
 a tip disposed at a front of the foam blank; and 
 a tail disposed at a rear of the foam blank, wherein first layer being defined by epoxy impregnated fiber reinforcement fabric configured to cover the rocker and the rails and wherein the first layer extends onto the deck at a middle portion of the foam blank and tapers toward the tip and tail so that the first layer does not extend onto the deck at the tip and the tail; and 
   applying a second layer to the foam blank, the second layer being defined by epoxy impregnated fiber reinforcement fabric configured to cover the deck and wherein the second layer extends to cover the rails at the middle portion of the foam blank and tapers toward the tip and tail so that the second layer covers less than half of the rails at the tip and the tail.   
     
     
         11 . The method according to  claim 10 , wherein the first layer and the second layer are applied to generate an overlap of the first layer and the second layer of about 110% to about 120% of a width of the rails at the middle portion of the foam blank and tapers to about 10% to about 20% of the width of the rails at the tip and the tail. 
     
     
         12 . The method according to  claim 10 , further comprising:
 applying a peel ply over the first layer;   applying a release film over the peel ply, the release film being defined by a non-perforated 0.00787 mm thick polymer film;   applying a breather cloth over the release film;   disposing the foam blank in a vacuum bag; and   generating a vacuum in the vacuum bag to compress the first layer onto the foam blank.   
     
     
         13 . The method according to  claim 12 , further comprising:
 applying the peel ply over the second layer;   applying the release film over the peel ply;   applying the breather cloth over the release film;   disposing the foam blank in the vacuum bag; and   generating the vacuum in the vacuum bag to compress the second layer onto the foam blank.   
     
     
         14 . The method according to  claim 13 , further comprising:
 applying a dent cloth between the foam blank and the second layer, the dent cloth defined by a perimeter of the deck.   
     
     
         15 . The method according to  claim 10 , further comprising:
 applying a hot coat over the first layer.   
     
     
         16 . The method according to  claim 15 , further comprising:
 applying the hot coat over the second layer.   
     
     
         17 . The method according to  claim 10 , further comprising:
 curing the epoxy in the first layer before applying the second layer.   
     
     
         18 . The method according to  claim 10 , wherein the first layer and the second layer are carbon fiber fabric. 
     
     
         19 . The method according to  claim 18 , wherein the carbon fiber fabric is 3K 94.8 grams/meter 2  (“g/m 2 ”) (4 oz/square yard) plain weave carbon fiber fabric. 
     
     
         20 . The method according to  claim 10 , further comprising installing one or more fin boxes disposed in the rocker proximal to the tail.