Sportsboard structures

Abstract

A sports board that includes an elongate, water impervious, thermoplastic foam core having an upper surface and an under surface; an upper layer covering at least a portion of the upper surface; and an under layer covering at least a portion of the under surface. The foam core is made of a foamed material having a water absorption (measured according to ASTM C-272) of less than 2 volume percent.

1 . A sports board comprising:
 (a) an elongate, water resistant, thermoplastic foam core having an upper surface and an under surface;   (b) an upper layer covering at least a portion of the upper surface; and   (c) an under layer covering at least a portion of the under surface;   
     wherein the foam core is made of a foam material that has a water absorption (measured according to ASTM C-272) of less than 2 volume percent. 
   
   
       2 . The sports board according to  claim 1 , wherein the foam core comprises an expandable polymer matrix comprising interpolymers of a polyolefin and in situ polymerized vinyl aromatic monomers, rubber modified polystyrene, polystyrene modified rubber, polyphenylene oxide, blends of polyolefins and at least one other polymer, and combinations and blends thereof. 
   
   
       3 . The sports board according to  claim 1 , wherein the foam core comprises an interpenetrating network of one or more polyolefins and one or more polymers of vinyl aromatic monomers. 
   
   
       4 . The sports board according to  claim 1 , wherein the foam core comprises a molded part with a skin formed on at least a portion of an outer surface of the molded part. 
   
   
       5 . The sports board according to  claim 1 , wherein a sealant is applied to at least a portion of an outer surface of the foam core. 
   
   
       6 . The sports board according to  claim 5 , wherein the sealant is selected from the group consisting of ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, ethylene-acrylic acid copolymers, styrene-butadiene polymers, styrene-isoprene polymers; styrene-butadiene-styrene block polymers; styrene-isoprene-styrene block polymers; and hydrogenated resins thereof and combinations thereof. 
   
   
       7 . The sports board according to  claim 1 , wherein the foam core has a flexural strength at 5% strain, measured according to ASTM C-203, of at least 60 psi at a molded density of about 2.25 lb/ft 3 . 
   
   
       8 . The sports board according to  claim 1 , wherein the foam core has a tensile strength (measured according to ASTM D-3575-T) of at least 75 psi at a molded density of about 2.25 lb/ft 3 . 
   
   
       9 . The sports board according to  claim 1 , wherein at least one of the upper layer and under layer coverings comprise a cloth comprising one or more fibers selected from the group consisting of carbon fibers, graphite fibers, aramid fibers, metal fibers, glass fibers, silicon carbide fibers, polyester fibers, composite fibers, fiberglass and combinations thereof. 
   
   
       10 . The sports board according to  claim 9 , wherein the cloth is secured to the upper surface by a laminating resin, which encases the cloth and forms a bond to the thermoplastic foam core. 
   
   
       11 . The sports board according to  claim 10 , wherein the laminating resin is selected from the group consisting of unsaturated polyester resins, saturated polyester resins, epoxy resins, phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins, unsaturated polyesteramide resins, vinyl ester resins, polyimide resins, poly amide-imide resins, unsaturated (meth)acrylic resins, acrylic-urethane resins, and combinations thereof. 
   
   
       12 . The sports board according to  claim 1 , wherein the upper layer covering and/or under layer covering comprise one or more polyolefins. 
   
   
       13 . The sports board according to  claim 1  comprising one or more axial and/or parabolic stringers. 
   
   
       14 . The sports board according to  claim 1  comprising one or more fins secured to and extending from the under side of the sports board. 
   
   
       15 . The sports board according to  claim 1  comprising one or more securing devices secured to and extending from the upper side of the sports board. 
   
   
       16 . The sports board according to  claim 1  comprising one or more wheels secured to and extending from the under side of the sports board. 
   
   
       17 . The sports board according to  claim 1 , wherein the sports board is selected from the group consisting of a surfboard, a body board, a sailboard, a wave board, a tow board, a water ski, a snow board, a sled, a toboggan, a snow ski, a go-kart, and a skate board. 
   
   
       18 . A sports board comprising
 (a) an elongate, water resistant, thermoplastic foam core having an upper surface and an under surface;   (b) one or more axial and/or parabolic stringers;   (c) an upper fabric layer covering at least a portion of the upper surface;   (d) an under fabric layer covering at least a portion of the under surface; and   (e) a laminating resin encasing the upper fabric layer and the under fabric layer bonded to the thermoplastic foam core;   
     wherein the foam core is made of a foam material that has a water absorption (measured according to ASTM C-272) of less than 2 volume percent. 
   
   
       19 . The sports board according to  claim 18 , wherein the sports board is selected from the group consisting of a surfboard, a body board, a sailboard, a wave board, a tow board, a water ski, a snow board, a sled, a toboggan, a snow ski, a go-kart, and a skate board. 
   
   
       20 . The sports board according to  claim 19 , wherein the sports board is a surfboard. 
   
   
       21 . The sports board according to  claim 20 , wherein the surfboard can be deflected using an Emerson 8510 compression tester apparatus 0.75 inches (1.9 cm) without demonstrating a deflection in the stress-strain curve. 
   
   
       21 . The sports board according to  claim 20 , wherein the surfboard does not fail when deflected 0.87 inches (2.2 cm). 
   
   
       22 . A surfboard comprising:
 (a) an elongate, water resistant, foam core comprising an interpenetrating network of one or more polyolefins and one or more polymers of vinyl aromatic monomers having an upper surface and an under surface;   (b) an upper layer covering at least a portion of the upper surface; and   (c) an under layer covering at least a portion of the under surface;   wherein the foam core is made of a foam material that has a water absorption (measured according to ASTM C-272) of less than 2 volume percent.   
   
   
       23 . The surfboard according to  claim 22 , wherein the surfboard can be deflected using an Emerson 8510 compression tester apparatus 0.75 inches (1.9 cm) without demonstrating a deflection in the stress-strain curve. 
   
   
       24 . A surfboard blank comprising:
 (a) an elongate, water resistant, first portion comprising an expandable polymer matrix having an inner edge, a lead end and a tail end;   (b) an elongate, water resistant, second portion comprising an expandable polymer matrix having an inner edge, a lead end and a tail end;   (c) a stringer disposed along and between the inner edges of the first portion and the second portion and secured thereto;   wherein the expandable polymer matrix comprises one or more resins selected from the group consisting of interpolymers of a polyolefin and in situ polymerized vinyl aromatic monomers, rubber modified polystyrene, polyolefins, polystyrene modified rubber, polyphenylene oxide, and combinations and blends thereof.   
   
   
       25 . A surfboard comprising the surfboard blank according to  claim 24  wrapped in one or more fabric layers, which are encased with a laminating resin bond to the expandable polymer matrix.