AU727913B3 - Improvements in watercraft and the manufacture thereof - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A PETTY PATENT Name of Applicant: Actual Inventor: Address for Service: Invention Title: SHALE GORDON SHALE GORDON CULLEN

CO.,

Patent Trade Mark Attorneys, 239 George Street, Brisbane, QId. 4000, Australia.

IMPROVEMENTS IN WATERCRAFT AND THE MANUFACTURE THEREOF Details of Associated Provisional Applications: The following statement is a full description of this invention including the best method of performing it known to me: IMPROVEMENTS IN WATERCRAFT AND THE MANUFACTURE THEREOF TECHNICAL FIELD This invention relates to watercraft and methods of manufacturing same.

BACKGROUND ART Traditionally watercraft such as surfboards, surf skis, sail boards, body boards and the like have been manufactured from a foam (usually polyurethane) core which includes an internal stringer (usually a strip of plywood). The core materials are shaped and then coated with a composite of resins and fibreglass to form an outer skin.

Whilst such watercraft can be produced in varying shapes and designs and in attractive finishes there are a number of acknowledged disadvantages associated with the traditional methods of construction including: 1. Polyurethane-foam cores are inherently weak, not impact resistant, and the processing of the foams is generally wasteful.

2. Stringers used to reinforce the core materials have little resilience and are heavy compared with the overall weight of a craft.

3. Resins which are commonly used are solvent based, highly toxic and environmentally damaging.

4. Commonly applied fibreglass skins are brittle, relatively heavy and are readily damaged by impacts and collisions.

Fibreglass is highly toxic in its application and a potential cause of lung, skin and liver disorders.

6. The watercraft are 100% non-recyclable.

There are increasing pressures on industries to use eco-friendly and sustainable manufacturing techniques, to eliminate the use of toxic materials, and to maximise the use of natural recyclable materials.

One natural material which is available in abundance is bamboo, a natural timber which is readily grown in tropical and semi-tropical regions of the world.

Whilst bamboos are used for building purposes and for making furniture poles, etc. its field of use has been relatively limited.

Bearing in mind that bamboo is in abundant supply, is a relatively renewable inexpensive resource, can be readily worked, is naturally strong it is surprising that the material is not used more extensively than it is.

It is an object of the present invention to provide a method of constructing watercraft such as surfboards, utilising bamboo as a protective veneer.

Further objects and advantages of the present invention will become apparent from the ensuing description.

DISCLOSURE OF INVENTION According to the present invention there is provided a method manufacturing watercraft comprising the steps of: shaping a hull from a foam material, and encasing the shaped hull with a natural bamboo veneer.

The core material can be an extruded polystyrene foam.

The bamboo sheet material can be applied to the hull under partial pressure.

The sheet material forms a protective outer skin which is sealed with epoxy and then may be finished by a layer or layers of epoxy, varnish, paints, lacquers or the like.

The partial pressure may be created within a chamber having a shaped bed which is complementary to the shape of the foam material.

The foam material may be encased in one or more stages.

BRIEF DESCRIPTION OF THE DRAWINGS Aspects of the present invention will now be described with reference to the accompanying drawing which is a cross-section of a watercraft manufactured in accordance with the methodology of the present invention.

A watercraft hull generally indicated by arrow 1 can be formed from a rigid foam core 2 protected by an outer veneer 3.

The outer veneer 3 is formed from sheets of bamboo. The bamboo which is in sheet form is taken from the internal "timber" region of bamboo plants. Depending on the parent material the bamboo sheet is provided in various sizes, approximately a millimetre thick.

The bamboo sheet material can be applied to the core in a natural or preconditioned state.

The preconditioning of the sheet material can include the application of adhesives and/or resins and a partial pressure environment used to apply the sheet material to the core.

The process of manufacture can include the steps of shaping the core materials by hand or machine or by pre-moulding. Resin impregnated bamboo sheet materials are then applied as a veneer to the core preferably within a partial pressure environment (a vacuum chamber).

The partial pressure environment can be subject to elevated temperatures.

The sheet materials are laid on a foam core and placed on a bed within the vacuum chamber, and when a vacuum is applied the sheets are drawn and adhere to the core.

The major surfaces of the hull may be covered in a two stage process.

The completed hull can then be removed from the chamber and finished in a variety of ways.

Finishing may entail sanding, the application of epoxy varnishes, paints, lacquers and the like, and the fitting of accessories such as rope ties, fins, skegs, rudders and the like.

The present invention has many advantages over conventional practices including; 1. Non-toxic foam (styrene), which vastly reduces waste and which is recyclable can be used.

2. Epoxy resins, which have fewer volatile organic compounds and less than 6% solvents can be used.

3. No stringer is used, which leads to a 15% overall weight reduction and increases performance for the same weight.

4. A bamboo veneer, which has twice the strength of fibreglass, for the same weight and is flexible, light, totally natural and nontoxic at all levels of manufacture.

Product produced utilising the methodology of the present invention has less toxicity, as it uses recyclable cores, organic substrates (bamboo) and epoxy resins.

6. Product is aesthetically appealing due to its natural appearance.

7. Easy blended repairs can be readily made.

Aspects of the present invention have been described by way of example only and it will be appreciated that modifications and additions thereto may be made without departing from the scope thereof, as defined in the appended claims.

Claims (3)

1. A method of manufacturing a watercraft which comprises a foam inner core and an outer layer of natural bamboo veneer, the method comprising thesteps of; applying an adhesive to a plurality of sheets of bamboo veneer, placing the sheets on the inner core drawing the sheets onto the core under a partial pressure environment, allowing the adhesive to cure.

2. A method as claimed in claim 1 wherein the core material is an extruded polystyrene foam.

3. A watercraft substantially as herein described with reference to the accompanying drawing, manufactured in accordance with claim 1 or claim 2. DATED this 16th day of October 2000 SHALE GORDON By his Patent Attorneys CULLEN CO.