DE102011101853A1 - Nose guard for surfboard to protect against high mechanical stress on outer skin of surfboard, has glass fiber fabric mat that is composed of extra light and impact resistant carbon fiber fabric - Google Patents

Abstract

The nose guard has a glass fiber fabric mat that is composed of an extra light and an impact resistant carbon fiber fabric.

Description

Protection nose for surfboards, called "Surfboard Carbon Nose Protector".

Protective noses for surfboards are basically used to protect them from mechanical impact. Such, such as the impact of the mast on the surfboard nose, can cause irreparable damage to the surfboard. Since a repair of the surfboard which is no longer possible involves considerable financial consequences, since the board can no longer be used completely and a new purchase must be made, this is to be avoided.

The "Surfboard Carbon Nose Protector" can be classified in the technical field of "Production of molded parts made of fiber composites".

I.

So far, such protective lugs consisted of glass fiber reinforced plastic (source: www.JP-Australia.com-Products Details ). These fiberglass mats are spun and powder bound but not interwoven. (Source: R & G Faserverbundwerkstoffe, Handbook, 3rd updated edition 2000/2001, page 162 ) In addition, the processing of polyester resin, wherein a high resin and low fiber content causes the protective noses are brittle, very heavy and not impact resistant. In addition, such protective noses are in a weight range of 500 to 530 g. Due to the material used, production is accompanied by differences in the fact that tolerances of up to 3 mm can occur between the surfboard and the protective nose, which result in damaging particles, such as sand, dirt, etc. to be able to state.

II.

The Applicant has faced the problem, by using other materials and improving the composition of these, to convert the disadvantages associated with the glass fiber reinforced plastic construction into advantages.

production:

Due to the individuality of each surfboard accordingly adapted protective noses are required.

1. Production of a prototype

• a) Dies erfolgt, indem zunächst auf das jeweilige Surfboard eine Trennschicht aufgetragen wird. Dazu wird durchsichtige Folie über die Surfboardnase gespannt und am unteren Teil des Surfboards befestigt. Als ”durchsichtige Folie” wird herkömmliche ”Frischhaltefolie” verwandt. Zur Vermeidung von Beschädigungen am Surfboard, gegebenenfalls aufgrund Durchdringen von Harz, besteht die Trennschicht aus 2 Folienüberzügen. Eventuell vorhandene geringe Faltenbildungen haben keine Auswirkungen, allerdings sollte der Folienauftrag möglichst faltenfrei vorgenommen werden.
• b) Auf die Trennschicht werden alsdann 5 Lagen Glasgewebe (280 g/qm) aufgebracht. Diese werden mit einer vormals gemischten Masse, bestehend aus 100 g Epoxydharz L und 40 g Härter L (140 g, UV-beständig), getränkt und im Anschluss 24 Stunden ausgehärtet.
• c) Nach dem Aushärten wird der Prototyp vom Surfboard entfernt und derart befräst, dass im Ergebnis eine Form verbleibt, die der Surfboardnase entspricht.
• d) Der Prototyp wird alsdann außenseitig mit einer Lackierung versehen, um eine glänzende Oberfläche zu erhalten. Die Lackierung erfolgt mit einem handelsüblichen Autolack, wobei auch diverse andere Lacke verwendet werden können.

At first, it is incessant to make a "prototype" of the respective surfboard.

• a) This is done by first applying a release layer to the respective surfboard. For this purpose, transparent film is stretched over the surfboard nose and attached to the lower part of the surfboard. As a "transparent film" conventional "cling film" is used. To avoid damage to the surfboard, possibly due to penetration of resin, the release layer consists of 2 film coatings. Any existing small wrinkles have no effect, but the film should be applied as possible wrinkle-free.
• b) 5 layers of glass fabric (280 g / m 2) are then applied to the release layer. These are impregnated with a previously mixed mass consisting of 100 g of epoxy resin L and 40 g of hardener L (140 g, UV-resistant), and then hardened for 24 hours.
• c) After curing, the prototype is removed from the surfboard and milled in such a way that the result is a shape that corresponds to the surfboard nose.
• d) The prototype is then painted on the outside to obtain a glossy finish. The painting is done with a standard car paint, although various other paints can be used.

2.) Production of a negative mold

• a) 6 layers of release agent are applied to the painted surface of the prototype. As a release agent, a special paraffin wax with the name "Formula Five Mold Release Wax" is used. This is applied at intervals of 6 hours each and then polished.
• b) Thereafter, a 2 to 3 mm thick cover layer "molding resin P" is applied.
• c) Subsequently, in the "wet in wet" process, 6 layers of glass fabric (280 g / m.sup.2) are applied to one another, each impregnated with the previously mixed mass consisting of 100 g of epoxy resin L and 40 g of hardener L and cured for 24 hours. The temperature during the curing process is 25 degrees Celsius. This temperature is at least necessary to properly ensure this process.
• d) After the curing process, all edges, i. H. protruding material, milled off.
• e) Finally, the prototype is removed from the negative form.

3. Production of surfboard nose

3.1) materials

a) carbon fiber fabric

Starting material is carbon fiber fabric with a weight of 204 gsm.

"The mechanical properties of the molding materials, eg. Tensile strength, flexural strength and impact resistance, as well as the ability to work, are mainly due to the properties of the fibers. "(Source: R & G Faserverbundwerkstoffe, Handbook, 3rd updated edition 2000/2001, page 16 )

b) "bedding compound" epoxy resin

Due to its properties, "bedding compound" is specifically used as "Epoxy Resin L".

(Quelle: R & G Faserverbundwerkstoffe, Handbuch, 3. aktualisierte Auflage 2000/2001, Seite 15 ) "Epoxy resins show the lowest strength drop even with several tens of thousands of load changes and thus the greatest dynamic strength."

(Source: R & G Faserverbundwerkstoffe, Handbook, 3rd updated edition 2000/2001, page 15 )

• • ”geringer Härtungsschwund,
• • gute Maßhaltigkeit,
• • starke Haftung, sehr gute Klebkraft,
• • hohe Temperaturbeanspruchbarkeit,
• • gute Chemikalien- und Witterungsbeständigkeit”

(Quelle: R & G Faserverbundwerkstoffe, Handbuch, 3. aktualisierte Auflage 2000/2001, Seite 31 )Other advantages of great importance are:

• • "low hardening shrinkage,
• Good dimensional stability,
• Strong adhesion, very good adhesion,
• High temperature resistance,
• • good chemical and weather resistance

(Source: R & G Faserverbundwerkstoffe, Handbook, 3rd updated edition 2000/2001, page 31 )

3.2) Manufacturing process

• a) In the present negative mold again 6 layers release agents are introduced. The release agent is again the special paraffin wax "Formula Five Mold Release Wax" used. At intervals of 6 hours, the application and appropriate polishing takes place.
• b) This is followed by the application of the inner surface of the mold with 1 coat of colorless Gelcoart (UV-resistant, polishable). At 25 degrees Celsius followed by a 2-hour curing.
• c) Thereafter, the carbon fiber fabric is placed on this layer and laminated with a resin layer. The total of 5 applied layers of carbon fiber fabric are arranged multidirectionally, so that a load in several directions is achieved and soaked with the formerly mixed mass consisting of 100 g of epoxy resin L and 40 g of hardener L (140 g, UV-resistant).

The drying time is 24 hours at a temperature of 45 degrees Celsius, whereby the complete form, including the incorporated fabric, is tempered in a temperature-adjustable device.

"The fibers are embedded in a liquid reaction resin composition and anchored in hardening of the resin in the resulting solid molding material. ... For the properties of the end product, therefore, careful processing and curing, in addition to component design (fiber orientation, fiber content, number of layers and fabric), are of vital importance. "(Source: R & G Faserverbundwerkstoffe, Handbook, 3rd updated edition 2000/2001, p. 15 ).

• d) Auf die letzte Kohlefaserschicht wird 1 Schicht Abreißgewebe (95 g/qm) einlaminiert. Das ”Abreißgewebe” mit Leinwandbindung trägt einen derartigen Namen und findet Verwendung, da es nach dem Härteprozess ”abgerissen” werden kann und somit eine gleichmäßig rauhe Oberfläche erzeugt, die im weiteren erforderlich ist, um die Surfboardnase auf dem Surfboard aufkleben zu können und damit eine größere Haftbarkeit erreicht wird.
• e) Die fertige Schutznase wird abschließend aus der Negativform herausgelöst.

The optical perfectionality can be compromised if the epoxy resin can not penetrate through the carbon fiber fabric, resulting in defects such as blistering and the like.

• d) 1 layer of tear-off fabric (95 g / qm) is laminated to the last carbon fiber layer. The "tear-off fabric" with plain weave carries such a name and is used because it can be "demolished" after the hardening process and thus produces a uniformly rough surface, which is further required in order to stick the surfboard nose on the surfboard and thus a greater liability is achieved.
• e) The finished protective nose is finally removed from the negative mold.

The claim offers by the carbon fiber reinforced plastic construction advantages in many areas, is mainly used to protect the surfboard from mechanical impact and can financially significant consequential costs due to damage. Improved absorption and dissipation reduces damage that other materials can not prevent. The combined use of carbon fiber mats and epoxy resin means that the protective noses are not brittle and thus impact resistant. With a weight of 230 to 250 g, they are significantly lighter than the materials previously used. The production does not lead to tolerances between the surfboard and the protective nose, so that no harmful particles can accumulate in the gaps. The perfected visual appearance of the protective nose significantly upgrades the surfboard.

The claim is due to the related materials not state of the art (§ 3 PatG), but goes beyond this. Likewise, an "inventive step" can be assumed, since this does not result in a manner obvious to the person skilled in the art from the state of the art and thus exceeds the ability of the average person skilled in the art. (§ 4 para. 1 PatG). So far, glass fiber reinforced materials - with the addition of polyester resin - for the production of protective noses, now is exceeded by the use of carbon fiber reinforced material processing epoxy resin, the "previous skill". The subject of the patent falls within the scope of commercial production and usability according to § 5 PatG, since it is not a "pure theory", but actively qualifies the surfing sector.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• www.JP-Australia.com-Products-Details [0003]
• R & G Faserverbundwerkstoffe, Handbuch, 3rd updated edition 2000/2001, page 162 [0003]
• R & G Composites, Handbook, 3rd updated edition 2000/2001, page 16 [0008]
• R & G Faserverbundwerkstoffe, Handbuch, 3rd updated edition 2000/2001, page 15 [0010]
• R & G Faserverbundwerkstoffe, Handbuch, 3rd updated edition 2000/2001, page 31 [0011]
• R & G Faserverbundwerkstoffe, Handbuch, 3rd updated edition 2000/2001, p. 15 [0013]

Claims (2)

A "protective nose" for a surfboard, which is to protect it at a high mechanical stress on the outer skin of the surfboard, characterized in that it is composed of a fiberglass mat fabric. The "protective nose" according to the claim, called "Surfboard Carbon Nose Protector", is characterized in that it is composed of an extra lightweight, impact-resistant carbon fiber fabric.