Injection molded surfboard insert having pre-impregnated composite fiber matrix structure

摘要

An insert for a water sports board, wherein the insert includes a pre-preg flange extending outwardly from an injection molded central housing to provide enhance structural properties of the insert, as well as enhanced intermediate bonding between the injection molded central housing and a surface polymer. The pre-preg flange further improves the strength to weight ratio when compared to conventional inserts.

主权项

1. A method of constructing a board insert configured for use with a water sports board, the method comprising the steps of:
providing a pre-preg flange formed of a pre-preg sheet, the pre-preg sheet including a plurality of structural strands bonded by a resin material, the pre-preg flange having:
opposed first and second surfaces;an outer peripheral region configured to be attachable to the water sports board; andan inner bonding region radially inward of the outer peripheral region and disposed about a central axis; forming a pre-preg opening within the inner bonding region, the pre-preg opening being disposed about the central axis; placing the pre-preg flange within a mold cavity; and injecting a polymer material into the mold cavity to at least partially form an insert housing within the pre-preg opening, the insert housing extending through the pre-preg flange adjacent the inner bonding region along the central axis, the insert housing being bonded to the inner bonding region of the pre-preg flange with the outer peripheral region of the pre-preg flange extending radially outward from the insert housing, the insert housing having:
a peripheral wall disposed about the central axis and extending away from the second surface of the pre-preg flange; andan end wall coupled to the peripheral wall with the peripheral wall disposed between the end wall and the second side of the pre-preg flange, the end wall extending generally orthogonal to the central axis, the peripheral wall and end wall collectively defining a cavity; and forming a lip coupled to the peripheral wall and extending around the central axis to define a lip opening in communication with the cavity, the lip extending away from the peripheral wall with the first surface disposed between the lip and the peripheral wall, the lip defining a distal end portion disposed about the lip opening and spaced from the first surface.