Granted Patent B2

US 6,908,351 · App. 10/603,225 · Granted Jun 21, 2005

Abstract

Claims (29)

1. A method of making an expanded polystyrene core sports board comprising:

laminating a first blended sheet of expanded polystyrene and polyethylene to a bottom surface of an expanded polystyrene sports board core;

laminating a slick skin to the first blended sheet of expanded polystyrene and polyethylene on the bottom of the expanded polystyrene sports board core;

laminating a surface sheet to a foam backer sheet to form a foam-backed sheet;

laminating the foam backer side of the foam-backed sheet to a second blended sheet of expanded polystyrene and polyethylene to form a composite top skin;

laminating the composite top skin to the top surface of the expanded polystyrene sports board core; and

laminating a set of rail skins having the same composite structure as the top skin to the rails of the expanded polystyrene sports board core.

2. The method of claim 1 , wherein laminating a first blended sheet of expanded polystyrene and polyethylene to a bottom surface of an expanded polystyrene sports board core includes laminating with a heat bonding lamination process.

3. The method of claim 2 , wherein the heat bonding lamination process is selected from the group consisting of hot air lamination, inferred heat lamination, and radiant heat lamination.

4. The method of claim 1 , wherein laminating a surface sheet to a foam backer sheet to form a foam-backed sheet includes laminating with a heat bonding lamination process.

5. The method of claim 4 , wherein the heat bonding lamination process is selected from the group consisting of hot air lamination, inferred heat lamination, and radiant heat lamination.

6. The method of claim 1 , wherein laminating the foam backer side of the foam-backed sheet to a second blended sheet of expanded polystyrene and polyethylene to form a composite top skin includes laminating with a heat bonding lamination process.

7. The method of claim 6 , wherein the heat bonding lamination process is selected from the group consisting of hot air lamination, inferred heat lamination, and radiant heat lamination.

8. The method of claim 1 , wherein laminating the composite top skin to the top surface of the expanded polystyrene sports board core includes laminating with a heat bonding lamination process.

9. The method of claim 8 , wherein the heat bonding lamination process is selected from the group consisting of hot air lamination, inferred heat lamination, and radiant heat lamination.

10. The method of claim 1 , wherein laminating a surface sheet to a foam baker sheet includes using heat bonding lamination process to bond the surface sheet to the foam backer sheet.

11. The method of claim 10 , wherein the heat bonding lamination process is selected from the group consisting of hot air lamination, inferred heat lamination, and radiant heat lamination.

12. The method of claim 1 , wherein laminating a set of rail skins having the same composite structure as the top skin to the rails of the expanded polystyrene sports board core includes laminating a blended expanded polystyrene and polyethylene sheet to the rails of the expanded polystyrene sports board core prior to laminating a foam backer sheet and a surface sheet.

13. A sports board comprising:

an expanded polystyrene sports board core;

a composite top skin heat bonded to the top surface of the expanded polystyrene sports board core, the top skin including, a solid top sheet of a polyolefin material, a polyethylene foam backer sheet heat bonded to the solid top sheet, and a blended sheet of expanded polystyrene and polyethylene heat bonded to the foam backer sheet;

composite side rail skins heat bonded to side rails of the expanded polystyrene sports board core; and

a composite slick bottom skin heat bonded to a bottom surface of the expanded polystyrene sports board core.

14. The sports board of claim 13 , wherein the composite side rail skins include:

a solid top sheet of a polyolefin material;

a polyethylene foam backer sheet heat bonded to the solid top sheet; and

a blended sheet of expanded polystyrene and polyethylene heat bonded to the foam backer sheet.

15. The sports board of claim 14 , wherein the composite slick bottom skin includes a solid surface layer heat bonded to a blended sheet of expanded polystyrene and polyethylene.

16. The sports board of claim 15 , wherein the solid surface layer includes a solid low friction polyolefin material.

Assignments (12)