EP1321358A2 - Structural sub-assembly, surfboard and method for their production - Google Patents

Structural sub-assembly, surfboard and method for their production Download PDF

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Publication number
EP1321358A2
EP1321358A2 EP02026117A EP02026117A EP1321358A2 EP 1321358 A2 EP1321358 A2 EP 1321358A2 EP 02026117 A EP02026117 A EP 02026117A EP 02026117 A EP02026117 A EP 02026117A EP 1321358 A2 EP1321358 A2 EP 1321358A2
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EP
European Patent Office
Prior art keywords
assembly
shell elements
interface
shell
shells
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EP02026117A
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German (de)
French (fr)
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EP1321358A3 (en
Inventor
Eric Metrot
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Salomon SAS
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Salomon SAS
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Publication date
Application filed by Salomon SAS filed Critical Salomon SAS
Publication of EP1321358A2 publication Critical patent/EP1321358A2/en
Publication of EP1321358A3 publication Critical patent/EP1321358A3/en
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B32/00—Water sports boards; Accessories therefor
    • B63B32/57—Boards characterised by the material, e.g. laminated materials

Definitions

  • the invention relates to a sub-assembly designed to produce a gliding board, in particular a board for gliding on water such as a surf float.
  • It also relates to a method of manufacturing such a subassembly and a board of sliding made from the sub-assembly in question.
  • a surf float is made from a foam bar, especially polyurethane foam, which is formed in a mold.
  • the foam bread is machined by planing and sanding to a small thickness to locally customize its shape then it is coated with a fiberglass shell impregnated with resin which forms a shell external reinforcement and gives the float its final shape. Decoration and frosting give to the float its final appearance.
  • the foam bread is cut longitudinally into two parts which are then glued against a wooden slat which strengthens its structure and imposes a predetermined longitudinal camber.
  • the disadvantage of such a construction technique is the weight of the float in the end.
  • the foam is relatively dense, typically its density is 50kg / m3. And he it is not possible a priori to decrease the density of the foam without harming the characteristics float mechanics.
  • the central foam bar is generally made of polystyrene foam. expanded. This material has the defect of taking water. It happens that during its existence the float hit against a reef or rock. If the outer shell is damaged. one runs the risk of water infiltration, water weighing down the float and being particularly difficult to evacuate.
  • This manufacturing technique allows for light boards. However. it is not possible to customize the shape of the float. In this case the shape of the outer shell depends exclusively on the shape of the mold.
  • An object of the invention is to propose an improved sub-assembly, which makes it possible to carry out lighter or larger boards for an equal weight, while keeping a customizable shape.
  • Figures 1 and 2 illustrate schematically and in cross section, a la production of a structural sub-assembly comprising two assembled half-shells in accordance with the invention, respectively before and after bonding;
  • Figures 3 and 4 are schematic views illustrating a detail of Figure 2, respectively before and after the machining of the side rails of the sub-assembly.
  • Figures 5 and 6 are views similar to those of Figures 3 and 4 illustrating a variant of the invention in which the foaming adhesive is deposited so as to form an extra thickness on the outside of the sub-assembly.
  • Figures 7 and 8 are views similar to those of Figures 3 and 4 illustrating a variant of the invention in which the foaming adhesive is deposited so as to form an extra thickness inside the sub-assembly which, at least in this embodiment, is hollow.
  • Figures 9 to 11 are views similar to those of Figures 2 to 4 illustrating a variant for carrying out the invention.
  • Figures 12 and 13 are views similar to those of Figures 1 and 3 further illustrating a another embodiment of the invention.
  • a surf float is presented as an elongated board with a central part, a tapered and slightly raised front spatula, and a slightly rear heel raised and with a reduced width.
  • Figures 1 to 4 a first embodiment of the invention in which a structural sub-assembly is produced from two assembled half-shells.
  • the subset is a hollow subset constructed according to a sandwich technology.
  • Such a particularly light sub-assembly will advantageously be used in the manufacture of a surf float.
  • the sub-assembly 10 can thus be formed by an upper half-shell 22, which will form the deck of the final float, and a lower half-shell 24 which will form the hull.
  • Each half-shell is formed of a foam plate 26, 28 which is first shaped. next the type of foam used, this shaping can use different techniques.
  • the foam used will be for example an extruded polystyrene foam which is present generally in the form of a flat plate which can be shaped by thermoforming to become a curved plate as illustrated in the figures.
  • this shaped plate 26 is covered, on an internal face 30, 32, with at least an inner shell layer (for example a fiberglass, carbon or other fabric fibrous material impregnated with polyester, epoxy or other resin).
  • the laminating operation of the internal face 30, 32 of the half-shells 22, 24 will be advantageously carried out under vacuum while the foam plate previously thermoformed 26, 28 is still in the thermoforming mold, so that the layer of resin-coated fabric hardens on the thermoformed sheet while it is still pressed against the mold.
  • the shape of the front half-shell is thus best guaranteed assembly.
  • a hollow rigid internal shell which is formed by the layers of resin-coated fabrics arranged on the internal faces of the half-shells, and on the other hand an outer foam envelope suitable for being machined.
  • the foams used are for example sheets of extruded polystyrene foam with a density of the order of 30 to 50 kg / m3.
  • the subassembly produced therefore comprises at least one hollow internal part 50, which gives it great lightness without sacrificing its rigidity.
  • one of the half-shells for example the lower half-shell 24, is also laminated on its outer face 34 before the assembly of the two half-shells.
  • the half-hull thus laminated on its two faces 32, 34 is then particularly rigid during assembly with the other half-shell, which allows better control of the assembly precision, and therefore the precision of the shape of the subset.
  • the foam envelope covering the shell is then no longer suitable for being machined over its entire surface. Indeed, one of the faces being already laminated at the time of assembly, the geometry of this face can no longer be profoundly changed.
  • the two half-shells are not not symmetrical. Indeed, it can be seen that the lower half-shell 24 does not have any side edges.
  • the foam plate 28 is curved in the direction longitudinal (which is therefore not visible in the drawings) to follow the camber curve longitudinal (sometimes called "rocker” or "scoop” curve). She could also be curved in the transverse direction, for example to form a V-shaped, concave or double concave, but in the example illustrated the lower half-shell has no transverse curvature.
  • the shaping of the plate may occur do without thermoforming, simply by pressing the plate against the mold by vacuum at the time of stratification. After the resin has hardened, the stiffness of the coated fabric resin 32 is sufficient to maintain the plate in the desired shape of the half-shell.
  • the upper half-shell 22 is thermoformed so as to be curved longitudinally, but also transversely to form curved side edges 36 down.
  • the internal faces that is to say the lower face 30 of the half-shell upper 22 and upper face 32 of lower half-shell 24
  • the lower face 34 of the lower half-shell 24 is also laminated, before the assembly of the two half-shells.
  • the assembly of the two half-shells is obtained by having glue 42 in the interface zone consisting on the one hand of the lower edge of the lateral edges 36 of the upper half-shell 22 and on the other hand of the peripheral part corresponding to the upper face 32 of the lower half-shell 24.
  • the bonding is carried out using a resin foaming adhesive, for example polyurethane foam.
  • a resin foaming adhesive for example polyurethane foam.
  • MDI Metal-Diphenyl-lsocyanate
  • the foam will have by example a density in free expansion of the order of 25 to 200 kg / m3.
  • the density of the resin at the interface of the two half-shells may be greater due to the compression effect.
  • the resin will be applied still in the liquid state so as to allow perfect docking of the two half-shells. The two half-shells will then be kept in pressure against each other when the resin to avoid any risk of deformation due to swelling of the adhesive resin foaming at the time of its expansion.
  • foaming adhesive resins such as example of epoxy foams, with a slightly higher density of free expanding foam high.
  • the foaming adhesive resin may be colored.
  • Figure 3 which illustrates in more detail the lateral edge of the sub-assembly just after assembly
  • most of the side edge in height 38 of the structural assembly is formed by the lateral edges 36 of the upper half-shell whose outer face 40 is made of foam.
  • the lower part of these side edges is formed by the side edge of the lower half-shell, which has a thickness of foam 28 framed (top and bottom) by two thicknesses of fabrics impregnated with resin 32, 34.
  • Like the thicknesses of fabrics 32, 34 are very small. they do not form an obstacle to shaping by machining the side edges.
  • FIG. 4 it can be seen that the geometry of the lateral edge 38 of the sub-assembly structural has been modified over the entire height of the lateral edge 38, for example by planing and by sanding.
  • the stratification of one of the external surfaces of the subassembly 10, in this case the lower surface 34 of the lower half-shell 24, may be total (as illustrated). She may also concern only part of the surface 34, for example the central part for further improve the machinability of the side edge 38.
  • the precise assembly of the two half-shells is facilitated by the high rigidity of the lower half-shell, and the sub-assembly remains suitable for being machined on its entire upper face and on its lateral edges, which leaves a large capacity for customization of the sub-assembly.
  • the structural subset is covered with an outer shell, for example a layer of fibers impregnated with resin to form the gliding board.
  • an outer shell for example a layer of fibers impregnated with resin to form the gliding board.
  • the half-shell laminated on its two faces is the upper half-shell, the lower half-shell then being laminated only on its face upper 32.
  • part of this envelope (which is not desired modify the geometry, for example the upper face of the upper half-shell or the face lower half-shell), can be covered with a rigid outer layer.
  • a longitudinal central partition connecting vertically the two half-shells, such a partition being moreover known to the skilled person under the name of "stringer".
  • a central partition is for example made of foam or wood.
  • the partition can be bordered by two layers 13 and 14 of fibers impregnated with resin, which optionally connect continuously with the shell wall.
  • the sub-assembly according to this first embodiment can be machined in the same way than a traditional foam bread, according to the desire of the manufacturer, provided that the thickness machining remains significantly less than the thickness of the foam.
  • FIGS. 5 to 8 have the advantage of allowing greater machining depth, without risking too much reduction in mechanical strength of the subset.
  • the foaming adhesive resin 42 is not deposited only at the interface of the two half-shells, but it is on the contrary deposited so as to form an additional thickness 44 to the outside of the sub-assembly, all along the lateral edge 38 thereof.
  • this extra thickness can be precisely defined with the help of a mold applied along the side edge 38.
  • This mold may be part of a tool ensuring the correct positioning of the two half-shells during assembly.
  • the shape of the allowance could also be given by a flexible depressurized enclosure in which the sub-assembly in order to exert on the half-shells the pressure necessary for bonding. In these in two cases, the foam forming the additional thickness will therefore be compressed. We will be able to otherwise allow the foaming resin to expand freely.
  • the extra thickness extends on the one hand against the external face 40 of the upper half-shell (we see that the thickness of the excess glue decreases as one moves away from the interface zone), and on the other hand on a part of the upper face 32 of the half-shell lower 24 which in this example protrudes transversely outward relative to the upper half-shell 22.
  • this overhang is less pronounced, or even nonexistent, in which case the extra thickness would also extend against the edge of the half-shell lower 24.
  • the extra thickness 44 being made of foam, it is easily machinable, and the additional thickness of foam it forms allows greater freedom in choosing the final geometry of the lateral edge 38 after machining, the latter retaining a thickness substantially equivalent to that of the non-machined parts of the sub-assembly. We do not weaken so not the float.
  • the bonding of the two half-shells and the formation of the extra thickness will be done in one single operation. However, in some cases, choose to do these two operations successively.
  • the extra thickness 44 is made of internal side of the interface.
  • the structural subset is hollow, that is to say that the shell elements 22 delimit at least one hollow internal part 50.
  • This strip 44 thus forms a containment partition preventing the resin foaming adhesive to extend too much towards the inside of the cavity of the hollow body. She permits also to ensure, by the pressure due to the expansion of the foaming resin, a perfect contact of the extra thickness 44 with the two half-shells.
  • the excess thickness 44 of glue is in the hollow internal part 50, it can be seen in FIG. 8 that it is not affected by the final machining of the sub-assembly 10. It follows that the additional thickness 44, if it is of a volume and / or a weight significant, could influence the mechanical behavior of the final board (in particular the stiffness in bending and torsion), but above all that it can modify the weight distribution and of inertia of the board, therefore modifying its dynamic behavior. Of course, we can make sure that the importance of the extra thickness varies along the perimeter of the board, by example that it does not exist in some places, and on the contrary very important in others places.
  • each half-shell was formed from a sheet of thermoformed foam of substantially constant thickness.
  • the construction technique of the half-shell upper 22 is slightly different, this in order to very easily obtain a upper half-shell 22 which has, at its lateral edges 38, a thickness of foam 26 greater than the thickness of foam on the deck of the float, at least before the machining of the lateral edges 38.
  • a thickness of foam 26 greater than the thickness of foam on the deck of the float, at least before the machining of the lateral edges 38.
  • This construction has a double advantage: on the one hand give an increased thickness of foam which gives more freedom to the time of machining to obtain the desired shape, and on the other hand, the area is increased of the interface zone which is used for bonding, which reinforces the solidity of this bonding.
  • the edge of the half-shell upper 22 which forms part of this interface is not flat. It includes a disbursement 48, the cross section of which may be semi-elliptical as illustrated, but which may also have other profiles.
  • the contact surface between the adhesive 42 and the upper half-shell 22 is is therefore increased. Thanks to the fact that the glue is a foaming resin which expands, is sure that the disbursement 48 is perfectly filled with the adhesive which comes into contact with the wall which delimits this disbursement. Bonding is therefore optimal.
  • the upper half-shell 22 is formed of a foam plate 26 whose thickness is substantially constant and which is laminated on its face internal 30.
  • the lower half-shell 24 is laminated on its two faces 32, 34 but we see that the peripheral edge 52 of the upper face 32 is devoid of lamination so that the bonding of the two half-shells can be foam against foam.
  • the song of the upper half-shell, which is intended to come opposite the peripheral edge 52 of the half-shell lower 24, includes a disbursement 48 similar to that described in the context of previous embodiment. In this case, the disbursement 48 is formed only on the side internal edge, that is to say on the side of the internal cavity 50.
  • a containment partition 54 forming a barrier along the contour of the board.
  • This containment partition 54 may have a height less than the height of the cavity 50 in the corresponding zone, so that it does not then come into contact with the upper half-shell 22 as seen in FIG. 13.
  • This version is interesting in terms of ease of manufacture, as there is no precise height tolerance to be observed for the containment wall. On the contrary, one could foresee that this partition of containment is adjusted in height to come just in contact with the upper half-shell.
  • This version if it is more restrictive in terms of manufacturing, has the advantage of give the containment partition an additional function of vertical reinforcement and stiffening in addition to its primary function of confining the adhesive joint.
  • This partition containment can be made of a block of foam cut to the desired shape or a bead of foam which is allowed to freely expand on the internal face 34. It can also be produced in the form of a plate element made of rigid material, for example wood or sandwich material.
  • a containment wall all along of the interface between the two shell elements, or on the contrary provide for sections of partitions only along certain areas of the interface. In all cases, the bulkhead of confinement delimits, in the vicinity of the bonding interface, a clearly determined volume that the bonding foam fills by expanding, thus coming into contact against the faces internal 30, 32 of the two half-shells.
  • this embodiment has the advantage that the contact surfaces sticky foam with the two half-shells is very important.
  • the containment partition 54 good contact of the adhesive with the upper half-shell is ensured 22.
  • the peripheral edge 50 without lamination. and disbursement 48 offset towards the inside allow very easy machining of the side edge 38 which is almost exclusively made of foam.
  • the structural sub-assembly with its layer of machined foam is intended to be covered with an external envelope.
  • This outer envelope is preferably a sheet (woven or non-woven) 9 of glass fibers or other resin coated, and it can receive finishing operations in the same way as for a traditional float. This gives a particularly efficient gliding board.
  • the envelope external may be carried out differently, for example by simple thermoforming of two sheets of thermoplastic material, as is known in particular in the field windsurfing floats.
  • the invention has just been described for a sub-assembly formed only of two elements shell, but it can be transposed without difficulty in case the sub-assembly is composed of more than two shell elements.
  • a subset may include several of the aspects of the invention described one by one above, for example an extra thickness of glue on both the internal and external sides, or an excess of adhesive on the internal side combined with a disbursement of the interface song, etc.
  • the invention could be applied for the construction of gliding boards other than surf floats, by example for windsurfing floats, floats intended for swimming in waves and overall, any nautical practice in which the float operates mainly in the planed mode.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Ocean & Marine Engineering (AREA)
  • Laminated Bodies (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)
  • Slide Fasteners, Snap Fasteners, And Hook Fasteners (AREA)

Abstract

A structural sub-assembly (10) is manufactured by forming ≥ 2 shell elements and assembling the shell elements with adhesive resin foam. <??>An Independent claim is also included for a method for manufacturing the gliding board comprising partially machining the structural sub-assembly until it obtains a desired shape and covering the machined assembly with an outer envelope.

Description

L'invention concerne un sous-ensemble prévu pour réaliser une planche de glisse, notamment une planche de glisse sur eau tel qu'un flotteur de surf.The invention relates to a sub-assembly designed to produce a gliding board, in particular a board for gliding on water such as a surf float.

Elle concerne également un procédé de fabrication d'un tel sous-ensemble et une planche de glisse réalisée à partir du sous-ensemble en question.It also relates to a method of manufacturing such a subassembly and a board of sliding made from the sub-assembly in question.

De façon traditionnelle, un flotteur de surf est réalisé à partir d'un pain de mousse, notamment de mousse de polyuréthane, qui est formé dans un moule. Le pain de mousse est usiné par rabotage et ponçage sur une faible épaisseur pour personnaliser localement sa forme puis il est revêtu d'une enveloppe en fibres de verre imprégnées de résine qui forme une coque externe de renfort et donne au flotteur sa forme finale. Une décoration et un glaçage donnent au flotteur son aspect final.Traditionally, a surf float is made from a foam bar, especially polyurethane foam, which is formed in a mold. The foam bread is machined by planing and sanding to a small thickness to locally customize its shape then it is coated with a fiberglass shell impregnated with resin which forms a shell external reinforcement and gives the float its final shape. Decoration and frosting give to the float its final appearance.

Dans certains cas, le pain de mousse est découpé longitudinalement en deux parties qui sont ensuite collées contre une latte de bois qui renforce sa structure et lui impose une cambrure longitudinale prédéterminée.In some cases, the foam bread is cut longitudinally into two parts which are then glued against a wooden slat which strengthens its structure and imposes a predetermined longitudinal camber.

L'inconvénient d'une telle technique de construction est le poids du flotteur en final. En effet, la mousse est relativement dense, typiquement sa masse volumique est de 50kg/m3. Et il n'est pas possible à priori de diminuer la densité de la mousse sans nuire aux caractéristiques mécaniques du flotteur.The disadvantage of such a construction technique is the weight of the float in the end. In Indeed, the foam is relatively dense, typically its density is 50kg / m3. And he it is not possible a priori to decrease the density of the foam without harming the characteristics float mechanics.

Selon une autre technique de construction issue de la planche à voile, on part d'un pain de mousse de densité relativement faible (par exemple 18 kg/m3) que l'on usine de façon à le mettre en forme. On recouvre ce pain d'une peau en fibres de verre imprégnées de résine. On rapporte autour de ce sous-ensemble une enveloppe de mousse de densité plus élevée. Puis on applique des nappes de fibres de verre imprégnées de résine, afin de former la coque externe.According to another construction technique from windsurfing, we start with a bread relatively low density foam (eg 18 kg / m3) which is machined so as to get in shape. This bread is covered with a fiberglass skin impregnated with resin. We around this subassembly brings a higher density foam envelope. Then we applies layers of resin-impregnated glass fibers to form the outer shell.

Un tel mode de construction permet un gain de poids d'environ 20% ou plus tout en gardant une bonne rigidité sous les pieds. Toutefois sa mise en oeuvre est relativement complexe. En outre le pain de mousse central est généralement en mousse de polystyrène expansé. Ce matériau a le défaut de prendre l'eau. Il arrive qu'au cours de son existence le flotteur soit heurté contre un récif ou un rocher. Si la coque externe est endommagée. on court le risque d'avoir des infiltrations d'eau, l'eau alourdissant le flotteur et étant particulièrement difficile à évacuer.Such a construction method allows a weight gain of about 20% or more while keeping good rigidity under the feet. However, its implementation is relatively complex. In addition, the central foam bar is generally made of polystyrene foam. expanded. This material has the defect of taking water. It happens that during its existence the float hit against a reef or rock. If the outer shell is damaged. one runs the risk of water infiltration, water weighing down the float and being particularly difficult to evacuate.

Enfin, il est connu de réaliser des flotteurs creux avec des peaux sandwich. Ou bien on réalise deux demi-coques qui sont ensuite assemblées entre elles, ou bien on réalise l'ensemble dans un moule fermé avec une vessie interne que l'on gonfle pour pousser et appliquer les peaux sandwich contre les parois du moule. Dans tous les cas, les flotteurs de ce type présentent des parois d'épaisseur constante Finally, it is known to make hollow floats with sandwich skins. Or else produces two half-shells which are then assembled together, or else the assembly is produced in a closed mold with an internal bladder which is inflated to push and apply the sandwich skins against the walls of the mold. In all cases, floats of this type have walls of constant thickness

Cette technique de fabrication permet de réaliser des planches légères. Toutefois. il n'est pas possible de personnaliser la forme du flotteur. Dans ce cas la forme de la coque externe dépend exclusivement de la forme du moule.This manufacturing technique allows for light boards. However. it is not not possible to customize the shape of the float. In this case the shape of the outer shell depends exclusively on the shape of the mold.

Un but de l'invention est de proposer un sous-ensemble amélioré, qui permet de réaliser des planches de glisses plus légères, ou plus volumineuses pour un poids égal, tout en conservant une forme personnalisable.An object of the invention is to propose an improved sub-assembly, which makes it possible to carry out lighter or larger boards for an equal weight, while keeping a customizable shape.

Ce but est atteint par un en mettant en oeuvre un procédé de fabrication d'un sous-ensemble structurel pour une planche de glisse caractérisé en ce qu'il comporte les étapes consistant à :

  • former deux demi-coques ;
  • assembler les deux demi-coques à l'aide d'une résine adhésive moussante.
This object is achieved by using a method of manufacturing a structural sub-assembly for a gliding board, characterized in that it comprises the steps consisting in:
  • form two half-shells;
  • assemble the two half-shells using a foaming adhesive resin.

L'invention sera mieux comprise en se référant à la description ci-dessous et aux dessins en annexe qui lui sont rattachés.The invention will be better understood by referring to the description below and to the drawings in annex attached to it.

Les figures 1 et 2 illustrent de manière schématique et en coupe transversale, une la réalisation d'un sous-ensemble structurel comportant deux demi-coques assemblées conformément à l'invention, respectivement avant et après le collage ;Figures 1 and 2 illustrate schematically and in cross section, a la production of a structural sub-assembly comprising two assembled half-shells in accordance with the invention, respectively before and after bonding;

Les figures 3 et 4 sont des vues schématiques illustrant un détail de la figure 2, respectivement avant et après l'usinage des rails latéraux du sous-ensemble.Figures 3 and 4 are schematic views illustrating a detail of Figure 2, respectively before and after the machining of the side rails of the sub-assembly.

Les figures 5 et 6 sont des vues similaires à celles des figures 3 et 4 illustrant une variante de réalisation de l'invention dans laquelle la colle moussante est déposée de manière à former une surépaisseur sur l'extérieur du sous-ensemble.Figures 5 and 6 are views similar to those of Figures 3 and 4 illustrating a variant of the invention in which the foaming adhesive is deposited so as to form an extra thickness on the outside of the sub-assembly.

Les figures 7 et 8 sont des vues similaires à celles des figures 3 et 4 illustrant une variante de réalisation de l'invention dans laquelle la colle moussante est déposée de manière à former une surépaisseur l'intérieur du sous-ensemble qui, au moins dans ce mode de réalisation, est creux.Figures 7 and 8 are views similar to those of Figures 3 and 4 illustrating a variant of the invention in which the foaming adhesive is deposited so as to form an extra thickness inside the sub-assembly which, at least in this embodiment, is hollow.

Les figures 9 à 11 sont des vues similaires à celles des figures 2 à 4 illustrant une variante de réalisation de l'invention.Figures 9 to 11 are views similar to those of Figures 2 to 4 illustrating a variant for carrying out the invention.

Les figures 12 et 13 sont des vues similaires à celles de figures 1 et 3 illustrant encore un autre mode de réalisation de l'invention.Figures 12 and 13 are views similar to those of Figures 1 and 3 further illustrating a another embodiment of the invention.

De façon connue, un flotteur de surf se présente comme une planche allongée avec une partie centrale, une spatule avant effilée et légèrement relevée, et un talon arrière légèrement relevée et avec une largeur diminuée.In known manner, a surf float is presented as an elongated board with a central part, a tapered and slightly raised front spatula, and a slightly rear heel raised and with a reduced width.

On a illustré sur les figures 1 à 4 un premier mode de réalisation de l'invention dans lequel un sous-ensemble structurel est réalisé à partir de deux demi-coques assemblées. Dans l'exemple illustré, le sous-ensemble est un sous-ensemble creux construit selon une technologie sandwich. Un tel sous-ensemble, particulièrement léger, sera avantageusement utilisé dans la fabrication d'un flotteur de surf. Pour d'autres types de planches de glisse, on pourra mettre en oeuvre l'invention avec d'autres modes de réalisation du sous-ensemble.There is illustrated in Figures 1 to 4 a first embodiment of the invention in which a structural sub-assembly is produced from two assembled half-shells. In the example illustrated, the subset is a hollow subset constructed according to a sandwich technology. Such a particularly light sub-assembly will advantageously be used in the manufacture of a surf float. For other types of boards, we may implement the invention with other embodiments of the sub-assembly.

Le sous-ensemble 10 peut ainsi être formé d'une demi-coque supérieure 22, qui formera le pont du flotteur définitif, et d'une demi-coque inférieure 24 qui formera la carène. Chaque demi-coque est formée d'une plaque de mousse 26, 28 qui est d'abord mise en forme. Suivant la type de mousse utilisé, cette mise en forme pourra mettre en oeuvre différentes techniques. La mousse utilisée sera par exemple une mousse de polystyrène extrudé qui se présente généralement sous la forme d'une plaque plane et qui peut être mise en forme par thermoformage pour devenir une plaque courbée tel qu'illustré sur les figures. Dans l'exemple illustré, cette plaque 26 mise en forme est recouverte, sur une face interne 30, 32, d'au moins une couche enveloppe interne (par exemple un tissu de fibres de verre, de carbone ou autre matériau fibreux imprégné de résine polyester, époxy ou autre). Dans l'exemple illustré, l'opération de stratification de la face interne 30, 32 des demi-coques 22, 24 sera avantageusement réalisée sous vide alors que la plaque de mousse préalablement thermoformée 26, 28 est encore dans le moule de thermoformage, ceci afin que la couche de tissu enduit de résine durcisse sur la plaque thermoformée alors que celle-ci est encore plaquée contre le moule. On garantit ainsi au mieux la forme de la demi-coque avant l'assemblage.The sub-assembly 10 can thus be formed by an upper half-shell 22, which will form the deck of the final float, and a lower half-shell 24 which will form the hull. Each half-shell is formed of a foam plate 26, 28 which is first shaped. next the type of foam used, this shaping can use different techniques. The foam used will be for example an extruded polystyrene foam which is present generally in the form of a flat plate which can be shaped by thermoforming to become a curved plate as illustrated in the figures. In the example illustrated, this shaped plate 26 is covered, on an internal face 30, 32, with at least an inner shell layer (for example a fiberglass, carbon or other fabric fibrous material impregnated with polyester, epoxy or other resin). In the example shown, the laminating operation of the internal face 30, 32 of the half-shells 22, 24 will be advantageously carried out under vacuum while the foam plate previously thermoformed 26, 28 is still in the thermoforming mold, so that the layer of resin-coated fabric hardens on the thermoformed sheet while it is still pressed against the mold. The shape of the front half-shell is thus best guaranteed assembly.

Lorsque les deux demi-coques 22, 24 sont assemblées l'une à l'autre, par exemple par collage, on obtient directement d'une part une coquille interne rigide creuse, qui est formée par les couches de tissus enduits de résine disposées sur les faces internes des demi-coques, et d'autre part une enveloppe de mousse externe apte à être usinée. Les mousses utilisées sont par exemple des plaques de mousse de polystyrène extrudé d'une densité de l'ordre de 30 à 50 kg/m3. Le sous-ensemble réalisé comporte donc au moins une partie interne creuse 50, ce qui lui confère une grande légèreté sans sacrifier sa rigidité.When the two half-shells 22, 24 are assembled to one another, for example by bonding, one obtains directly on the one hand a hollow rigid internal shell, which is formed by the layers of resin-coated fabrics arranged on the internal faces of the half-shells, and on the other hand an outer foam envelope suitable for being machined. The foams used are for example sheets of extruded polystyrene foam with a density of the order of 30 to 50 kg / m3. The subassembly produced therefore comprises at least one hollow internal part 50, which gives it great lightness without sacrificing its rigidity.

Pour la mise en oeuvre de ce mode de réalisation de l'invention, il peut être intéressant de prévoir que l'une des demi-coques, par exemple la demi-coque inférieure 24, soit aussi stratifiée sur sa face extérieure 34 avant l'assemblage des deux demi-coques. La demi-coque ainsi stratifiée sur ses deux faces 32, 34 est alors particulièrement rigide lors de l'assemblage avec l'autre demi-coque, ce qui permet de mieux maítriser la précision de l'assemblage, et donc la précision de la forme du sous-ensemble. Bien sûr, l'enveloppe en mousse recouvrant la coquille n'est alors plus apte à être usinée sur toute sa superficie. En effet, l'une des faces étant déjà stratifiée au moment de l'assemblage, la géométrie de cette face ne peut plus être profondément modifiée. Cependant, on s'est aperçu que, pour modifier de manière sensible le comportement final du flotteur de glisse, il suffit bien souvent de modifier la géométrie des bords latéraux du flotteur (généralement appelés les rails du flotteur). Or cette géométrie peut être modifiée même si l'une des faces externes du flotteur (par exemple la face inférieure) est déjà stratifiée.For the implementation of this embodiment of the invention, it may be advantageous to provide that one of the half-shells, for example the lower half-shell 24, is also laminated on its outer face 34 before the assembly of the two half-shells. The half-hull thus laminated on its two faces 32, 34 is then particularly rigid during assembly with the other half-shell, which allows better control of the assembly precision, and therefore the precision of the shape of the subset. Of course, the foam envelope covering the shell is then no longer suitable for being machined over its entire surface. Indeed, one of the faces being already laminated at the time of assembly, the geometry of this face can no longer be profoundly changed. However, we have noticed that, in order to appreciably modify the final behavior of the gliding float, it is often enough to modify the geometry of the side edges of the float (usually called the float rails). This geometry can be modified even if one of the external faces of the float (for example the lower face) is already stratified.

Dans l'exemple illustré sur les figures 1 à 4, on peut voir que les deux demi-coques ne sont pas symétriques. En effet, on peut voir que la demi-coque inférieure 24 ne comporte pas de rebords latéraux. Lors de sa mise en forme, la plaque de mousse 28 est courbée dans le sens longitudinal (ce qui n'est donc pas visible sur les dessins) pour suivre la courbe de cambrure longitudinale (parfois appelée courbe de « rocker » ou de « scoop »). Elle pourrait aussi être courbée dans le sens transversal, par exemple pour former une carène en V, en concave ou en double concave, mais dans l'exemple illustré la demi-coque inférieure ne présente pas de courbure transversale. Dans ce cas, étant donné que la déformation de la plaque de mousse par rapport à son état plan initial est relativement faible, la mise en forme de la plaque peut se faire sans thermoformage, simplement en plaquant la plaque contre le moule par dépression au moment de la stratification. Après durcissement de la résine, la rigidité du tissu enduit de résine 32 suffit à maintenir la plaque à la forme souhaitée de la demi-coque.In the example illustrated in FIGS. 1 to 4, it can be seen that the two half-shells are not not symmetrical. Indeed, it can be seen that the lower half-shell 24 does not have any side edges. During its shaping, the foam plate 28 is curved in the direction longitudinal (which is therefore not visible in the drawings) to follow the camber curve longitudinal (sometimes called "rocker" or "scoop" curve). She could also be curved in the transverse direction, for example to form a V-shaped, concave or double concave, but in the example illustrated the lower half-shell has no transverse curvature. In this case, since the deformation of the foam plate by compared to its initial plan state is relatively weak, the shaping of the plate may occur do without thermoforming, simply by pressing the plate against the mold by vacuum at the time of stratification. After the resin has hardened, the stiffness of the coated fabric resin 32 is sufficient to maintain the plate in the desired shape of the half-shell.

Au contraire, la demi-coque supérieure 22 est thermoformée de manière à être courbée longitudinalement, mais aussi transversalement pour former de rebords latéraux 36 recourbés vers le bas. Selon l'invention les faces internes (c'est-à-dire la face inférieure 30 de la demi-coque supérieure 22 et la face supérieure 32 de la demi-coque inférieure 24) sont stratifiées avec une ou plusieurs couches de tissus de fibres imprégnées de résine thermodurcissable. Comme on peut le voir à la figure 1, la face inférieure 34 de la demi-coque inférieure 24 est elle aussi stratifiée, avant l'assemblage des deux demi-coques.On the contrary, the upper half-shell 22 is thermoformed so as to be curved longitudinally, but also transversely to form curved side edges 36 down. According to the invention the internal faces (that is to say the lower face 30 of the half-shell upper 22 and upper face 32 of lower half-shell 24) are laminated with one or more layers of fiber fabrics impregnated with thermosetting resin. As can be seen in FIG. 1, the lower face 34 of the lower half-shell 24 is also laminated, before the assembly of the two half-shells.

Comme on peut le voir à la figure 2, l'assemblage des deux demi-coques est obtenu en disposant de la colle 42 dans la zone d'interface constituée d'une part du bord inférieur des rebords latéraux 36 de la demi-coque supérieure 22 et d'autre part de la partie périphérique correspondante de la face supérieure 32 de la demi-coque inférieure 24.As can be seen in Figure 2, the assembly of the two half-shells is obtained by having glue 42 in the interface zone consisting on the one hand of the lower edge of the lateral edges 36 of the upper half-shell 22 and on the other hand of the peripheral part corresponding to the upper face 32 of the lower half-shell 24.

Conformément aux enseignements de l'invention, le collage est réalisé à l'aide d'une résine adhésive moussante, par exemple une mousse de polyuréthane. On choisira par exemple une mousse de polyuréthane de type MDI (Methyl-Diphenyl-lsocyanate) comportant un ratio (en poids) polyol/isocyanate de l'ordre de 100/140 ou de l'ordre de 100/110. La mousse aura par exemple une masse volumique en expansion libre de l'ordre de 25 à 200 kg/m3. Bien entendu, la masse volumique de la résine au niveau de l'interface des deux demi-coques pourra être plus importante du fait de l'effet de compression. De préférence, la résine sera appliquée encore à l'état liquide de manière à permettre un parfait accostage des deux demi-coques. Les deux demi-coques seront alors maintenues en pression l'une contre l'autre lors de la prise de la résine pour éviter tout risque de déformation dû au gonflement de la résine adhésive moussante au moment de son expansion.In accordance with the teachings of the invention, the bonding is carried out using a resin foaming adhesive, for example polyurethane foam. We will choose for example a polyurethane foam type MDI (Methyl-Diphenyl-lsocyanate) with a ratio (in weight) polyol / isocyanate of the order of 100/140 or of the order of 100/110. The foam will have by example a density in free expansion of the order of 25 to 200 kg / m3. Of course, the density of the resin at the interface of the two half-shells may be greater due to the compression effect. Preferably, the resin will be applied still in the liquid state so as to allow perfect docking of the two half-shells. The two half-shells will then be kept in pressure against each other when the resin to avoid any risk of deformation due to swelling of the adhesive resin foaming at the time of its expansion.

On pourra aussi utiliser d'autres types de résines moussantes adhésives, comme par exemple des mousses d'époxy, avec une densité de mousse en expansion libre légèrement plus élevée. Dans tous les cas, la résine adhésive moussante pourra être colorée.We can also use other types of foaming adhesive resins, such as example of epoxy foams, with a slightly higher density of free expanding foam high. In all cases, the foaming adhesive resin may be colored.

Avec cette construction, on voit à la figure 3 (qui illustre plus en détail le bord latéral du sous-ensemble juste après l'assemblage) que la plus grande partie en hauteur du bord latéral 38 de l'ensemble structurel est formée par les rebords latéraux 36 de la demi-coque supérieure dont la face externe 40 est constituée de mousse. La partie inférieure de ces bords latéraux est constituée par le chant latéral de la demi-coque inférieure, lequel présente une épaisseur de mousse 28 encadrée (dessus et dessous) par deux épaisseurs de tissus imprégnés de résine 32, 34. Comme les épaisseurs de tissus 32, 34 sont très faibles. elles ne forment pas obstacle à la mise en forme par usinage des bords latéraux.With this construction, we see in Figure 3 (which illustrates in more detail the lateral edge of the sub-assembly just after assembly) that most of the side edge in height 38 of the structural assembly is formed by the lateral edges 36 of the upper half-shell whose outer face 40 is made of foam. The lower part of these side edges is formed by the side edge of the lower half-shell, which has a thickness of foam 28 framed (top and bottom) by two thicknesses of fabrics impregnated with resin 32, 34. Like the thicknesses of fabrics 32, 34 are very small. they do not form an obstacle to shaping by machining the side edges.

Entre les parties inférieure et supérieure de ces bords latéraux, on peut voir le joint de collage 42 réalisé à l'aide de la résine adhésive moussante. Grâce à la structure de ce matériau de collage, qui est très proche de celle de la mousse que l'on va chercher à usiner, on évite la présence d'une couche particulièrement dure qui serait due à la superposition d'une couche de colle compacte et rigide, comme par exemple une colle époxy, avec la face supérieure 32 stratifiée de la demi-coque inférieure 24.Between the lower and upper parts of these side edges, we can see the seal of collage 42 made using foaming adhesive resin. Thanks to the structure of this material bonding, which is very close to that of the foam that we are going to try to machine, we avoid the presence of a particularly hard layer which would be due to the superposition of a layer of compact and rigid adhesive, for example an epoxy adhesive, with the upper face 32 laminate of the lower half-shell 24.

Ainsi, sur la figure 4, on peut voir que la géométrie du bord latéral 38 du sous-ensemble structurel a été modifiée sur toute la hauteur du bord latéral 38, par exemple par rabotage et par ponçage.Thus, in FIG. 4, it can be seen that the geometry of the lateral edge 38 of the sub-assembly structural has been modified over the entire height of the lateral edge 38, for example by planing and by sanding.

Toutefois, en variante, on pourra faire en sorte que la partie périphérique de la face supérieure 32 de la demi-coque inférieure 24 soit dépourvue de stratification de telle sorte que les rebords latéraux 36 de la demi-coque supérieure 22 soient assemblé par le joint de mousse collante 42 directement contre la mousse 28, ceci afin d'assurer une meilleure continuité du matériau formant le bord latéral 38 qui, grâce à l'invention qui prévoit l'utilisation d'une résine adhésive moussante, n'est alors plus constitué que de mousse. Une telle caractéristique est présente dans le mode de réalisation décrit plus bas en relation aux figures 12 et 13.However, as a variant, it will be possible to ensure that the peripheral part of the face upper 32 of the lower half-shell 24 is devoid of stratification so that the side edges 36 of the upper half-shell 22 are assembled by the foam seal sticky 42 directly against the foam 28, this in order to ensure better continuity of the material forming the side edge 38 which, thanks to the invention which provides for the use of a resin foaming adhesive, then only consists of foam. One such characteristic is present in the embodiment described below in relation to FIGS. 12 and 13.

La stratification de l'une des surfaces externes du sous-ensemble 10, en l'occurrence la surface inférieure 34 de la demi-coque inférieure 24, peut être totale (comme illustré). Elle peut aussi ne concerner qu'une partie de la surface 34, par exemple la partie centrale pour améliorer encore l'usinabilité du bord latéral 38.The stratification of one of the external surfaces of the subassembly 10, in this case the lower surface 34 of the lower half-shell 24, may be total (as illustrated). She may also concern only part of the surface 34, for example the central part for further improve the machinability of the side edge 38.

Avec cette construction, l'assemblage précis des deux demi-coques est facilité par la grande rigidité de la demi-coque inférieure, et le sous-ensemble reste apte à être usiné sur toute sa face supérieure et sur ses bords latéraux, ce qui laisse une grande capacité de personnalisation du sous-ensemble. Une fois personnalisé, le sous-ensemble structurel est recouvert d'une enveloppe externe, par exemple une couche de fibres imprégnées de résine pour former la planche de glisse. Suivant les cas, on pourra choisir de recouvrir aussi la surface externe déjà stratifiée 34 du sous-ensemble avec cette couche externe, pour augmenter la rigidité et la solidité du flotteur, ou au contraire choisir de ne pas recouvrir cette surface déjà stratifiée 34, ceci afin de limiter le poids du flotteur.With this construction, the precise assembly of the two half-shells is facilitated by the high rigidity of the lower half-shell, and the sub-assembly remains suitable for being machined on its entire upper face and on its lateral edges, which leaves a large capacity for customization of the sub-assembly. Once customized, the structural subset is covered with an outer shell, for example a layer of fibers impregnated with resin to form the gliding board. Depending on the case, we can choose to also cover the already laminated external surface 34 of the sub-assembly with this external layer, to increase the rigidity and solidity of the float, or on the contrary choose not to cover this surface already laminated 34, this in order to limit the weight of the float.

Bien entendu, dans le cas où l'on souhaite privilégier la possibilité de personnaliser la carène du flotteur, on pourrait prévoir que la demi-coque stratifiée sur ses deux faces soit la demi-coque supérieure, la demi-coque inférieure n'étant alors stratifiée que sur sa face supérieure 32. Optionnellement une partie de cette enveloppe (dont on ne souhaite pas modifier la géométrie, par exemple la face supérieure de la demi-coque supérieure ou la face inférieur de la demi-coque inférieure), peut être recouverte d'une couche externe rigide.Of course, in the case where one wishes to privilege the possibility of personalizing the hull of the float, one could foresee that the half-shell laminated on its two faces is the upper half-shell, the lower half-shell then being laminated only on its face upper 32. Optionally part of this envelope (which is not desired modify the geometry, for example the upper face of the upper half-shell or the face lower half-shell), can be covered with a rigid outer layer.

Pour améliorer encore sa rigidité, on pourra avantageusement prévoir de munir le sous-ensemble structurel des figures 1 à 4 d'une cloison centrale longitudinale reliant verticalement les deux demi-coques, une telle cloison étant par ailleurs connue de l'homme du métier sous le nom de "stringer". Une telle cloison centrale est par exemple réalisée en mousse ou en bois. La cloison peut être bordée de deux couches 13 et 14 de fibres imprégnées de résine, qui éventuellement se raccordent en continu avec la paroi de la coquille.To further improve its rigidity, provision may advantageously be made for providing the sub-assembly structural of Figures 1 to 4 of a longitudinal central partition connecting vertically the two half-shells, such a partition being moreover known to the skilled person under the name of "stringer". Such a central partition is for example made of foam or wood. The partition can be bordered by two layers 13 and 14 of fibers impregnated with resin, which optionally connect continuously with the shell wall.

Naturellement, la présente description n'est donnée qu'à titre indicatif, et l'on pourrait adopter d'autres mises en oeuvre de celle-ci sans pour autant sortir du cadre de la présente invention, par exemple avoir plusieurs cloisons longitudinales, transversales ou autres directions appropriées, ces cloisons formant des liaisons entre le pont et la carène du flotteur. Eventuellement, ces cloisons pourront créer un cloisonnement de la coquille interne en plusieurs compartiments étanches.Naturally, the present description is given for information only, and one could adopt other implementations thereof without departing from the scope of this invention, for example having several longitudinal, transverse or other partitions appropriate directions, these partitions forming connections between the deck and the hull of the float. Optionally, these partitions may create a partitioning of the internal shell by several watertight compartments.

Le sous-ensemble selon ce premier mode de réalisation peut être usiné de la même façon qu'un pain de mousse traditionnel, selon le désir du façonnier, pourvu que l'épaisseur d'usinage reste nettement inférieure à l'épaisseur de la mousse.The sub-assembly according to this first embodiment can be machined in the same way than a traditional foam bread, according to the desire of the manufacturer, provided that the thickness machining remains significantly less than the thickness of the foam.

Les deux modes de réalisation illustrés aux figures 5 à 8 présentent l'avantage de permettre une plus grande profondeur d'usinage, sans risquer de trop diminuer la résistance mécanique du sous-ensemble.The two embodiments illustrated in FIGS. 5 to 8 have the advantage of allowing greater machining depth, without risking too much reduction in mechanical strength of the subset.

En effet, on peut voir que, dans le second mode de réalisation illustré aux figures 5 et 6, la résine adhésive moussante 42 n'est pas déposée uniquement à l'interface des deux demi-coques, mais elle est au contraire déposée de manière à former une surépaisseur 44 à l'extérieur du sous-ensemble, tout le long du bord latéral 38 de celui-ci.Indeed, it can be seen that, in the second embodiment illustrated in FIGS. 5 and 6, the foaming adhesive resin 42 is not deposited only at the interface of the two half-shells, but it is on the contrary deposited so as to form an additional thickness 44 to the outside of the sub-assembly, all along the lateral edge 38 thereof.

La forme de cette surépaisseur pourra être définie avec précision avec l'aide d'un moule appliqué le long du bord latéral 38. Ce moule pourra faire partie d'un outil assurant le bon positionnement des deux demi-coques lors de l'assemblage. La forme de la surépaisseur pourra aussi être donnée par une enceinte souple dépressurisée dans laquelle on enforme le sous-ensemble afin d'exercer sur les demi-coques la pression nécessaire au collage. Dans ces deux cas, la mousse formant la surépaisseur se trouvera donc comprimée. On pourra au contraire laisser la résine moussante s'expanser librement. Dans l'exemple illustré, la surépaisseur s'étend d'une part contre la face externe 40 de la demi-coque supérieure (on voit que l'épaisseur de la surépaisseur de colle diminue au fur et à mesure que l'on s'éloigne de la zone d'interface), et d'autre part sur une partie de la face supérieure 32 de la demi-coque inférieure 24 qui, dans cet exemple dépasse transversalement vers l'extérieur par rapport à la demi-coque supérieure 22. On pourrait prévoir que ce débord soit moins prononcé, voire inexistant, auquel cas la surépaisseur s'étendrait aussi contre le chant de la demi-coque inférieure 24.The shape of this extra thickness can be precisely defined with the help of a mold applied along the side edge 38. This mold may be part of a tool ensuring the correct positioning of the two half-shells during assembly. The shape of the allowance could also be given by a flexible depressurized enclosure in which the sub-assembly in order to exert on the half-shells the pressure necessary for bonding. In these in two cases, the foam forming the additional thickness will therefore be compressed. We will be able to otherwise allow the foaming resin to expand freely. In the example shown, the extra thickness extends on the one hand against the external face 40 of the upper half-shell (we see that the thickness of the excess glue decreases as one moves away from the interface zone), and on the other hand on a part of the upper face 32 of the half-shell lower 24 which in this example protrudes transversely outward relative to the upper half-shell 22. One could predict that this overhang is less pronounced, or even nonexistent, in which case the extra thickness would also extend against the edge of the half-shell lower 24.

La surépaisseur 44 étant constituée de mousse, elle est facilement usinable, et le surcroít d'épaisseur de mousse qu'elle forme autorise une plus grande liberté dans choix de la géométrie finale du bord latéral 38 après usinage, ce dernier conservant une épaisseur sensiblement équivalente à celle des parties non usinées du sous-ensemble. On ne fragilise ainsi pas le flotteur. The extra thickness 44 being made of foam, it is easily machinable, and the additional thickness of foam it forms allows greater freedom in choosing the final geometry of the lateral edge 38 after machining, the latter retaining a thickness substantially equivalent to that of the non-machined parts of the sub-assembly. We do not weaken so not the float.

Avantageusement, le collage des deux demi-coques et la formation de la surépaisseur seront fait au cours d'une seule et même opération. Cependant, on pourra dans certain cas choisir de faire ces deux opérations successivement.Advantageously, the bonding of the two half-shells and the formation of the extra thickness will be done in one single operation. However, in some cases, choose to do these two operations successively.

Un autre avantage tiré de la réalisation de ces surépaisseurs avec la résine adhésive moussante réside dans le fait que l'on augmente ainsi la surface de collage entre les deux demi-coques, donc la résistance de l'assemblage.Another advantage derived from the realization of these extra thicknesses with the adhesive resin foaming lies in the fact that this increases the bonding surface between the two half-shells, therefore the strength of the assembly.

Dans le mode de réalisation illustré aux figures 7 et 8, la surépaisseur 44 est réalisée du côté interne de l'interface. Cela suppose bien entendu que le sous-ensemble structurel soit creux, c'est-à-dire que les éléments de coque 22 délimitent au moins une partie interne creuse 50. Dans ce mode de réalisation, on peut soit laisser la surépaisseur s'expanser librement, soit la confiner à l'aide, par exemple, d'une bande 46 de tissus imprégnée de résine qui relie la face supérieure 32 de la demi-coque inférieure 24 à la face inférieure 30 de la demi-coque supérieure. Cette bande 44 forme ainsi une cloison de confinement empêchant la résine adhésive moussante de s'étendre trop vers l'intérieur de la cavité du corps creux. Elle permet aussi d'assurer, par la pression due à l'expansion de la résine moussante, un parfait contact de la surépaisseur 44 avec les deux demi-coques. Lorsque la surépaisseur 44 de colle est dans la partie interne creuse 50, on voit à la figure 8 qu'elle n'est pas affectée par l'usinage final du sous-ensemble 10. Il en résulte que la surépaisseur 44, si elle est d'un volume et/ou d'un poids significatif, pourra influer sur le comportement mécanique de la planche finale (notamment la raideur en flexion et en torsion), mais surtout qu'elle pourra modifier la répartition de poids et d'inertie de la planche, donc modifier son comportement dynamique. Bien entendu, on peut faire en sorte que l'importance de la surépaisseur varie le long du pourtour de la planche, par exemple qu'elle soit inexistante à certains endroits, et au contraire très importante à d'autres endroits.In the embodiment illustrated in FIGS. 7 and 8, the extra thickness 44 is made of internal side of the interface. This of course assumes that the structural subset is hollow, that is to say that the shell elements 22 delimit at least one hollow internal part 50. In this embodiment, it is possible either to allow the allowance to expand freely, or confine it using, for example, a strip 46 of resin-impregnated tissue which connects the face upper 32 of the half-shell lower 24 to the lower face 30 of the half-shell higher. This strip 44 thus forms a containment partition preventing the resin foaming adhesive to extend too much towards the inside of the cavity of the hollow body. She permits also to ensure, by the pressure due to the expansion of the foaming resin, a perfect contact of the extra thickness 44 with the two half-shells. When the excess thickness 44 of glue is in the hollow internal part 50, it can be seen in FIG. 8 that it is not affected by the final machining of the sub-assembly 10. It follows that the additional thickness 44, if it is of a volume and / or a weight significant, could influence the mechanical behavior of the final board (in particular the stiffness in bending and torsion), but above all that it can modify the weight distribution and of inertia of the board, therefore modifying its dynamic behavior. Of course, we can make sure that the importance of the extra thickness varies along the perimeter of the board, by example that it does not exist in some places, and on the contrary very important in others places.

Les modes de réalisation illustrés et décrits plus hauts sont construits sur la base d'un sous-ensemble structurel dans lequel chaque demi-coque était formée à partir d'une feuille de mousse thermoformée d'épaisseur sensiblement constante.The embodiments illustrated and described above are constructed on the basis of a subset structural in which each half-shell was formed from a sheet of thermoformed foam of substantially constant thickness.

Dans la variante des figures 9 à 11, la technique de construction de la demi-coque supérieure 22 est légèrement différente, ceci afin de permettre d'obtenir très facilement une demi-coque supérieure 22 qui présente, au niveau de ses bords latéraux 38, une épaisseur de mousse 26 supérieure à l'épaisseur de mousse sur le pont du flotteur, tout au moins avant l'usinage des bords latéraux 38. Ainsi, on peut choisir de réaliser la couche de mousse 26 de la demi-coque supérieure 22 par moulage, cette couche 26 moulée étant ensuite recouverte sur sa face inférieure d'une couche interne stratifiée 30. Cette construction présente un double avantage : d'une part donner une épaisseur accrue de mousse qui laisse plus de liberté au moment de l'usinage pour obtenir la forme désirée, et d'autre part, on augmente la superficie de la zone d'interface qui sert au collage, ce qui renforce la solidité de ce collage.In the variant of Figures 9 to 11, the construction technique of the half-shell upper 22 is slightly different, this in order to very easily obtain a upper half-shell 22 which has, at its lateral edges 38, a thickness of foam 26 greater than the thickness of foam on the deck of the float, at least before the machining of the lateral edges 38. Thus, one can choose to produce the foam layer 26 of the upper half-shell 22 by molding, this molded layer 26 then being covered on its underside of a laminated inner layer 30. This construction has a double advantage: on the one hand give an increased thickness of foam which gives more freedom to the time of machining to obtain the desired shape, and on the other hand, the area is increased of the interface zone which is used for bonding, which reinforces the solidity of this bonding.

Pour encore augmenter la superficie de collage, on peut voir que le chant de la demi-coque supérieure 22 qui forme partie de cette interface n'est pas plat. Il comporte un décaissement 48, dont la section peut être semi-elliptique comme illustré, mais qui peut aussi présenter d'autres profils. La surface de contact entre la colle 42 et la demi-coque supérieure 22 s'en trouve donc augmentée. Grâce au fait que la colle est une résine moussante qui s'expanse, on est sûr que le décaissement 48 est parfaitement rempli par la colle qui vient bien au contact de la paroi qui délimite ce décaissement. Le collage est donc optimal.To further increase the bonding area, we can see that the edge of the half-shell upper 22 which forms part of this interface is not flat. It includes a disbursement 48, the cross section of which may be semi-elliptical as illustrated, but which may also have other profiles. The contact surface between the adhesive 42 and the upper half-shell 22 is is therefore increased. Thanks to the fact that the glue is a foaming resin which expands, is sure that the disbursement 48 is perfectly filled with the adhesive which comes into contact with the wall which delimits this disbursement. Bonding is therefore optimal.

Après usinage, comme on peut le voir à la figure 11, on retrouve une épaisseur de l'enveloppe de mousse 28 qui est sensiblement équivalente le long du bord latéral 38 à ce qu'elle est sur le reste de la demi-coque 22. Ainsi, l'usinage ne crée pas d'affaiblissement du sous-ensemble structurel. Dans le cas où on a prévu un décaissement 48 de l'interface, on peut voir que l'usinage met à jour une partie du joint de collage 42 dont l'épaisseur est relativement importante. Le fait que le joint de collage soit réalisé à l'aide du matériau moussant, donc aisément usinable, est ici particulièrement important pour rendre possible une mise en forme aisée du bord latéral 38.After machining, as can be seen in Figure 11, we find a thickness of the foam envelope 28 which is substantially equivalent along the lateral edge 38 to this that it is on the rest of the half-shell 22. Thus, the machining does not create a weakening of the structural subset. In the case where a disbursement 48 of the interface has been planned, one can see that the machining updates part of the bonding joint 42 whose thickness is relatively important. The fact that the bonding joint is made using the foaming material, therefore easily machinable, is particularly important here to make shaping possible easy from the side edge 38.

Sur les figures 12 et 13, on a illustré un mode de réalisation de l'invention qui comporte certaines des caractéristiques déjà décrites. La demi-coque supérieure 22 est formée d'une plaque de mousse 26 dont l'épaisseur est sensiblement constante et qui est stratifiée sur sa face interne 30. La demi-coque inférieure 24 est stratifiée sur ses deux faces 32, 34 mais on voit que le bord périphérique 52 de la face supérieure 32 est dépourvu de stratification de façon que le collage des deux demi-coques puisse se faire mousse contre mousse. Le chant de la demi-coque supérieure, qui est destiné à venir en regard du bord périphérique 52 de la demi-coque inférieure 24, comporte un décaissement 48 analogue à celui décrit dans le cadre du précédent mode de réalisation. Dans ce cas, le décaissement 48 est formé uniquement du côté interne du chant, c'est-à-dire du côté de la cavité interne 50. Dans ce mode de réalisation, il est prévu de réaliser une surépaisseur 44 du côté interne du joint de colle 42, c'est à-dire dans la cavité interne 50. Pour éviter que la surépaisseur ne s'étende trop transversalement vers l'intérieur de la cavité, on a disposé, par exemple sur la face interne 34 de la demi-coque inférieure 24, une cloison de confinement 54 formant barrière le long du contour de la planche. Cette cloison de confinement 54 peut présenter une hauteur inférieure à la hauteur de la cavité 50 dans la zone correspondante, de sorte qu'elle ne vient alors pas en contact avec la demi-coque supérieure 22 comme on le voit à la figure 13. Cette version est intéressante en termes de facilité de fabrication, car il n'y a pas de tolérance de hauteur précise à respecter pour la cloison de confinement. Au contraire, on pourrait prévoir que cette cloison de confinement soit ajustée en hauteur pour venir juste au contact de la demi-coque supérieure. Cette version, si elle est plus contraignante en termes de fabrication, présente l'avantage de conférer à la cloison de confinement une fonction supplémentaire de renfort vertical et de rigidification en plus de sa fonction première de confinement du joint de colle. Cette cloison de confinement peut être réalisée d'un bloc de mousse découpé à la forme voulue ou d'un cordon de mousse que l'on laisse expanser librement sur la face interne 34. Elle peut aussi être réalisée sous la forme d'un élément de plaque en matériau rigide, par exemple en bois ou en matériau sandwich. Bien entendu, on peut disposer une cloison de confinement, tout le long de l'interface entre les deux éléments de coque, ou au contraire prévoir de tronçons de cloisons uniquement le long de certaines zones de l'interface. Dans tous les cas, la cloison de confinement délimite, au voisinage de l'interface de collage, un volume bien déterminé que la mousse de collage vient remplir en s'expansant, venant ainsi en contact contre les faces internes 30, 32 des deux demi-coques.In Figures 12 and 13, an embodiment of the invention is illustrated which comprises some of the features already described. The upper half-shell 22 is formed of a foam plate 26 whose thickness is substantially constant and which is laminated on its face internal 30. The lower half-shell 24 is laminated on its two faces 32, 34 but we see that the peripheral edge 52 of the upper face 32 is devoid of lamination so that the bonding of the two half-shells can be foam against foam. The song of the upper half-shell, which is intended to come opposite the peripheral edge 52 of the half-shell lower 24, includes a disbursement 48 similar to that described in the context of previous embodiment. In this case, the disbursement 48 is formed only on the side internal edge, that is to say on the side of the internal cavity 50. In this embodiment, it is planned to make an additional thickness 44 on the internal side of the adhesive joint 42, that is to say in the internal cavity 50. To prevent the excess thickness from extending too transversely towards inside the cavity, for example on the internal face 34 of the half-shell lower 24, a containment partition 54 forming a barrier along the contour of the board. This containment partition 54 may have a height less than the height of the cavity 50 in the corresponding zone, so that it does not then come into contact with the upper half-shell 22 as seen in FIG. 13. This version is interesting in terms of ease of manufacture, as there is no precise height tolerance to be observed for the containment wall. On the contrary, one could foresee that this partition of containment is adjusted in height to come just in contact with the upper half-shell. This version, if it is more restrictive in terms of manufacturing, has the advantage of give the containment partition an additional function of vertical reinforcement and stiffening in addition to its primary function of confining the adhesive joint. This partition containment can be made of a block of foam cut to the desired shape or a bead of foam which is allowed to freely expand on the internal face 34. It can also be produced in the form of a plate element made of rigid material, for example wood or sandwich material. Of course, we can have a containment wall, all along of the interface between the two shell elements, or on the contrary provide for sections of partitions only along certain areas of the interface. In all cases, the bulkhead of confinement delimits, in the vicinity of the bonding interface, a clearly determined volume that the bonding foam fills by expanding, thus coming into contact against the faces internal 30, 32 of the two half-shells.

Une fois, assemblé, ce mode de réalisation présente l'avantage que les surfaces de contact de la mousse collante avec les deux demi-coques sont très importantes. Notamment, grâce à la cloison de confinement 54, on assure un bon contact de la colle avec la demi-coque supérieure 22. Par ailleurs, le bord périphérique 50 dépourvu de stratification. et le décaissement 48 décalé vers l'intérieur permettent d'obtenir une très grande facilité d'usinage du bord latéral 38 qui est composé quasi exclusivement de mousse.Once assembled, this embodiment has the advantage that the contact surfaces sticky foam with the two half-shells is very important. In particular, thanks to the containment partition 54, good contact of the adhesive with the upper half-shell is ensured 22. Furthermore, the peripheral edge 50 without lamination. and disbursement 48 offset towards the inside allow very easy machining of the side edge 38 which is almost exclusively made of foam.

Enfin, une fois mis en forme, le sous-ensemble structurel avec sa couche de mousse usinée est prévu pour être recouvert d'une enveloppe externe. Cette enveloppe externe est de préférence une nappe (tissée ou non tissée) 9 de fibres de verre ou autre enduite de résine, et elle peut recevoir les opérations de finition de la même façon que pour un flotteur traditionnel. On obtient ainsi une planche de glisse particulièrement performante. Toutefois, l'enveloppe externe peut-être réalisée de manière différente, par exemple par simple thermoformage de deux feuilles de matériau thermoplastique, comme cela est connu notamment dans le domaine des flotteurs de planches à voile.Finally, once shaped, the structural sub-assembly with its layer of machined foam is intended to be covered with an external envelope. This outer envelope is preferably a sheet (woven or non-woven) 9 of glass fibers or other resin coated, and it can receive finishing operations in the same way as for a traditional float. This gives a particularly efficient gliding board. However, the envelope external may be carried out differently, for example by simple thermoforming of two sheets of thermoplastic material, as is known in particular in the field windsurfing floats.

L'invention vient d'être décrite pour un sous-ensemble formé uniquement de deux éléments de coque, mais elle pourra être transposée sans difficulté au cas où le sous-ensemble est composé de plus de deux éléments de coque. De même, un sous-ensemble pourra comporter plusieurs des aspects de l'invention décrits un à un ci-dessus, par exemple une surépaisseur de colle à la fois du côté interne et du côté externe, ou une surépaisseur de colle du côté interne combinée à un décaissement du chant d'interface, etc.... De plus, l'invention pourrait être appliquée pour la construction de planches de glisse autres que les flotteurs de surf, par exemple pour des flotteurs de planche à voile, des flotteurs destinés à la nage dans les vagues et globalement, toute pratique nautique dans laquelle le flotteur fonctionne majoritairement dans le mode déjaugé.The invention has just been described for a sub-assembly formed only of two elements shell, but it can be transposed without difficulty in case the sub-assembly is composed of more than two shell elements. Similarly, a subset may include several of the aspects of the invention described one by one above, for example an extra thickness of glue on both the internal and external sides, or an excess of adhesive on the internal side combined with a disbursement of the interface song, etc. In addition, the invention could be applied for the construction of gliding boards other than surf floats, by example for windsurfing floats, floats intended for swimming in waves and overall, any nautical practice in which the float operates mainly in the planed mode.

Claims (25)

Procédé de fabrication d'un sous-ensemble structurel (10) pour une planche de glisse, caractérisé en ce qu'il comporte les étapes consistant à : former au moins deux éléments de coque (22, 24) ; assembler les deux éléments de coque (22, 24) à l'aide d'une résine adhésive moussante (42). Method for manufacturing a structural sub-assembly (10) for a gliding board, characterized in that it comprises the steps consisting in: forming at least two shell elements (22, 24); assemble the two shell elements (22, 24) using a foaming adhesive resin (42). Procédé selon la revendication 1, caractérisé en ce que la résine adhésive d'assemblage (42) est déposée à l'interface entre les éléments de coque (22, 24) mais aussi autour de l'interface pour former une surépaisseur (44).A method according to claim 1, characterized in that the adhesive assembly resin (42) is deposited at the interface between the shell elements (22, 24) but also around the interface to form an additional thickness (44). Procédé selon la revendication 2, caractérisé en ce que la surépaisseur (44) de résine adhésive moussante est comprise dans une zone (38) des demi-coques (22, 24) qui est destinée à être usinée après l'assemblage des demi-coques.Method according to claim 2, characterized in that the additional thickness (44) of foaming adhesive resin is included in a zone (38) of the half-shells (22, 24) which is intended to be machined after the assembly of the half-shells . Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les éléments de coque (22, 24) assemblés délimitent une partie interne creuse (50).Method according to any one of the preceding claims, characterized in that the assembled shell elements (22, 24) delimit a hollow internal part (50). Procédé selon la revendication 4, caractérisé en ce que la résine adhésive moussante est déposée de manière à former une surépaisseur (44) du côté de la partie interne creuse (50).Method according to claim 4, characterized in that the foaming adhesive resin is deposited so as to form an additional thickness (44) on the side of the hollow internal part (50). Procédé selon la revendication 5, caractérisé en ce qu'il comporte l'étape de disposer, à l'intérieur de la partie interne creuse (50). au moins une cloison de confinement (46, 54) destinée à limiter l'expansion de la surépaisseur (44) de résine adhésive moussante.Method according to claim 5, characterized in that it includes the step of placing, inside the hollow internal part (50). at least one containment partition (46, 54) intended to limit the expansion of the additional thickness (44) of foaming adhesive resin. Procédé selon la revendication 6, caractérisé en ce que la cloison de confinement est disposée à proximité de l'interface entre les deux éléments de coque (22, 24).Method according to claim 6, characterized in that the containment partition is arranged near the interface between the two shell elements (22, 24). Procédé selon l'une quelconque des revendications 2 à 7, caractérisé en ce que la surépaisseur (44) de résine adhésive moussante s'étend de part et d'autre de l'interface de contact (42) des éléments de coque (22, 24).Method according to any one of Claims 2 to 7, characterized in that the additional thickness (44) of foaming adhesive resin extends on either side of the contact interface (42) of the shell elements (22, 24). Procédé selon l'une quelconque des revendications 2 à 8, caractérisé en ce que la surépaisseur (44) s'entend le long d'une partie au moins du contour de l'interface.Method according to any one of Claims 2 to 8, characterized in that the additional thickness (44) is understood along at least part of the contour of the interface. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le sous-ensemble (10) est formé de deux demi-coques (22, 24) présentant chacune une forme de plaque, l'une (22) au moins des deux plaques étant galbée, et en ce que l'interface (42) entre les deux demi-coques est formée par une face (32) d'une des plaques (24) et par le chant de l'autre plaque (22).Method according to any one of the preceding claims, characterized in that the sub-assembly (10) is formed by two half-shells (22, 24) each having a plate shape, at least one (22) of the two plates being curved, and in that the interface (42) between the two half-shells is formed by a face (32) of one of the plates (24) and by the edge of the other plate (22). Procédé selon la revendication 10, caractérisé en ce que les deux demi-coques (22, 24) sont recouvertes, sur une face interne (30, 32), d'une couche de matériau composite rigide.Method according to claim 10, characterized in that the two half-shells (22, 24) are covered, on an internal face (30, 32), with a layer of rigid composite material. Procédé selon la revendication 11, caractérisé en ce que les parties (52) de l'interface située sur les demi-coques (22, 24) sont dépourvues de matériau composite rigide. Method according to claim 11, characterized in that the parts (52) of the interface located on the half-shells (22, 24) are devoid of rigid composite material. Procédé selon l'une quelconque des revendications 2 à 12, caractérisé en ce que la forme de la surépaisseur (44) de résine adhésive moussante est définie, lors de l'expansion de la résine moussante, par un élément de moule.Method according to any one of Claims 2 to 12, characterized in that the shape of the additional foaming resin (44) is defined, during the expansion of the foaming resin, by a mold element. Procédé selon l'une quelconque des revendications 2 à 13, caractérisé en ce que la zone (38) des éléments de coque (22, 24) qui est destinée à être usinée après assemblage est composée au moins partiellement d'une mousse (26, 28).Method according to any one of Claims 2 to 13, characterized in that the zone (38) of the shell elements (22, 24) which is intended to be machined after assembly is composed at least partially of a foam (26, 28). Procédé selon la revendication 14, caractérisé en ce que la zone (38) des éléments de coque (22, 24) qui est destinée à être usinée est composée au moins partiellement d'une mousse de polyuréthane (26,28).Method according to claim 14, characterized in that the area (38) of the shell elements (22, 24) which is intended to be machined is composed at least partially of a polyurethane foam (26,28). Procédé selon la revendication 14, caractérisé en ce que la zone (38) des éléments de coque (22, 24) qui est destinée à être usinée est composée au moins partiellement d'une mousse époxy (26, 28).Method according to claim 14, characterized in that the area (38) of the shell elements (22, 24) which is intended to be machined is composed at least partially of an epoxy foam (26, 28). Sous-ensemble structurel pour une planche de glisse, caractérisé en ce qu'il comporte au moins deux éléments de coque (22, 24) qui sont assemblés l'un à l'autre à l'aide d'une résine adhésive moussante (42).Structural sub-assembly for a gliding board, characterized in that it comprises at least two shell elements (22, 24) which are joined to one another using a foaming adhesive resin (42 ). Sous-ensemble structurel selon la revendication 17, caractérisé en ce que la résine adhésive d'assemblage (42) est déposée à l'interface entre les éléments de coque (22, 24) mais aussi autour de l'interface pour former une surépaisseur (44).Structural subassembly according to claim 17, characterized in that the adhesive assembly resin (42) is deposited at the interface between the shell elements (22, 24) but also around the interface to form an additional thickness ( 44). Sous-ensemble structurel selon l'une des revendications 17 ou 18, caractérisé en ce qu'il délimite au moins une partie interne creuse (50).Structural subassembly according to one of claims 17 or 18, characterized in that it delimits at least one hollow internal part (50). Sous-ensemble structurel selon la revendication 19, caractérisé en ce que la résine adhésive moussante est déposée de manière à former une surépaisseur (44) du côté de la partie interne creuse (50).Structural subassembly according to claim 19, characterized in that the foaming adhesive resin is deposited so as to form an additional thickness (44) on the side of the hollow internal part (50). Sous-ensemble structurel selon la revendication 20, caractérisé en ce qu'il comporte, à l'intérieur de la partie interne creuse (50), au moins une cloison de confinement (46, 54) destinée à limiter l'expansion de la surépaisseur (44) de résine adhésive moussante.Structural subassembly according to claim 20, characterized in that it comprises, inside the hollow internal part (50), at least one containment partition (46, 54) intended to limit the expansion of the additional thickness (44) of foaming adhesive resin. Sous-ensemble structurel selon la revendication 21, caractérisé en ce que la cloison de confinement est disposée à proximité de l'interface entre les deux éléments de coque (22, 24).Structural subassembly according to claim 21, characterized in that the containment partition is arranged near the interface between the two shell elements (22, 24). Procédé de fabrication d'une planche de glisse, caractérisé en ce qu'il comporte les étapes consistant à : usiner au moins partiellement un sous-ensemble structurel (10) comportant des éléments de coque (22, 24) assemblés l'un à l'autre à l'aide d'une résine adhésive moussante (42, 44), jusqu'à obtenir une forme voulue du sous-ensemble ; recouvrir le sous-ensemble (10) usiné d'une enveloppe externe. Method for manufacturing a gliding board, characterized in that it comprises the steps consisting in: at least partially machining a structural sub-assembly (10) comprising shell elements (22, 24) assembled to each other using a foaming adhesive resin (42, 44), until obtaining a desired shape of the subset; cover the machined sub-assembly (10) with an external envelope. Planche de glisse, caractérisée en ce qu'elle comporte un sous-ensemble structurel conforme à l'une quelconque des revendications 17 à 22.Gliding board, characterized in that it comprises a structural sub-assembly according to any one of claims 17 to 22. Planche de glisse selon la revendication 24, caractérisée en ce que le sous-ensemble structurel est recouvert d'une enveloppe externe.Gliding board according to claim 24, characterized in that the structural sub-assembly is covered with an external envelope.
EP02026117A 2001-12-19 2002-11-23 Structural sub-assembly, surfboard and method for their production Withdrawn EP1321358A3 (en)

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FR0116965A FR2833565B1 (en) 2001-12-19 2001-12-19 METHODS OF MANUFACTURING A STRUCTURAL SUB-ASSEMBLY AND A SLIDING BOARD: STRUCTURAL SUB-ASSEMBLY AND SLIDING BOARD OBTAINED BY SUCH A METHOD
FR0116965 2001-12-19

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US20030114054A1 (en) 2003-06-19
EP1321358A3 (en) 2005-06-01
FR2833565A1 (en) 2003-06-20
US6669519B2 (en) 2003-12-30
FR2833565B1 (en) 2004-02-27

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