A method of manufacturing a polyurethane (pu)- expanded polystyrene (eps) hybrid material surfboard

Abstract

A method of manufacturing a polyurethane-expanded polystyrene hybrid material surfboard, the method comprising: (i) inserting a sheet of expanded polystyrene comprising a plurality of positioning lugs into an interior of a mould cavity formed from at least one mould; (ii) clamping the mould such that the sheet of expanded polystyrene is enclosed; (iii) injecting polyurethane into the mould cavity such that the void between the expanded polystyrene and mould cavity is filled with the polyurethane; (iv) setting and removing the surfboard from the mould; (v) subjecting the surfboard blank to further processing to fine tune the surfboard profile and shape; and (vi) glassing the shaped board using bio-based epoxy resin along with advanced recycled cloth fibres and finally subjecting to sanding process to obtain the final surfboard.

Dependencies are inferred from the claim text.