A detailed analysis of design features and a comparison with industry standards.
1. Signature Jimmy Lewis Sandwich Construction
The core of Jimmy Lewis technology is an engineering process aimed at creating a rigid and impact-resistant board “skin”. The construction consists of the following layers:
- Core: Expanded Polystyrene (EPS), widely known as foam.
- Inner layer: Fiberglass impregnated with epoxy resin, applied directly to the EPS.
- Sandwich layer: High-density PVC foam.
- Outer layer: A second layer of fiberglass with epoxy resin, applied over the PVC.
- Fixation process: All layers are bonded together using vacuum pressing.
Technical justification: The structural strength is due to the principle of separating the two fiberglass layers. The greater the distance between these layers, the higher the overall structural rigidity. This method is applied on both sides of the board, making it, according to the manufacturer, the strongest and lightest in the industry.
2. Comparison with basic competitor constructions
Most boards on the market use significantly simplified manufacturing schemes, which negatively affects their operational characteristics:
- Standard assembly: Consists of just one or two layers of fiberglass (usually two 6-ounce layers) applied directly to the foam core.
- Test results: A construction of two layers of 6-ounce fiberglass demonstrates a critical lack of rigidity and easily deforms even under minimal weight.
3. Critical analysis of “bamboo” constructions
Many brands position their boards as “sandwich constructions” when using bamboo, however, a detailed analysis shows the inconsistency of this definition with reality:
- Competitors’ method: Bamboo veneer is vacuumed directly onto the EPS core, after which a single layer of fiberglass is applied on top.
- Definition problem: According to Jimmy Lewis, this is not a true sandwich, as it lacks the critically important layer of fiberglass underneath the bamboo. Without separating two glass layers, the material’s rigidity remains insufficient.
- Strength indicators: Although bamboo with one layer of glass is stronger than regular fiberglass, it is still subject to significant bending under loads.
Comparative indicators of rigidity and strength
During demonstration tests, the degree of deformation of various materials under weight was evaluated. The results are presented in the table below:
The technological advantage of Jimmy Lewis constructions is based on strict adherence to the principles of an engineering “sandwich”. The use of PVC foam as a separator between fiberglass layers creates a structural synergy that is impossible to achieve by directly layering materials onto a soft core. Tests confirm that the Jimmy Lewis construction is five times superior to standard solutions in its ability to resist deformation, while providing an optimal strength-to-weight ratio.