CARBON FIBER REINFORCED SKATEBOARD

Abstract

A carbon fiber reinforced skateboard is formed of laminated wood layers having identified grain directions. Upper and lower wood layers will have a grain direction parallel to a long axis of the skateboard. The skateboard will have interspersed wood layers with identified grain directions perpendicular to the long axis. Carbon fiber reinforcing material is adhered to interior plies of the skateboard along the long axis. A central portion of the reinforcing material is adhered below a central vertical point of the skateboard between the skateboard trucks. Anterior and posterior portions of the reinforcing material are adhered above the central vertical point and are located around the attachment locations for the skateboard trucks. The reinforcing material is located to provide a strengthened spine for the skateboard. A first concavity is located between the skateboard trucks parallel to the long axis. Second and third concavities are located perpendicular to the long axis.

Claims

1. A carbon fiber reinforced skateboard comprising: an upper layer, said upper layer being formed of at least a first wood ply and having an upper surface; a lower layer, said lower layer being formed of at least a second wood ply and having a lower surface; a core layer, said core layer being formed of at least a third wood ply and being disposed between said upper layer and said lower layer; first and second skateboard trucks, said skateboard trucks having first and second mounting plates, first and second wheel sets, said wheel sets being rotatably mounted to said skateboard trucks, mounting hardware adapted to attach said mounting plates to at least said lower surface of said lower layer; reinforcing material, said reinforcing material disposed between said upper layer and said lower layer; an adhesive, said adhesive securing said reinforcing material to at least one of a lower surface of said upper layer, an upper surface of said lower layer or said core layer; said upper layer, said lower layer and said core layer being laminated together using, pressure and industrial wood glue laminating material.

2. The carbon fiber reinforced skateboard, as described in claim 1, wherein said adhesive is an aliphatic rubbery synthetic polymer.

3. The carbon fiber reinforced skateboard, as described in claim 2, wherein said aliphatic rubbery synthetic polymer has a formula of (C.sub.4H.sub.6O.sub.2).sub.n.

4. The carbon fiber reinforced skateboard, as described in claim 1, wherein said adhesive is selected from the group consisting of: Polyvinyl acetate (PVA), PVAc and poly(ethenyl ethanoate).

5. The carbon fiber reinforced skateboard, as described in claim 1, wherein upper and lower wood plies of said core layer have a defined wood grain direction perpendicular to a wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer.

6. The carbon fiber reinforced skateboard, as described in claim 5, wherein said core layer comprises at least three plies.

7. The carbon fiber reinforced skateboard, as described in claim 5, wherein a center ply of said core layer has a defined wood grain direction parallel to said wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer.

8. The carbon fiber reinforced skateboard, as described in claim 5, wherein said core layer comprises at least five plies.

9. The carbon fiber reinforced skateboard, as described in claim 8, wherein said center ply of said core layer has said defined wood grain direction parallel to said wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer and wood plies adjacent to said center ply have a defined wood grain direction perpendicular to said defined wood grain direction said center ply.

10. The carbon fiber reinforced skateboard, as described in claim 9, wherein wood plies adjacent to said lower surface of said upper layer and said upper surface of said lower layer have a defined wood grain direction parallel to said wood grain direction of said upper layer and said lower layer.

11. The carbon fiber reinforced skateboard, as described in claim 1, wherein said reinforcing material is selected from the group consisting of: woven carbon fiber fabric, non-crimp stitch bonded carbon fiber fabric, stitch bonded carbon fiber fabric, and 45/−45 double bias carbon fiber fabric.

12. The carbon fiber reinforced skateboard, as described in claim 1, wherein said reinforcing material comprises: a center portion, said center portion disposed along a lengthwise axis of said skateboard and centered on a perpendicular cross axis of said skateboard; an anterior portion, said anterior portion disposed along said lengthwise axis of said skateboard and centered about mounting holes for said first mounting plate; and a posterior portion, said posterior portion disposed along said lengthwise axis of said skateboard and centered about mounting holes for said second mounting plate.

13. The carbon fiber reinforced skateboard, as described in claim 12, wherein said center portion is adhered to said core layer on a wood ply disposed below a vertical center point of said core layer.

14. The carbon fiber reinforced skateboard, as described in claim 13, wherein said anterior portion and said posterior portion are adhered to said core layer on a wood ply disposed above said vertical center point of said core layer.

15. The carbon fiber reinforced skateboard, as described in claim 12, wherein said center portion is adhered to a wood ply of said core layer having a defined wood grain parallel to said wood grain direction of said upper surface of said lower layer.

16. The carbon fiber reinforced skateboard, as described in claim 12, wherein said anterior portion and said posterior portion are adhered to a wood ply of said core layer having a defined wood grain parallel to said wood grain direction of said lower surface of said upper layer.

17. The carbon fiber reinforced skateboard, as described in claim 12, wherein said center portion is 1″ to 4″ in width and 18″ to 24″ in length.

18. The carbon fiber reinforced skateboard, as described in claim 12, wherein said anterior portion and said posterior portion are 1″ to 4″ in width and 3″ to 6″ in length.

19. The carbon fiber reinforced skateboard, as described in claim 1, wherein said mounting hardware extends through each of said upper layer, core layer and lower layer and is secured against an underside of said mounting plates with threaded fasteners.

20. The carbon fiber reinforced skateboard, as described in claim 1, wherein said industrial wood glue is selected from the group consisting of: polyvinyl acetate (PVA), aliphatic resin, polyurethane, phenol formaldehyde, and resorcinol-formaldehyde.

21. The carbon fiber reinforced skateboard, as described in claim 1, wherein the reinforcing material ranges from 0.0005″ to 0.009″ in thickness.

22. The carbon fiber reinforced skateboard, as described in claim 1, wherein said wood plies range in thickness from range in thickness from 0.05″ to 0.08″.

23. The carbon fiber reinforced skateboard, as described in claim 13, wherein said upper layer, said lower layer and said core layer further comprise a first concavity, said first concavity being parallel to said lengthwise axis and extending from a point adjacent said first skateboard truck to a point adjacent said second skateboard truck.

24. The carbon fiber reinforced skateboard, as described in claim 23, wherein said first concavity ranges from 0.25″ to 1.5″ in depth.

25. The carbon fiber reinforced skateboard, as described in claim 13, wherein said upper layer, said lower layer and said core layer further comprise a second concavity, said second concavity being perpendicular to said lengthwise axis, disposed adjacent said first skateboard truck and extending from a first side edge to a second side edge of said layers.

26. The carbon fiber reinforced skateboard, as described in claim 25, wherein said second concavity ranges from 0.25″ to 1.5″ in depth.

27. The carbon fiber reinforced skateboard, as described in claim 13, wherein said upper layer, said lower layer and said core layer further comprise a third concavity, said third concavity being perpendicular to said lengthwise axis, disposed adjacent said second skateboard truck and extending from a first side edge to a second side edge of said layers.

28. The carbon fiber skateboard, as described in claim 27, wherein said third concavity ranges from 0.25″ to 1.5″ in depth.

29. A method of making a carbon fiber reinforced skateboard, comprising the steps of: forming an upper layer, said upper layer being formed of at least a first wood ply and having an upper surface; forming a lower layer, said lower layer being formed of at least a second wood ply and having an lower surface; forming a core layer, said core layer being formed of at least a third wood ply and being disposed between said upper layer and said lower layer; providing first and second skateboard trucks, said skateboard trucks having first and second mounting plates; providing first and second wheel sets, said wheel sets being rotatably mounted to said skateboard trucks; providing mounting hardware, said mounting hardware being adapted to attach said mounting plates to at least said lower surface of said lower layer; providing reinforcing material, said reinforcing material being disposed between said upper layer and said lower layer; providing an adhesive; securing said reinforcing material with said adhesive to at least one of a lower surface of said upper layer, an upper surface of said lower layer or said core layer; laminating said upper layer, said lower layer and said core layer together using, pressure and industrial wood glue laminating material.

30. The method of making a carbon fiber reinforced skateboard, as described in claim 29, wherein said adhesive is an aliphatic rubbery synthetic polymer.

31. The method of making a carbon fiber reinforced skateboard, as described in claim 30, wherein said aliphatic rubbery synthetic polymer has a formula of (C.sub.4H.sub.6O.sub.2).sub.n.

32. The method of making a carbon fiber reinforced skateboard, as described in claim 29, wherein said adhesive is selected from the group consisting of: polyvinyl acetate (PVA), PVAc and poly(ethenyl ethanoate).

33. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of orienting a defined wood grain direction of upper and lower wood plies of said core layer perpendicular to a wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer.

34. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing said core layer comprises with at least three plies.

35. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of orienting a center ply of said core layer, having a defined wood grain direction, parallel to a wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer.

36. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing said core layer comprises with at least five plies.

37. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of orienting said core layer such that a center ply of said core layer has a defined wood grain direction parallel to a wood grain direction of said lower surface of said upper layer and said upper surface of said lower layer and wood plies adjacent to said center ply have a defined wood grain direction perpendicular to said center ply.

38. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of orienting said core layer such that wood plies adjacent to said lower surface of said upper layer and said upper surface of said lower layer have a defined wood grain direction parallel to a wood grain direction of said upper layer and said lower layer.

39. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing reinforcing material selected from the group consisting of: woven carbon fiber fabric, non-crimp stitch bonded carbon fiber fabric, stitch bonded carbon fiber fabric, and 45/−45 double bias carbon fiber fabric.

40. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the steps of: providing a center portion of said reinforcing material, said center portion being disposed along a lengthwise axis of said skateboard and centered on a perpendicular cross axis of said skateboard; providing an anterior portion of said reinforcing material, said anterior portion being disposed along a lengthwise axis of said skateboard and centered about mounting holes for said first mounting plate; and providing a posterior portion of said reinforcing material, said posterior portion being disposed along a lengthwise axis of said skateboard and centered about mounting holes for said second mounting plate.

41. The method of making a carbon fiber reinforced skateboard, as described in claim 40, further comprising the step of adhering said center portion to said core layer on a wood ply disposed below a vertical center point of said core layer.

42. The method of making a carbon fiber reinforced skateboard, as described in claim 40, further comprising the step of adhering said anterior portion and said posterior portion to said core layer on a wood ply disposed above a vertical center point of said core layer.

43. The method of making a carbon fiber reinforced skateboard, as described in claim 40, further comprising the step of adhering said center portion to a wood ply of said core layer having a defined wood grain parallel said wood grain direction of said upper surface of said lower layer.

44. The method of making a carbon fiber reinforced skateboard, as described in claim 40, further comprising the step of adhering said anterior portion and said posterior portion a wood ply of said core layer having a defined wood grain parallel to said wood grain direction of said lower surface of said upper layer.

45. The method of making a carbon fiber reinforced skateboard, as described in claim 40, wherein said center portion is 1″ to 4″ in width and 18″ to 24″ in length.

46. The method of making a carbon fiber reinforced skateboard, as described in claim 40, wherein said anterior portion and said posterior portion are 1″ to 4″ in width and 3″ to 6″ in length.

47. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the steps of: providing apertures for said mounting hardware that extend through said upper layer, said core layer and said lower layer; disposing said mounting hardware through said apertures; mounting said first and second mounting plates on said mounting hardware; and securing said first and second mounting plates to said skateboard with threaded fasteners.

48. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing industrial wood glue selected from the group consisting of: polyvinyl acetate (PVA), aliphatic resin, polyurethane, phenol formaldehyde, and resorcinol-formaldehyde.

49. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing reinforcing material having a thickness ranging from 0.0005″ to 0.009″.

50. The method of making a carbon fiber reinforced skateboard, as described in claim 29, further comprising the step of providing wood plies range in thickness from range in thickness from 0.05″ to 0.08″.

51. The method of making carbon fiber reinforced skateboard, as described in claim 40, wherein said upper layer, said lower layer and said core layer further comprise a first concavity, said first concavity being parallel to said lengthwise axis and extending from a point adjacent said first skateboard truck to a point adjacent said second skateboard truck.

52. The method of making carbon fiber reinforced skateboard, as described in claim 51, wherein said first concavity ranges from 0.25″ to 1.5″ in depth.

53. The method of making carbon fiber reinforced skateboard, as described in claim 40, wherein said upper layer, said lower layer and said core layer further comprise a second concavity, said second concavity being perpendicular to said lengthwise axis, disposed adjacent said first skateboard truck and extending from a first side edge to a second side edge of said layers.

54. The method of making carbon fiber reinforced skateboard, as described in claim 53, wherein said second concavity ranges from 0.25″ to 1.5″ in depth.

55. The method of making carbon fiber reinforced skateboard, as described in claim 40, wherein said upper layer, said lower layer and said core layer further comprise a third concavity, said third concavity being perpendicular to said lengthwise axis, disposed adjacent said second skateboard truck and extending from a first side edge to a second side edge of said layers.

56. The method of making carbon fiber reinforced skateboard, as described in claim 55, wherein said third concavity ranges from 0.25″ to 1.5″ in depth.

Description

DESCRIPTION OF THE Drawings

[0076] FIG. 1 is a perspective view of the carbon fiber reinforced skateboard of the preferred embodiment of the invention;

[0077] FIG. 2 is a perspective view of the underside of the FIG. 1 embodiment;

[0078] FIG. 3 is a perspective view of the wood ply layers of the of the FIG. 1 embodiment illustrating the placement of reinforcing materials between the plies;

[0079] FIG. 4 is a perspective view of the wood ply layers of an alternative embodiment illustrating the placement of reinforcing materials between the plies;

[0080] FIG. 5 is a plan view of two of the plies of the FIG. 1 embodiment illustrating the location of the central, anterior and posterior portions of the reinforcing material;

[0081] FIG. 6 is a perspective view of a skateboard deck formed of the FIG. 1 embodiment illustrating the first, second and third concavities;

[0082] FIG. 7 is plan view of the FIG. 3 embodiment illustrating the mounting apertures for skateboard trucks;

[0083] FIG. 8 is a side elevational view of the FIG. 6 embodiment illustrating the first, second and third concavities;

[0084] FIG. 9 is a cross-sectional view of the FIG. 6 embodiment taken along the line 6-6;

[0085] FIG. 10 is a cross-sectional view of woven carbon fiber fabric;

[0086] FIG. 11 is a plan view of the FIG. 7 embodiment;

[0087] FIG. 12 is a side elevational view of non-crimp stitch bonded carbon fiber fabric;

[0088] FIG. 13 is a plan view of the FIG. 9 embodiment; and

[0089] FIG. 14 is a partial sectional perspective view of 45/−45 double bias carbon fiber fabric.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0090] (1) As illustrated in FIGS. 1-3, a carbon fiber reinforced skateboard 10 providing the desired features may be constructed from the following components. An upper layer 14 is provided. The upper layer 14 is formed of at least a first wood ply 18 and has an upper surface 22. A lower layer 26 is provided. The lower layer 26 is formed of at least a second wood ply 30 and has a lower surface 34. A core layer 38 is provided. The core layer 38 is formed of at least a third wood ply 42 and is located between the upper layer 14 and the lower layer 26. First 46 and second 50 skateboard trucks are provided. The skateboard trucks 46, 50 have first 54 and second 58 mounting plates and first 62 and second 66 wheel sets. The wheel sets 62, 66 are rotatably mounted to the skateboard trucks 46, 50. Mounting hardware 70 is provided which is adapted to attach the mounting plates 54, 58 to at least the lower surface 34 of the lower layer 26.

[0091] Reinforcing material 74 is provided. The reinforcing material 74 is located between the upper layer 14 and the lower layer 26. An adhesive 78 is provided. The adhesive 78 secures the reinforcing material 74 to at least one of a lower surface 82 of the upper layer 14, an upper surface 86 of the lower layer 26 or the core layer 38. The upper layer 14, the lower layer 26 and the core layer 38 are laminated together using, pressure and industrial wood glue laminating material 90.

[0092] (2) In a variant of the invention, the adhesive 78 is an aliphatic rubbery synthetic polymer 94.

[0093] (3) In another variant, the aliphatic rubbery synthetic polymer 94 has a formula of (C.sub.4H.sub.6O.sub.2).sub.n.

[0094] (4) In still another variant, the adhesive 78 is selected from the group consisting of: Polyvinyl acetate (PVA) 98, PVAc (not shown) and poly(ethenyl ethanoate) (not shown).

[0095] (5) In yet another variant, as illustrated in FIG. 4, upper 110 and lower 114 wood plies of the core layer 38 have a defined wood grain direction 118 perpendicular to a wood grain direction 122 of the lower surface 82 of the upper layer 14 and the upper surface 86 of the lower layer 26. NEW DRAWING

[0096] (6) In a further variant, the core layer 38 comprises at least three plies.

[0097] (7) In still a further variant, as illustrated in FIG. 3, a center ply 126 of the core layer 38 has a defined wood grain direction 130 parallel to the wood grain direction 122 of the lower surface 82 of the upper layer 14 and the upper surface 86 of the lower layer 26.

[0098] (8) In yet a further variant, the core layer 38 comprises at least five plies.

[0099] (9) In another variant of the invention, the center ply 126 of the core layer 38 has the defined wood grain direction 130 parallel to the wood grain direction 122 of the lower surface 82 of the upper layer 14 and the upper surface 86 of the lower layer 26 and wood plies 134, 138 adjacent to the center ply 126 have a defined wood grain direction 142 perpendicular to the defined wood grain direction 130 of the center ply 126.

[0100] (10) In still another variant, wood plies 146, 150 adjacent to the lower surface 82 of the upper layer 14 and the upper surface 86 of the lower layer 26 have a defined wood grain direction 154 parallel to the wood grain direction 122 of the upper layer 14 and the lower layer 26.

[0101] (11) In yet another variant, as illustrated in FIGS. 10-14, the reinforcing material 74 is selected from the group consisting of: woven carbon fiber fabric 158, non-crimp stitch bonded carbon fiber fabric 162, stitch bonded carbon fiber fabric 164 and 45/−45 double bias carbon fiber fabric 166.

[0102] (12) In a further variant, as illustrated in FIG. 5, the reinforcing material 74 includes a center portion 170. The center portion 170 is located along a lengthwise axis 174 of the skateboard 10 and centered on a perpendicular cross axis 178 of the skateboard 10. The reinforcing material 74 further includes an anterior portion 182. The anterior portion 182 is located along the lengthwise axis 174 of the skateboard 10 and centered about mounting holes 186 for the first mounting plate 54. The reinforcing material 74 further includes a posterior portion 190. The posterior portion 190 is located along the lengthwise axis 174 of the skateboard 10 and centered about mounting holes 194 for the second mounting plate 58.

[0103] (13) In still a further variant, as illustrated in FIG. 3, the center portion 170 is adhered to the core layer 38 on a wood ply 198 located below a vertical center point 202 of the core layer 38.

[0104] (14) In yet a further variant, the anterior portion 182 and the posterior portion 190 are adhered to the core layer 38 on a wood ply 206 located above the vertical center point 202 of the core layer 38.

[0105] (15) In another variant of the invention, the center portion 170 is adhered to a wood ply 210 of the core layer 38 that has a defined wood grain 214 parallel to the wood grain direction 122 of the upper surface 86 of the lower layer 26.

[0106] (16) In still another variant, the anterior portion 182 and the posterior portion 190 are adhered to a wood ply 218 of the core layer 38 that has a defined wood grain 222 parallel to the wood grain direction 122 of the lower surface 82 of the upper layer 14.

[0107] (17) In yet another variant, as illustrated in FIG. 5, the center portion 170 is 1″ to 4″ in width and 18″ to 24″ in length.

[0108] (18) In a further variant, the anterior portion 182 and the posterior portion 190 are 1″ to 4″ in width and 3″ to 6″ in length.

[0109] (19) In still a further variant, as illustrated in FIGS. 1 and 2, the mounting hardware 70 extends through each of the upper layer 14, core layer 38 and lower layer 26 and is secured against an underside 226 of the mounting plates 54, 58 with threaded fasteners 230.

[0110] (20) In yet a further variant, the industrial wood glue 90 is selected from the group consisting of: polyvinyl acetate (PVA) 234, aliphatic resin (not shown), polyurethane (not shown), phenol formaldehyde (not shown), and resorcinol-formaldehyde (not shown).

[0111] (21) In another variant of the invention, the reinforcing material 74 ranges from 0.0005″ to 0.0015″ in thickness.

[0112] (22) In still another variant, the wood plies 18, 30, 42 range in thickness from range in thickness from 0.05″ to 0.08″.

[0113] (23) In another variant of the invention, as illustrated in FIGS. 1, 2 and 6-9, the upper layer 14, the lower layer 26 and the core layer 38 further include a first concavity 238. The first concavity 238 is parallel to the lengthwise axis 174 and extends from a point 242 adjacent the first skateboard truck 46 to a point 246 adjacent the second skateboard truck 50.

[0114] (24) In still another variant, the first concavity 238 ranges from 0.25″ to 1.5″ in depth.

[0115] (25) In yet another variant, the upper layer 14, the lower layer 26 and the core layer 38 further include a second concavity 250. The second concavity 250 is perpendicular to the lengthwise axis 174, disposed adjacent the first skateboard truck 46 and extending from a first side edge 254 to a second side edge 258 of the layers 14, 26, 38.

[0116] (26) In a further variant, the second concavity 250 ranges from 0.25″ to 1.5″ in depth.

[0117] (27) In still a further variant, the upper layer 14, the lower layer 26 and the core layer 38 further comprise a third concavity 262, the third concavity 262 is perpendicular to the lengthwise axis 174, disposed adjacent the second skateboard truck 50 and extends from a first side edge 254 to a second side edge 258 of the layers 14, 26, 38.

[0118] (28) In yet a further variant, the third concavity 262 ranges from 0.25″ to 1.5″ in depth. The carbon fiber reinforced skateboard 10 has been described with reference to particular embodiments. Other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow.