Composite discus

Abstract

A discus has a top plate formed of a perforated aluminum sheet fused with carbon fiber, a bottom plate formed of a perforated aluminum sheet fused with carbon fiber, a weighted spool between the top plate and the bottom plate, and a ring connecting the top plate to the bottom plate.

Claims

1. A discus comprising: (a) a circular top plate with an outer edge, the circular top plate formed of a perforated aluminum sheet fused with carbon fiber; (b) a circular bottom plate with an outer edge, the circular bottom plate formed of a perforated aluminum sheet with carbon fiber; (c) a weighted spool sandwiched between the circular top plate and the circular bottom plate, the weighted spool having a top female threaded opening and a bottom female threaded opening; (d) a top fastener passing through the circular top plate and into the top female threaded opening of the weighted spool; (e) a bottom fastener passing through the circular bottom plate and into the bottom female threaded opening of the weighted spool; and (f) a metal rim attached to the outer edge of the circular top plate and to the outer edge of the circular bottom plate.

2. The discus of claim 1 wherein the perforated aluminum sheets fused with carbon fiber of the circular top and bottom plates comprise a plurality of carbon fiber sheets.

3. A discus comprising: (a) a top plate formed of a perforated aluminum sheet fused with carbon fiber; (b) a bottom plate formed of a perforated aluminum sheet fused with carbon fiber; and (c) a ring attached to the top plate and to the bottom plate.

4. The discus of claim 3 wherein the perforated aluminum sheets fused with carbon fiber of the circular top and bottom plates comprise a plurality of carbon fiber sheets.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top plan view of a preferred embodiment of the discus of this invention.

(2) FIG. 2 is a side elevation view thereof.

(3) FIG. 3 is an exploded perspective view thereof.

(4) FIG. 4 is an exploded perspective view of the manufacture of a plate.

(5) FIG. 5 is a top view of a plate.

(6) FIG. 6 is a detailed sectional view thereof taken along the line in FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

(7) This invention is best understood by reference to the drawings. Referring to FIGS. 1 to 3, a preferred embodiment of the discus 10 of this invention has a top plate 20, a bottom plate 30, a weighted spool 40, a rim 50, and fasteners 60. The components of the discus are discussed in more detail below.

(8) Referring now to FIG. 4, the top plate 20 is a metal sheet 21 fused with carbon fiber, generally in the form of multiple sheets 22. The top plate and the bottom plate are identical or similar in construction so only the top plate is described. The top plate is manufactured by placing the metal sheet and carbon fiber into a mold. The mold is then subjected to extreme heat and pressure, preferably about 280 F. and about 40 pounds per square inch for about forty-five minutes, to form a composite. Unless otherwise indicated expressly or by context, the term about is used herein to mean plus or minus 25 percent of the measurement or other quantified property referenced. The metal sheet in the resulting top plate is flush in the carbon fiber so the top plate is completely smooth to the touch. The upper, outer surface of the top plate is left unfinished, painted, or otherwise finished as desired. The shape and dimensions of the top plate are matters of choice that depend on the desired shape and size of the discus. The top plate is generally circular and convex (bowed) with either a continuous curve or a series of relatively flat portions. As best seen in FIG. 2, the preferred top plate has a generally flat circular inner portion and an angled annular portion.

(9) The metal sheet of the top plate is preferably perforated to form a lattice. The perforated metal sheet provides a surprising increase in strength to the carbon fiber while adding only minimal additional weight. Preferred metals are light in weight, strong, and malleable and include aluminum, copper, tin, alloys thereof, and the like. Aluminum is the most preferred metal because of its superior physical properties and relatively low cost. A preferred perforated aluminum sheet is model 92725T42 sold by McMaster-Carr Supply Company of Elmhurst, Ill. This sheet is perforated with hexagonal openings and has a weight of 0.02 ounces per square inch.

(10) As previously described, the carbon fiber is generally added to the mold in the form of sheets forming multiple layers. A preferred carbon fiber sheet is model T300 manufactured and sold by Cytec Solvay Group of Woodland Park, N.J. Five to ten sheets of this carbon fiber are generally used. The preferred number is determined by the desired weight.

(11) The weighted spool 40 is conventional and is best seen in FIG. 3. The weighted spool is typically made of metal and sandwiched between the top plate and bottom. The weighted spool is generally secured in position with fasteners and/or adhesives. In the preferred embodiment shown, the weighted spool has female threaded openings at the top and bottom to receive top and bottom screws 60 that hold the discus assembly together.

(12) The rim 50 is conventional and is best seen in FIG. 3. The rim is typically made of steel. The rim typically has inner ledges along its top and bottom surfaces to accept the top and bottom plates. The rim is thus attached to the outer edge of the top plate and to the outer edge of the bottom plate.

(13) The discus is used in a conventional manner. Testing of the discus has revealed a surprising increase in durability. The top plate and bottom plate have shown no signs of cracking despite multiple throws.