Skateboard decks and methods for constructing skateboard decks
10137357 ยท 2018-11-27
Assignee
Inventors
- Mark Anthony Rosolowski (Huntington Beach, CA, US)
- Gregory David Rosolowski (Huntington Beach, CA, US)
Cpc classification
B29C70/34
PERFORMING OPERATIONS; TRANSPORTING
B32B1/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
A63C17/012
HUMAN NECESSITIES
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/52
PERFORMING OPERATIONS; TRANSPORTING
B29K2711/14
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B29K2063/00
PERFORMING OPERATIONS; TRANSPORTING
A63C2203/42
HUMAN NECESSITIES
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B21/10
PERFORMING OPERATIONS; TRANSPORTING
B29C70/545
PERFORMING OPERATIONS; TRANSPORTING
B32B21/14
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
B32B3/02
PERFORMING OPERATIONS; TRANSPORTING
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
International classification
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
B32B21/04
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A skateboard deck that has a reduced weight, improved strength, and is, overall, more resilient. The addition of composite laminate layers improves the strength and performance of the skateboard. A composite layer may include carbon fiber layers, which are used to reduce the weight and thickness of the skateboard, while increasing the resilience and strength. Layered, high-strength tipfills and layered side edges may prevent chipping and delamination. The composite layers may inlay into the tipfills and side edges, allowing for protection of the composite layers. The tipfills and side edges protect the various other layers and prevent normal wear from abrasion, chipping, and delamination of the deck.
Claims
1. A skateboard deck, comprising: a first composite layer; at least two wood layers; and a second composite layer; wherein said first composite layer comprises at least one first composite sheet and at least two first tipfills; wherein said second composite layer comprises at least one second composite sheet and at least two second tipfills; wherein said at least two wood layers each comprise at least one wood sheet and at least two third tipfills; wherein an epoxy is applied to said first composite layer, said at least two wood layers, and said second composite layer; wherein said at least two wood layers are stacked between said first composite layer and said second composite layer; wherein said first composite layer, said at least two wood layers, and said second composite layer are pressed together in a mold and said epoxy cures to create an uncut skateboard deck; wherein said uncut skateboard deck is cut and smoothed.
2. The skateboard deck of claim 1, wherein said at least two first tipfills, said at least two second tipfills, and said at least two third tipfills are plastic.
3. The skateboard deck of claim 1, wherein at least one of said first composite layer, said at least two wood layers, and said second composite layer, comprise at least two protective side edges.
4. The skateboard deck of claim 3, wherein said at least two protective side edges are materials selected from the group of materials consisting of: wood, plastic, and combinations thereof.
5. The skateboard deck of claim 1, wherein said first composite layer, at least one of said at least two wood layers, and said second composite layer, each comprise at least two protective side edges.
6. The skateboard deck of claim 1, wherein said first composite layer, said at least two wood layers, and said second composite layer, each comprise at least two protective side edges.
7. The skateboard deck of claim 1, wherein said first composite sheet and said second composite sheet are materials selected from the group of materials consisting of: fiberglass, carbon fiber, aramid fibers, and combinations thereof.
8. The skateboard deck of claim 1, further comprising a third composite layer; wherein said third composite layer consists of a third composite sheet that is saturated with epoxy and layered outside of said first composite layer or said second composite layer.
9. The skateboard deck of claim 8, wherein said third composite sheet is a material selected from the group of materials consisting of: fiberglass, carbon fiber, aramid fibers, and combinations thereof.
10. A skateboard deck, comprising: a precure top layer, a precure bottom layer, at least two inner-core layers, and at least two outer-core layers; wherein each of said at least two inner-core layers comprise: an inner-core ply; at least two inner-core tipfills, and at least two inner-core side edges; wherein said at least two inner-core tipfills matingly inlay with said inner-core ply at opposite ends of said inner-core ply; wherein said at least two inner-core side edges matingly inlay with said inner-core ply on opposite sides of said inner-core ply; wherein each of said at least two outer-core layers comprise: an outer-core ply, at least two outer-core side edges, and at least four outer-core tipfills; wherein a first set of two of said at least four outer-core tipfills matingly inlay with said outer-core ply at opposite ends of said outer-core ply; wherein a second set of two of said at least four outer-core tipfills are stacked above said first set of two of said at least four outer-core tipfills at said opposite ends of said outer-core ply; wherein said at least two outer-core side edges are stacked above two opposite side edges of said outer-core ply and run between said second set of two of said at least four outer-core tipfills; wherein said precure top layer comprises at least one top layer composite sheet that is saturated in an epoxy, cured, and cut, such that said precure top layer is configured to matingly inlay within said at least two outer-core side edges and said second set of two of said at least four outer-core tipfills; wherein said precure bottom layer comprises at least one bottom layer composite sheet that is saturated in said epoxy, cured, and cut, such that said precure bottom layer is configured to matingly inlay within said at least two outer-core side edges and said second set of two of said at least four outer-core tipfills; wherein resin is applied to all of said layers and said precure top layer is stacked above a first of said at least two outer-core layers, which is stacked above said at least two inner-core layers, which are stacked above a second of said at least two outer-core layers, which is stacked above said precure bottom layer, to form a stack of resin coated layers; wherein said resin coated layers are pressed together and cured, such that an uncut skateboard deck is created; and wherein said uncut skateboard deck is cut and smoothed.
11. The skateboard deck of claim 10, wherein the precure top layer comprises a fiberglass sheet and a carbon fiber sheet.
12. The skateboard deck of claim 10, wherein the precure bottom layer comprises a fiberglass sheet.
13. The skateboard deck of claim 10, further comprising: at least two truck supports and at least two carbon stringers.
14. The skateboard deck of claim 10, wherein said first set of two of said at least four outer-core tipfills are shaped differently than said second set of said at least four outer-core tipfills.
15. The skateboard deck of claim 10, wherein at least one of said at least two inner-core layers does not comprise two or more inner-core side edges.
16. The skateboard deck of claim 10, wherein said inner-core ply of said at least two inner-core layers is wood; and wherein said outer-core ply of said at least two outer-core layers is wood.
17. The skateboard deck of claim 10, wherein said at least two inner-core tipfills and said at least four outer-core tipfills are plastic.
18. The skateboard deck of claim 10, wherein said at least two inner-core side edges and said at least four outer-core side edges are plastic.
19. A skateboard deck, comprising: a precure top layer, a precure bottom layer, at least two inner-core layers, and two outer-core layers; wherein each of said at least two inner-core layers comprise: an inner-core ply; at least two inner-core tipfills, and at least two inner-core side edges; wherein said at least two inner-core tipfills matingly inlay with said inner-core ply at opposite ends of said inner-core ply; wherein at least two inner-core side edges matingly inlay with said inner-core ply on opposite sides of said inner-core ply; wherein each of said two outer-core layers comprise: an outer-core ply, at least two outer-core side edges, and at least four outer-core tipfills; wherein a first set of two of said at least four outer-core tipfills matingly inlay with said outer-core ply at opposite ends of said outer-core ply; wherein a second set of two of said at least four outer-core tipfills are stacked above said first set of two of said at least four outer-core tipfills at said opposite ends of said outer-core ply; wherein said at least two outer-core side edges are stacked above two opposite side edges of said outer-core ply and run between said second set of two of said at least four outer-core tipfills; wherein said precure top layer comprises a fiberglass sheet and a carbon fiber sheet are saturated in an epoxy, cured, and cut, such that said precure top layer is configured to matingly inlay within said at least two outer-core side edges and said second set of two of said at least four outer-core tipfills; wherein said precure bottom layer comprises a fiberglass sheet that is saturated in said epoxy, cured, and cut, such that said precure bottom layer is configured to matingly inlay within said at least two outer-core side edges and said second set of two of said at least four outer-core tipfills; wherein resin is applied to all layers and said precure top layer is stacked above a first of said at least two outer-core layers, which is stacked above said at least two inner-core layers, which are stacked above a second of said at least two outer-core layers, which is stacked above said precure bottom layer, to form a stack of resin coated layers; wherein said resin coated layers are pressed together and cured, such that an uncut skateboard deck is created; wherein said uncut skateboard deck is cut and smoothed; wherein said at least two inner-core tipfills and said at least four outer-core tipfills are plastic; wherein said inner-core ply of said at least two inner-core layers is wood; and wherein said outer-core ply of said two outer-core layers is wood.
20. The skateboard deck of claim 19, wherein at least one of said at least two inner-core layers does not comprise two or more inner-core side edges.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The drawings are of illustrative embodiments. They do not illustrate all embodiments. Other embodiments may be used in addition or instead. Details which may be apparent or unnecessary may be omitted to save space or for more effective illustration. Some embodiments may be practiced with additional components or steps and/or without all of the components or steps that are illustrated. When the same numeral appears in different drawings, it refers to the same or like components or steps.
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DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
(14) In the following detailed description of various embodiments, numerous specific details are set forth in order to provide a thorough understanding of various aspects of the embodiments. However, the embodiments may be practiced without some or all of these specific details. In other instances, well-known procedures and/or components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
(15) While some embodiments are disclosed here, other embodiments will become obvious to those skilled in the art as a result of the following detailed description. These embodiments are capable of modifications of various obvious aspects, all without departing from the spirit and scope of protection. The Figures, and their detailed descriptions, are to be regarded as illustrative in nature and not restrictive. Also, the reference or non-reference to a particular embodiment shall not be interpreted to limit the scope of protection.
(16) In the following description, certain terminology is used to describe certain features of one or more embodiments. For purposes of the specification, unless otherwise specified, the term substantially refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, in one embodiment, an object that is substantially located within a housing would mean that the object is either completely within a housing or nearly completely within a housing. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of substantially is also equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result.
(17) As used herein, the terms approximately and about generally refer to a deviance of within 5% of the indicated number or range of numbers. In one embodiment, the term approximately and about, may refer to a deviance of between 0.0001-10% from the indicated number or range of numbers.
(18) In accordance with the embodiments disclosed herein, the present disclosure is directed to methods for constructing a composite-layered skateboard deck that, when compared to standard skateboards, has a reduced weight, improved strength, and is, overall, more resilient. The addition of composite laminate layers improves the strength and performance of the skateboard. A composite layer may include carbon fiber layers, which are used to reduce the weight and thickness of the skateboard, while increasing the resilience and strength. High-strength tipfills and side edges are added to the skateboard to prevent chipping and delamination. The composite layers may inlay into the tipfills and side edges (also referred to as sidewalls), allowing for protection of the composite layers. The tipfills and side edges protect the various other layers and prevent normal wear from abrasion, chipping, and delamination of layer.
(19) The term tipfill and tipfills, as used herein, refers to an edge or end inlay of a material that is different than the material that it is inlayed against. The inlay or tipfill may have the same or substantially the same thickness as the layer with which it is matingly dovetailed.
(20) The term composite, as used herein, refers to a material, such as, but not limited to fiberglass, carbon fiber, carbon fibre, aramid fibers, and the like, that is combined with a resin. The composite may include more than one type of material, such as including both fiberglass and carbon fiber.
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(23) The second layer is one or more layers 111, 121, which are below the first layer 101, and may comprise a wood sheet 118, 128 that may have cutout shapes at the ends that are similar to, but preferably not identical to, the composite first layer 101. The ends of each of the wood sheets 118, 128, may have tipfills 113, 115, 123, 125, which are inserted at the ends of the wood sheets 118, 128 to form second layer 111, 121, but, as shown, may have a smaller inset to prevent breaking points. The tipfills 113, 115, 123, 125 preferably matingly inlay with the wood sheets 118, 128 of layers 111, 121.
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(25) Preferably, the layers 101, 111, 121, 131 have main layers that are different, even if just slightly, in shape, so that the inlays (tipfills and protective side edges) do not identically overlap, which might cause a break point.
(26) The third layer 131 may comprise a bottom composite layer that is assembled in a method similar to the first layer 101. The third layer 131 is placed below the second layer 111 and any subsequent additional second layers 121. The third layer may comprise composite sheet 138, tipfills 133, 135, and protective side edges 139. The protective side edges 139 may be plastic or wood.
(27) The fourth layer 141 is below the third layer 131 and may be made of composite material 148. The fourth layer 141 may also be made of wood or other suitable material, such as a very thin wood veneer, or a thick plastic film. The Layer 4 141 may serve the purpose of protecting the layers above it. There may also be a protective layer on the top of the first layer 101 as well.
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(33) The inner-core tipfills 510, 511, 512, 513 and inner-core side edges 520, 521 may be plastic or other durable material that provide a protective edge and end to the skateboard deck. The inner-core tipfills 510, 511, 512, 513 and inner-core side edges 520, 521 may be created as a thin sheet that is preferably the same or substantially the same thickness as the inner-core ply 505. The specific shapes of the inner-core tipfills 510, 511, 512, 513 and inner-core side edges 520, 521 may then be cut and placed next to the inner-core ply 505. In one embodiment, either the tipfills 510, 511, 512, 513 or inner-core side edges 520, 521, may be wood.
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(37) The grain direction of the various layers of the skateboard deck may vary, similar to plywood, to increase strength and prevent break points.
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(41) These and other features, and characteristics of the present technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosure. As used in the specification and in the claims, the singular form of a, an, and the include plural referents unless the context clearly dictates otherwise.
(42) Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, locations, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.
(43) The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
(44) The foregoing description of the preferred embodiment has been presented for the purposes of illustration and description. While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the above detailed description. These embodiments are capable of modifications in various obvious aspects, all without departing from the spirit and scope of protection. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive. Also, although not explicitly recited, one or more embodiments may be practiced in combination or conjunction with one another. Furthermore, the reference or non-reference to a particular embodiment shall not be interpreted to limit the scope of protection. It is intended that the scope of protection not be limited by this detailed description, but by the claims and the equivalents to the claims that are appended hereto.
(45) Except as stated immediately above, nothing that has been stated or illustrated is intended or should be interpreted to cause a dedication of any component, step, feature, object, benefit, advantage, or equivalent, to the public, regardless of whether it is or is not recited in the claims.
(46) Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.
(47) It will be apparent to those of ordinary skill in the art that various modifications and variations may be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.