Abstract:
An equine saddletree is disclosed that has increased strength and minimal torquing due to the alternation of the multiple wood layers with layers of graphite. The interior graphite layers consist of at least one layer of woven graphite sheet material having a warp and fill and extending from the cantle to the pommel. The woven graphite sheet placement on the wood layer defines whether the wood layer is considered a parallel or an angled layer. The parallel and angled graphite layers are alternated to form the saddletree. Additionally, each of the graphite layers has at least one strip of graphite tape covering the pommel, approximately perpendicular to the sidebars. Strips of graphite tape extend diagonally, in alternating directions, along each length of both the first surface and the second surface to prevent torque. A second layer of graphite tape pommel strips is applied to both the first and second surfaces covering at least a portion of the pommel. A pocket-receiving tab is secured within a notch in opposing ends of the pommel and interacts with the tab-receiving pocket on the cushioning panels to position the cushioning panels.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates to an improved saddletree designed to add strength while reducing weight over the standard wood saddletree.  
           [0003]    2. Brief Description of the Prior Art  
           [0004]    Few changes have been made over the centuries that saddles have been in use. The English saddle tree has kept approximately the same shape and has been made primarily of wood for hundreds of years until after WWII. At that time sprint steel attachments were incorporated into the design to allow the tree more elasticity combined with flexibility. Until the recent use of plastics, and other mamnade materials, little had been done to reduce weight. The latest major advancement in saddles trees was disclosed in U.S. Pat. No. 6,044,630, in which a saddle having improved balance and fit of a saddle is disclosed; the &#39;630 patent being incorporated herein as though recited in full.  
           [0005]    Strength, however, remained an issue. Saddles must provide some flexibility, however excessive torque has been a problem with prior art trees of wood construction. A professional quality saddle is an expensive investment and expected to last many years. A cracked, weakened or broken tree, however, immediately makes the saddle unusable. It would be easy to strengthen a saddle if weight wasn&#39;t also a concern.  
           [0006]    In U.S. Pat. 5,101,614 a hollow saddletree formed of rotationally molded cross-linked polyethylene was disclosed. The hollow saddletree is of unitary, one piece construction and formed of cross-linked polyethylene by a rotational molding process with all of the structural elements of the saddle being of substantially equal thickness. Because the saddletree it is hollow, light and sufficiently flexible, it conforms to the contours of back of the horse.  
           [0007]    Fiberglass reinforced plastics have also been used to reduce the cost of saddle manufacturing. Saddletrees of this nature are described in U.S. Pat. No. 3,293,828 to Hessler incorporated herein by reference. The problem with fiberglass-reinforced saddletrees is that they are too rigid and, under the stresses of usage, show a distinct tendency to break down. In addition, saddletrees formed of fiber reinforced plastics are too stiff and do not conform to the horse&#39;s back. In consequence, they cause abrasion to the sides of the horse, to the material discomfort of the horse. Saddles formed of foam-filled fiber reinforced plastics have also been described in U.S. Pat. No. 3,258,894 to Hoaglin. In this construction, two sections are molded from fiber reinforced plastic, combined together and the interior filled with urethane foam.  
           [0008]    Injected molded saddles have also been tried and described in U.S. Pat. Nos. 3,712,024 and 3,780,494. High cost of molding, difficulty of quality control and lack of versatility have been the problems with injected molded saddles.  
           [0009]    None of the foregoing prior art saddles, however, have been able to make a lightweight saddletree that provides fit and balance combined with flexibility without torque. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    The advantages of the instant disclosure will become more apparent when read with the specification and the drawings, wherein:  
         [0011]    [0011]FIG. 1 is a cutaway, cross-sectional side view of the disclosed saddletree illustrating the alternating layers of wood and graphite in finished form;  
         [0012]    [0012]FIG. 2 is a top view of the disclosed saddletree showing interior layers of woven graphite at right angles to tree centerline and showing two strips of graphite tape across the pommel;  
         [0013]    [0013]FIG. 3 is a top view of the disclosed saddletree showing interior layers of woven graphite at 45 degree angles to centerline and strips of graphite tape across pommel;  
         [0014]    [0014]FIG. 4 is a top view of the disclosed saddletree showing the front to back interior strips of graphite tape applied to the laminated saddletree;  
         [0015]    [0015]FIG. 5 is a top view of the disclosed saddletree showing the exterior front to back strips of graphite applied to the laminated saddletree; and  
         [0016]    [0016]FIG. 6 illustrates a top view of the disclosed saddletree having all four front-to-back graphite strips applied. 
     
    
     SUMMARY OF THE INVENTION  
       [0017]    An equine saddletree is disclosed that has a first surface, a second surface, a cantle, a pommel, and a pair of sidebars extending between the cantle and pommel to form a length, leaving a center cutout section. The saddletree has increased strength and minimal torquing due to the alternation of the multiple wood layers with layers of graphite.  
         [0018]    The interior graphite layers consist of at least one layer of woven graphite sheet material having a warp and fill and extending from the cantle to the pommel. The woven graphite sheet placement on the wood layer defines whether the wood layer is considered a parallel or an angled layer. Graphite layers having either the warp or fill approximately parallel to the length form a parallel layer while layers with has one of said warp or fill at approximately a 45-degree angle to said length forming the angled layer. The parallel and angled graphite layers are alternated to form the saddletree. Additionally, each of the graphite layers has at least one strip of unidirectional graphite tape covering the pommel, approximately perpendicular to the sidebars.  
         [0019]    Strips of unidirectional graphite tape extend diagonally along each length of both the first surface and the second surface to prevent torque. A first strip tape is placed adjacent to the center cutout section proximate said cantle at a first end and adjacent an exterior edge proximate said pommel at a second end. A second strip of tape is applied adjacent to an exterior edge proximate the cantle at a first end and adjacent to the center cutout section proximate said pommel at a second end. A second layer of graphite tape pommel strips is also applied, on both the first and second surfaces covering at least a portion of the pommel, perpendicular to the length.  
         [0020]    To secure the cushioning panels, a point tab is secured within a notch in opposing ends of the pommel points. The point tab interacts with a receiving pocket on the cushioning panels to position the cushioning panels adjacent to the second surface of said saddletree  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    The traditional saddletree is comprised of thin layers of wood, with glue in between, that are molded into the desired form. Additionally, the life span of the glued wood trees with metal reinforcement is limited as eventually use stretches the width of the tree and increases the possibility of severe torquing. Prior art methods of compensating for the breakdown of the traditional tree has been to add metal reinforcements, which subsequently add weight. Many saddles eventually fail from the affects of constant and, at times, considerable torque.  
         [0022]    In the disclosed saddletree the layers of laminated wood traditionally used for saddletrees are reinforced with layers of woven graphite and strips of graphite tape. To optimize the torque resistance taught herein, the graphite tape should be unidirectional, however, it is the torque resistance that is critical and multi-directional tape can be used if the desired criteria are met. Additionally, although reference herein is to graphite, an equivalent material can be used. In order to provide optimum strength, the woven graphite is turned to place the weave at alternating 90° or 45° angles to the centerline. This combination eliminates torque while providing the required flexibility.  
         [0023]    The preferred unidirectional graphite tape for use herein has a width of about 1.0 inch, a weight of about 11 oz. and a thickness of about 0.0011 to 0.0015. The woven graphite is produced commercially as sheet material and preferably has approximately the same thickness as the graphite tape. The saddle is laminated using West Systems Epoxy Resins, or an equivalent that is compatible with both the wood and carbon. Lamination of unidirectional and woven graphite materials together with about 1.5 mm plywood in alternating layers provides optimum strength and stiffness while allowing a suitable substrate for the application of staples necessary to affix other saddle components to the tree.  
         [0024]    The graphite tape is a critical factor in the elimination of distortion in the saddletree. The tape, once bonded with the resin, becomes inflexible and encases the saddle with sufficient strength to prevent distortion as well as end-to-end and side-to-side movement.  
         [0025]    The alternating wood  70  and woven graphite  72  and  74  pattern is illustrated in FIG. 1. As can be seen, the woven graphite is placed between the wood layers  70 , leaving the top wood layer  78  without the woven graphite layer. The addition of woven graphite layers on the exterior faces can, depending upon the thickness of the graphite and wood layers, make the tree excessively stiff. In order to move with the horse, there must be some flexibility to the tree. Preferably that flexibility is in the range of about at lest 5% and less than 20% from pommel contact points when the tree is laid upon a horizontal surface. The extra layers of woven graphite, especially around the periphery, interferes with the ability to staple, or otherwise secure, the subsequent layers to the tree. The woven graphite used herein preferably has a thickness in the range of 0.011 and 0.015, although this can be adjusted based upon size of saddle and intended end use and will be evident to those skilled in the art. The woven graphite  72  and  74  does not address the torque issue, but rather the strength of the tree, eliminating unwanted side-to-side and end-to-end movement and providing a general stiffening that prevents breakage. Saddletrees are frequently placed under substantial pressure and, up until the disclosed saddletree, have been forced to use metal to reinforce the structure and counter the rider applied pressure. The woven structure of the graphite, once bonded with the wood and reinforced with the graphite tape, enables the removal of the standard metal reinforcements, thereby reducing the weight of the saddle.  
         [0026]    The disclosed patent uses the inherent make up of the woven graphite&#39;s warp and fill maximize strength. To obtain the maximum strength benefit, it is preferred that the directional placement of the woven graphite  72 , FIG. 2 and  74 , FIG. 3, be alternated between the horizontal (90°) and the diagonal (45°) in relationship to the centerline between the pommel  46  and cantle  44 , thereby creating bracing in multiple directions. In this manner the strongest directions, those of the straight line of the fibers, are alternated between the horizontal/vertical and the diagonal.  
         [0027]    In addition to the layer of woven graphite  72  or  74 , each graphite/wood layer  70  has two parallel strips of unidirectional graphite tape  52  and  54  laminated to the top surface of the tree across the pommel  46 . The graphite tape strips  52  and  54  are generally placed over the woven graphite  72  and  74 , although the layering could be reversed, with the woven sheet placed over the graphite tape without diminishing the advantages. Whether the tape strips  52  and  54  are placed over or under the woven graphite  72  and  74 , it is beneficial to extend the edge  56  of the woven graphite  72  and  74  to approximately the edge of the pommel  46 , thereby further reinforcing the weakest point of the saddletree. The width of the strips of graphite tape  52  and  54  must be sufficient to enable the strips, when placed edge to edge, to extend across the entire pommel area. As seen in these figures, the tape  52  can extend across the end of the center cutout  18 . The graphite tape  52  should extend to approximately the edge of the saddletree while the graphite tape  54  should extend at least past the bottom of the stirrup bars, or about one inch from the edge of the pommel point  58 . Preferably, the unidirectional graphite tape  52  and  54  extend to the edges of the tree, thereby covering between about 95% and 100% of the pommel area. The use of the strips of unidirectional graphite tape across the pommel  46  on each layer, sufficiently stiffens and braces the tree, thereby eliminating the need for the prior art metal gullet plate and top plate.  
         [0028]    Generally the disclosed saddletree will consist of five (5) layers of wood, the interior four (4) layers containing graphite to form wood/ woven graphite layers, two at 90° and two at 45° from the horizontal, as described in conjunction with FIGS. 2 and 3. The top layer of wood is covered with the graphite tape as described hereinafter. It should be noted that the specifications set forth herein are to ensure reliability and long-term use for a saddle that is being used professionally. In embodiments where the saddletree is for a lightly used child&#39;s saddle, the number of layers as well as the amount and weight of the graphite can be reduce as much as about 40% to 50%.  
         [0029]    Once the layers of wood and graphite forming the saddletree  10  have been laminated together, graphite tape strips  112  and  116  are placed along the length of the tree, stretching from the cantle  144  to the pommel  146  along the top surface as illustrated in FIGS.  4 - 6 . As can be seen from these figures, the interior strips  112  and exterior strips  116  starts proximate the cantle  144  of the tree  10  and extend toward the pommel  146  at an angle. It is not necessary to extend the strips  112  and  116  to the edge of the cantle  144  as the cantle  144  does not receive the stress that is received by the pommel  146  and main body  140  of the tree  10 .  
         [0030]    For clarity, the interior strips  112  and exterior strips  116  are shown applied separately in FIGS. 4 and 5. In FIG. 4, the interior strips  112  are shown applied along the length of the body  140  of the saddletree  10  starting adjacent the center cutout  18  by the cantle  144  and angling toward the outer edge of the tree  10  proximate the pommell  46 . In FIG. 5, the exterior strips  116  have been applied and run along the exterior edge of the body  40  approximate the cantle  144 , angling inward at the pommel  146 . The angling of the graphite strips  112  and  116  provides additional reinforcement against torque by placing the linear strength in the direction of the potential torquing action. Once the interior and exterior strips  112  and  116  have been appropriately secured, a final pair of pommel strips  162  and  164  are then applied and the secured with the appropriate resin.  
         [0031]    In FIG. 6, both the exterior strips  116  and interior strips  112  are illustrated; with the exterior strips  116  have been applied first, with the interior strips  112  being applied over them. It is not the sequence of the layering that is important, but rather the angled placement of the strips as the angle and pattern of placement of the interior and exterior strips, extending from inside to outside in a crisscross manner, braces the saddle against excessive lateral movement. Although this is the preferred pattern, other taping patterns can be used. The cross over pattern of the strips does, however, provide additional reinforcement against the torque and should be, in some manner, maintained. Although not illustrated in the figures herein, the exterior underside of the saddletree  10  is preferably also covered with the interior and exterior strips at described for the upper surface. The use of unidirectional graphite strips along the bottom exterior surface of the saddletree  10  further serves to stiffen the tree and further prevents torquing. The combination of the unidirectional graphite strips with the other graphite layers also braces the saddle against sagging of the mid-section under the rider&#39;s weight and stress of rider impact.  
         [0032]    It should be noted that the graphite should be spaced from the actual edge of the saddletree a distance sufficient to enable the leather to be stapled, or otherwise secured, to the tree.  
         [0033]    The wood/ graphite laminate is made in two stages. First the wood is laminated with the graphite layers placed in the interior only. When this has cured, the wood is dressed down, a bevel given to all of the top edges and then sanded. The bevel is important to provide a comfortable transition for the rider from saddle to horse. The top layers are then applied.  
         [0034]    The open center  18  of the saddle is smaller than in many prior art saddletrees and should be in the range of about 2 to 3.5 inches in the cantle area for a 17-inch saddle. The change in dimensioning with the increase or decrease saddle size will be evident to those skilled in the art. It should be noted that the open center  18  is narrower by the pommel  46  widening toward the cantle area where it is arced, maintaining the maximum width proximate the cantle. Since the torquing of the tree has been eliminated, as the horse moves the saddle moves side to side, rather than twisting diagonally. With a narrow open area  18  proximate the cantle, the back of the saddle catches and bumps the horse&#39;s spine at each stride. By widening the open area  18  proximate the cantle, the horse is free to move forward without affect to the spine. The underside of the tree is preferably chamfered toward the open area  18  to further prevent any sharp areas that could bump or catch the horse&#39;s spine. The open area  18  proximate the pommel  46  is narrower than on prior art saddles in order to increase the surface area of the sidebars  70 , enabling the angled placement of the unidirectional graphite strips. To achieve maximum resistance again torque, the strips must be angled as described heretofore.  
         [0035]    The disclosed saddletree is manufactured without the addition of any reinforcing metal. The disclosed graphite layered system provides the support previously obtained through the use of metal not only because of the nature of the material but through the ability to eliminate the need for rivets or other affixing devices. In prior art saddletrees rivets were used to attach the metal to the wood, thereby weakening the wood at each point of penetration. Through the use of graphite layers, the wood is not compromised.  
         [0036]    The addition of the graphite enabled the removal of the metal from the saddletree, thereby lightening, however the removal of the gullet also removed the securing system for the under panels. To provide for an attachment mechanism to replace the attachment provided by the gullet, the point  158  is routed, as illustrate in FIGS. 7 and 8, to receive the plastic tab  80 . The receiving notch  82  is routed into the point  58  approximately {fraction (1/4)} inch and a staple  84  is used to maintain the plastic tab  80  in place. An alternate method of securing the tab  80  is to place tubing over the tab  80  and a portion of the point  58 . The tubing is then heated and, in the shrinking process, locks the tab  80  in place. The thickness of the plastic tab  80  is about {fraction (1/16)}th of an inch and it is critical that if either this thickness or depth are increased, that the increase does not compromise the integrity of the wood. The foregoing dimensions are preferred and increasing these dimensions substantially will lessen the strength of the tree. The under panels that are place over the tree are manufactured with a pocket to receive the point  158  and secured plastic tab  80 .  
         [0037]    In order to provide consistency in the manufacturing process, the stirrup bar receiving holes  90  and  92  are drilled into the saddletree  10  immediately after completion of the molding process, thereby enabling the placement of the receiving holes  90  and  92  to be consistent from saddle to saddle. The stirrup bar receiving holes  90  and  92  also provide a convenient method of aligning the saddletree for routing the receiving notch  82  as well as any other precise measurements. To route the receiving notch  82  a jig has been build with prongs for the receiving holes  90  and  92  and a track to receive the router, thereby maintaining the receiving notch  82  at a consistent depth and centered with in the point  158 .  
         [0038]    Because of the curvature of the saddletree, all the graphite used must have the flexibility to smoothly conform to the tree shape. In tests that were conducted, the torque of the tree presented the greatest problems. It was found that the trees that had only woven graphite in the interior layers did not withstand the pressure applied to the saddle, reinforcing the need to include the graphite tape on the outer layers.  
         [0039]    Vacuum forming the graphite to the outer layers of a finished saddletree made with no interior layers of graphite caused distortion in the saddletree shape. Saddletrees formed with only a single layer of graphite tape top and bottom in addition to the interior layers permitted too much torque. In high stress applications, such as would be encountered with professional jumpers or rodeo riders, additional support can be beneficial. To increase the strength of the saddletree, one or two layers of the woven graphite are replaced with the graphite tape in the same pattern as disclosed heretofore. Alternatively, additional layers of graphite tape can be added to the top and/or bottom of the tree, as long as the above noted flexibility remains.