Ski with replaceable edge

The invention disclosed herein provides a replaceable edge cassette for skis or a snowboard. The skis have a top, a base, a core, two sides, and edges along the sides of the base. The cassette includes an edge portion removably secured adjacent the base of the ski. The edge portion has an attachment portion for securing the edge portion to the ski and a peripheral portion for contact with the surface to be ridden. The cassette includes a sidewall portion secured to the edge portion. A fastener is connectable through the sidewall portion to be secured to the ski adjacent the core. Base material is also secured beneath the removable edge portion so as to be adjacent the main base portion when the cassette is secured to the side of the ski. The edge cassette is removable and replaceable by removing the fasteners secured through the sidewall. The edge alone may also be separately replaceable by removing it from the sidewall portion.

FIELD OF THE INVENTION

This invention relates generally to boards for gliding on snow and, more specifically, to skis and snowboards with partially replaceable edges and sidewalls.

BACKGROUND OF THE INVENTION

Skis and snowboards are typically constructed with a wood or foam core, composite layers (usually fiberglass) above and below the core, a polyethylene base (such as “P-Tex”), an ABS top sheet and sidewalls, and steel edges. The steel edges include an exposed corner portion, which is rectangular in cross section, and ears extending from the corner section to be secured between the base and the core of the ski. The ears include T-shaped extensions, as shown inFIG. 1, that allow the composite material to hold the edge in place. Thus, once the ski is molded, the edges are non-removably secured to the body of the ski (note that the discussion referencing a “ski” applies equally to a snowboard unless otherwise noted).

If a ski is damaged, such as with a scrape to the base, it is normally repairable at a reasonable cost. The base can be repaired by base welding, patching, or by the simple addition of melted P-Tex into the damaged area. However, if the damage includes a significantly bent edge or a broken edge, the repair is much more difficult. Often the ski must simply be replaced (both skis would be replaced together, as they need to be paired).

Bent and/or cracked edges have become more common as skiers spend more and more time doing tricks in the parks and pipes and even in off-piste terrain. The ski edges are often slid over obstacles, such as benches, rails, table tops, trees, stumps, and walls. Such maneuvers can easily damage an edge and require replacement of the pair of skis. Even when skiing without performing stunts, ski edges may be blown when a rock is hit. This occurrence is also increasing in frequency due to the opening of boundaries and more off-piste skiing or skiing in areas where unmarked obstacles exist. Cracks often occur due to the hardness of the steel required to keep a sharp edge.

Attempts to solve the bent and cracked-edge problems have focused on providing thicker edges on skis intended to be used in terrain parks. The thick edge is more difficult to bend. However, making edges thick enough to withstand most bends may overly increase the stiffness of the ski underfoot (where damage typically is focused). Furthermore, damage from scrapes and other wear on the edges will still accumulate, requiring ski replacement. Damage to the sidewall may also occur with damage to an edge. If the sidewall is damaged the edge has less to support it to keep it strong and properly in place. Replacing a portion of a sidewall is also difficult and, thus, costly.

Another problem with ski edges is associated with the sharp corner the edge provides. The corners help hold the ski from skidding on ice or hard-packed snow. However the sharp corner can also cause increased friction when ground on obstacles, such as a pipe or box rail, during skiing. The friction can heat the steel to lead to excessive hardness and cracking. The sharp edge tends to “grab” on discontinuities. This mars and distorts the edge, and excessively damages the surface ridden. The square edge also catches on the metal, wood, plastic, and concrete rails, and wears out the rails. The edges also catch when attempting to pivot the skis or switch from forwards to backwards on the skis.

Thus, an unmet need exists to better address the damage done to skis by obstacles skied over or upon. The solution should be less costly than replacing skis. It should also be a solution that could be optionally handled by the consumer, without extensive recourse to a dealer or manufacturer.

SUMMARY OF THE INVENTION

The present invention comprises a board, such as a ski or snowboard, for sliding on snow. The board includes a top, a base, a first edge, a removable edge assembly, and an anchor member. The base is positioned below the top. The first edge is secured adjacent the base. The removable edge assembly is secured adjacent the base and adjacent the first edge. The edge assembly includes a removal fastener. The anchor member is adjacent the base and receives the removal fastener to removably and replaceably secure the edge assembly.

In accordance with a preferred aspect of the invention, the removable edge assembly includes a sidewall portion and an edge portion secured to the sidewall portion. In this embodiment, the removal fastener extends through the sidewall portion above the edge portion. The edge assembly includes a base plug secured adjacent the edge portion. The edge portion also includes steel having a peripheral portion and an inner portion secured to the sidewall portion. The base plug is secured to the inner portion of the edge portion. In accordance with another aspect of the invention, the edge portion is removably and replaceably secured to the sidewall portion. The edge assembly further includes an edge fastener secured between the edge portion and the sidewall portion.

In accordance with yet another aspect of the invention, the edge portion is constructed of a different material from the sidewall portion, the edge portion being fixed to the sidewall portion. In one preferred embodiment, the sidewall portion is secured to the edge portion by molding the sidewall portion about at least a part of the edge portion.

In accordance with additional aspects of the invention, the board includes a sidewall secured between the top and the base with an anchor being secured within the sidewall. The anchor member includes an insert for threaded engagement with the removable fastener. The base plug includes a fastener secured to the edge portion. In one preferred embodiment, the sidewall portion includes a lower portion with a base recess. The removable edge assembly includes the base plugs secured within the base recess arranged adjacent to the base.

In accordance with another preferred aspect of the invention, the sidewall portion includes the portion outward of the base plug. Preferably, the sidewall portion is constructed of a thermoplastic material.

The present invention also preferably includes a replaceable edge cassette for a surface sliding board. The board has a top, a base, a core, two sides, and edges along the sides of the base. The cassette comprises an edge portion removeably secured adjacent the base of the sliding board and a fastener for securing the edge portion to the board. The edge portion has an attachment portion for securing the edge portion to the board and a peripheral portion for contact with the surface to be ridden.

In accordance with further aspects of this preferred embodiment, a sidewall portion is provided. This sidewall portion is secured to the edge portion. The sidewall portion is securable to the board adjacent the core. Preferably, the fastener is securable to the core. An edge fastener is also preferably provided to secure the edge portion to the sidewall portion.

A base plug is secured to the edge portion beneath the attachment portion of the edge portion.

The invention also comprises a method of replacing an edge portion of a sliding board having a top, a base, a core, two sides, and edges. The method includes the steps of providing an edge cassette having an edge portion and a fastener, loosening the fastener, removing the cassette from the side of the sliding board, positioning another edge cassette, and securing the fastener. The fastener secures the edge portion to the sliding board. The edge cassette is positioned adjacent the side of the sliding board.

Preferably, the method includes the step of providing an edge cassette having a sidewall, the edge portion being attached to the sidewall. The sidewall is attached to the sliding board with the fastener. A base plug is also preferably secured to the bottom of the edge portion.

In yet another preferred embodiment of the invention, a board for sliding on snow is provided. The board has a mid portion, a forward portion, and a rearward portion. The board comprises a top, a base, a core, and a mid-edge portion. The base is positioned below the top. The core is positioned between the base and the top. The mid-edge portion runs along the mid portion of the board. The mid edge portion includes a mounting portion secured above the base and an outer portion. The outer portion has a lower corner for contact with the snow. The lower corner includes a rounded portion.

In a preferred aspect of this embodiment, the mid-edge portion is held by a removable cassette. The removable cassette is securable adjacent the base at the mid portion of the board. The cassette includes a sidewall and a fastener, the fastener being removably securable to the core. Preferably, the base includes a cassette portion and a main portion. The cassette portion is secured beneath the mid-edge portion. The main portion of the base is under the core, adjacent the cassette portion.

The many preferred aspects of the invention provide several advantages to the user of the board to overcome the drawbacks encountered in the prior art. For example, the rounded radius edge under the mid portion of the ski allows easier side sliding at the portion of the ski that receives the skier's foot, and thus the most force on the ski. This construction aids skiers who ski in variable mountain and natural terrain conditions or in terrain parks and hit obstacles while sliding sideways. The radius steel edge allows the ski to slide easier without catching an edge. The radius reduces friction, thus helping keep the steel from changing its hardness and cracking. The rounded radius also helps to prevent marring and distortion of the steel edge. The rounded edge also does not grip the metal, wood, plastic, and concrete rails: allowing the ski to slide without catching like a square edge. Skiers may roll their ankles placing the skis on edge when sliding the rail. The rounded edges help the skis slide more smoothly. It also causes less wear and tear to the rails and affords less maintenance. The skis pivot easier, the edge grabs less, allowing the skier to switch from going forward to backward and vice versa. Thus, the skis are more maneuverable while sliding rails and boxes, making it easier to spin 180 degrees or more while staying in contact with the rail. The removal assembly (whether just the steel edge or a full edge and sidewall cassette) allows the user to remove the cassette or the steel edge material when damage occurs to the edges. It allows the user to change the out damaged edges due to rails and rocks. It also allows the user to change the out edges for rounded edges or sharp edges depending on the terrain to be skied.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The construction and advantages of the present invention will be more clearly understood by reference to the following description of the preferred embodiments and by reference to the attached drawings referred to herein.

FIG. 1illustrates a cut-away of a typical prior-art ski construction. This particular illustration shows a laminate construction of a ski10. The ski includes a top sheet12, a base14and a core16sandwiched one on top of the other. An upper composite layer18may be situated between top sheet12and core16. A separate composite layer would typically be fiberglass or other composites in a resin matrix as is commonly known in the art. Other layers between core16and top sheet12are also possible such as metal sheets22. A lower composite layer20is also provided between base14and core16. Top sheet12may be of a plastic material such as ABS. Face14is typically constructed with a polyethylene material. Core16may be constructed with foam, wood or other materials.FIG. 1illustrates core16with a laminated wood material.

An edge24is secured above base14, typically intertwined with and above lower composite layer20. A sidewalk26also extends upward above edge24adjacent core16to top sheet12or one of the intermediate layers between top sheet12and core16. Sidewall26is typically constructed of an ABS material.

Edge24includes ears28that project inwardly toward the center of the ski basically in a plane parallel to the plane of base14. The gaps between these ears allow the composite layer20with its resin to form a mechanical bond in the gaps to hold edge24in place. Edge24also includes an outer portion30that has a squared edge for cutting into snow and ice for a secure grip while skiing.

The construction shown and described with regard toFIG. 1is a standard ski construction that those skilled in the art will recognize. Many variations thereto have also been used with many of the same elements, such as metal edges, base material, composite layers, top sheets and cores. For example, torsion box constructions or cap constructions are also well known.

The remaining figures illustrate a ski that includes somewhat of a standard construction in the fore and aft portion of the ski while the mid-portion of the ski includes an edge cassette32that is removable from the main body of the ski and replaceable. In order to accommodate edge cassette32the standard ski construction is reduced in width in the mid portion such that recesses are provided in the sides of the ski10into which edge cassettes32are secured. Edge cassettes32preferably extend along approximately a third of the length of ski10in the region of the ski that would be adjacent the boot bindings. Thus, this is the area of the ski that receives the most direct force from the skier and would be the portion of the ski which is underfoot.

As seen inFIGS. 3 and 4, edge cassette32includes a cassette sidewall34and a cassette edge36. Cassette sidewall34is secured on the outer side of edge cassette32so as to be along the side of the ski when assembled adjacent sidewall26that extends in the fore and aft portion of the ski. Cassette edge36is secured beneath cassette sidewall34so as to lie in the mid-portion of the ski for a continuous edge extending from edges24in the fore and aft portions of the ski to be adjacent thereto. Edge cassette32is secured within the recesses in the sides of ski10with cassette fasteners38. In the preferred embodiment illustrated, three cassette fasteners38secure edge cassette32through openings within cassette sidewall34with fasteners passing into the main body of the ski. Inserts may be employed within core16or fasteners38may simply be anchored directly to core16. Other anchor arrangements may be used and held within the main body of ski10. Thus, fasteners38are preferably bolts that are threaded and include heads that may be turned to fasten the threads within a threaded anchor held within ski10. A section of base material may be used to form a base plug40that is secured to the bottom of edge cassette32below sidewall34and ears28prime of cassette edge36.

FIG. 6illustrates a bottom view of cassette sidewall34provided with an edge recess40into which the ears of cassette edge36may be secured. The particular ears28preferably used with cassette edge36include apertures therein that may be secured over a molded recess with projections to fit within the apertures. The ears may be of any suitable shape (e.g., T-slot, rounded, etc.) to retain them onto cassette sidewall34, sidewall26, or any other part of ski10to which they may be secured in a particular embodiment. Preferably, the ears have openings or holes to accept fasteners for replaceable securement.

Also shown in the bottom view ofFIG. 6are the base plug apertures42into which plug fasteners44may be secured to hold a base plug40in place beneath ears28and cassette sidewall34. Alternate means of securing cassette edge36and base plug40may be employed. For example, if the entire assembly is to be used and replaced as a unit there may be no need for removal fasteners such that adhesive bonding or chemical bonding may be employed to secure the materials together. Further discussion of alternate ways of interconnecting these elements will be discussed below in connection withFIG. 7.

Sidewall34is preferably constructed of ABS or another thermoplastic material. Alternatively, sidewall34is constructed of other materials, in one embodiment metal is used in at least a portion of sidewall34.

The width of cassette sidewall34is preferably between 5 and 8 millimeters but could be more or less depending upon the specific construction desired. For example, in an alternate preferred embodiment, the width of cassette sidewall34is only 2 millimeters and ears28prime overlap not only cassette sidewall34but extend beneath a recessed portion of the main body of ski10adjacent cassette sidewall34. In this embodiment, the recesses in the sides of ski10, such as those shown inFIG. 2, do not need to be very extensive on the top side with appropriate recesses for edge ears28prime on the bottom side.

Base plug40is preferably constructed with an ABS material or another thermoplastic material such as Delrin or Hytrill (both trademarks of DuPont). Alternatively, base plug40is constructed of metal. In one embodiment base plug40is a metal extension of cassette edge36.

FIGS. 7a-7dillustrate various details of construction of different preferred embodiments of the invention.FIG. 7aillustrates a basic construction with a cassette fastener38extending through cassette sidewall34to be anchored within core16or an alternate anchor structure held adjacent to or within core16. The head of cassette fastener38is secured within a recess in the outer wall of cassette sidewall34. The outer wall of cassette sidewall34may have a rounded slope or may extend vertically depending on the aesthetics desired in the ski and on some performance criteria. Cassette edge36is secured with edge fastener46to the underside of cassette sidewall34through a hole in an ear28prime of cassette edge36. Outer portion30prime of cassette edge36includes a rounded radius for ease of sliding and grinding with reduced friction, reduced edge marring and reduced damage to rails or other objects on which the skier may grind or slide. Apertures are also provided within ears28and adjacent ears28within cassette sidewall34for plug fasteners44of base plug40. These fasteners allow base plug30to be secured in place beneath cassette edge36. In this embodiment, the removal of base plug40is required in order to access edge fastener46to remove cassette edge36from cassette sidewall34. Thus, if damage occurs to outer portion30prime of cassette edge36the entire cassette assembly may be removed by loosening cassette fastener38and replacing the entire assembly. Alternatively, the user may simply wish to replace cassette edge36and then has the further option of replacing base plug40. Note that base plug40when installed sits adjacent base14for a smooth transition between the two.

In alternate embodiments portion30′ of cassette edge36may have a square edge for carving. Thus, edge cassette32may be swapped with various other edge cassettes depending on the type of skiing that the skier wishes to do.

Referring toFIG. 7b, cassette edge36may be molded directly to cassette sidewall34alleviating the need for a separate edge fastener46. In this instance, cassette edge36would simply be placed in the mold when the thermoplastic material is shot into the mold. In this instance, special edge apertures48are provided into which material may flow to bind cassette edge36to cassette sidewall34.

Referring toFIG. 7c, a separate metal or other material edge may be omitted entirely in favor of simply having the material of cassette sidewall34also function as the outer edge30double prime of edge cassette32. In this instance, base plug40is fastened directly to cassette sidewall34. This embodiment may be preferable when excessive sliding or grinding is simply desired without steel edge grip or durability. This provides extra smoothness and sliding ability on rails, for example. The cassette sidewall material used may be a more durable material such as ultra-high molecular weight plastic. Delrin or other such materials may be used. The material may be machined, extruded or molded or formed in any other fashion. In fact, the entire cassette sidewall may be alternatively constructed of a metal whether a softer metal, such as aluminum, or a harder steel or other metal.

Referring toFIG. 7d, sidewall26is part of the main body of ski10and is not removable. Thus, in this instance, edge cassette32comprises cassette edge36and base plug40. Edge fastener46is employed to removably secure the assembly to sidewall26. An anchor, such as a threaded insert may be secured within sidewall26for securing edge fastener46and making repeated securement and removal of the assembly easier.

Referring now toFIG. 7e, an alternate embodiment of the invention employing a fastener insert50is disclosed. This embodiment is similar to that described above in connection withFIG. 7a. However, cassette sidewall34includes insert50, preferably molded therein, to secure removable edge fastener46. Insert50is comprised of metal and includes threads for engagement of fastener46. The outer surface of insert50includes projections and recesses such that sidewall34engages firmly thereto as it is molded around insert50. The outer dimensions of insert50are preferably at least somewhat non-cylindrical so as to better resist rotating relative to sidewall34as fastener46is tightened. Multiple fastener inserts50spaced along the length of sidewall34are preferably used where desirable to secure a fastener46. In this embodiment, fastener46is a machine screw or bolt having threads that matingly engage insert50. Thus, cassette edge36can be repeatedly removed and replaced within degradation of the engagement threads within sidewall34.

FIG. 7fillustrates an alternate embodiment with a vertical edge ear28configuration. Rather than position edge ear28between base plug40and sidewall34, edge ear28is secured with fastener46to the outer side of sidewall34. In this embodiment, ear28is outwardly exposed. Outer portion30is positioned on the lower outer corner of ski10and abuts base plug40. Replacement of cassette edge36is simplified, as base plug40does not need to be removed to gain access. Mating recesses within the outer wall of sidewall34hold ears28of edge36along with fasteners46.

Numerous preferred and alternate embodiments have been discussed, these have been discussed in relation to a ski although a snowboard or other snow-riding device may work equally well with the present invention and are encompassed herein. Other materials may also be substituted. Fastening methods may be changed as well without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiments. Instead, the invention should be determined entirely by reference to the claims that follow.