Abstract:
A skateboard deck is formed of several layers pressed and bonded together. Apertures are formed through the bottom-most layers, and impact support members are arranged within the apertures. The impact support members are more rigid than the other portions of the skateboard deck, and provide localized impact support while allowing the remaining layers of the deck to retain their performance characteristics and feel while strengthening the most vulnerable areas of the deck.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 11/938,148, which was filed Nov. 9, 2007, now U.S. Pat. No. 7,810,824 and which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/879,862, which was filed Jan. 10, 2007. The entire contents of each of the priority applications are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a skateboard deck construction, and more particularly to a skateboard deck having a member that absorbs impact forces. 
     2. Description of the Related Art 
     Skateboard decks constructed from laminated wood are well known. Typically, such laminated decks are constructed of several sheets of wood glued and pressed together to form a desired shape. Such a skateboard deck typically includes first and second truck mount portions at which wheeled trucks are attached to the deck, typically via bolts or screws extending through mount holes formed through the deck. Although such skateboard decks have attained wide acceptance, they suffer from drawbacks in terms of strength, weight and durability. 
     Accordingly, efforts have been made to strengthen skateboard decks. Some such efforts employ using alternative materials and technologies, such as composite materials. However, skateboarders are familiar with the feel and performance characteristics of wooden decks, and many skateboarders prefer the feel of such decks to alternatives that may incorporate additional technologies. Also, some alternative deck technologies create problems of their own, and may in some cases substantially increase the cost and weight of associated skateboard decks. 
     SUMMARY OF THE INVENTION 
     Accordingly, there is a need in the art for a skateboard deck having the feel of a traditional wood deck, but having increased strength and durability without increasing weight. 
     Applicants have noted that wooden laminate skateboard decks are particularly vulnerable to wear and breakage along a zone or line generally adjacent the inner truck bolt holes, or the truck bolt holes closest to the center of the deck. 
     Accordingly, there is a need in the art for a skateboard deck that is reinforced in the area(s) in which the deck is particularly vulnerable to breakage. 
     In accordance with one embodiment, the present invention provides a skateboard deck comprising a plurality of layers of wood pressed and bonded together. A truck mount zone is adapted to receive a skateboard truck mounted thereon. An impact support member comprises a fiber-reinforced composite and has a generally ovoid shape. The impact support member is generally aligned with the truck mount zone, the impact support member radiating outwardly from the truck mount zone and terminating between the truck mount zone and an edge of the deck. The impact support member disperses impact forces. 
     In one such embodiment, the bottom-most layer of wood has an aperture which complements the impact support member, and the impact support member is disposed in the aperture. In another embodiment, a density of adhesive between the impact support member and the adjacent layer is greater than an average density of adhesive between layers in the skateboard deck. In a further embodiment, a density of adhesive between the bottom-most layer adjacent the aperture and the adjacent layer is greater than an average density of adhesive between layers in the skateboard deck. 
     In another embodiment, the impact support member is circular. 
     In a further embodiment, one of the layers comprises an aperture that complements the impact support member, and the impact support member is disposed in the aperture. In one such embodiment, the impact support member and the layer have substantially the same thickness, and the thickness is less than an average thickness of the other layers. In another such embodiment, the thickness is less than a thickness of each of the other layers. In a further embodiment, the aperture and impact support member are disposed in the bottom-most layer of the deck. 
     In yet another embodiment, at least two adjacent layers each comprise an aperture, the apertures being substantially aligned, and an impact support member fits complementarily within the aligned apertures. 
     In accordance with another embodiment, the present invention provides a method of making a skateboard, comprising providing a plurality of layers of wood, providing an impact support member comprising a fiber-reinforced composite having a generally ovoid shape, pressing and bonding the wood layers together to form a deck, designating a truck mount zone adapted to receive a skateboard truck mounted thereon, and arranging the impact support member on the deck and generally aligned with the truck mount zone, the impact support member radiating outwardly from the truck mount zone to a terminus between the truck mount zone and an edge of the deck. The impact support member disperses impact forces. 
     One embodiment additionally comprises forming an aperture through one of the layers of wood, the aperture shaped and sized to complement the impact support member, and arranging the impact support member in the aperture. Another embodiment comprises applying an adhesive between layers of the skateboard deck, and a density of adhesive applied between the layer having the aperture and an adjacent layer is greater in an area adjacent the aperture than between an average density of adhesive between layers throughout the skateboard. In one such embodiment, a density of adhesive applied between a face of the impact support member and an adjacent layer is greater than an average density of adhesive between layers throughout the skateboard. 
     Another embodiment additionally comprises placing the layer having the aperture in the bottom-most position of the layers making up the skateboard deck. In one such embodiment, the bottom-most layer and the impact support member have substantially the same thickness, and the thickness is less than an average thickness of the layers in the skateboard deck. 
     In another embodiment, the impact support layer comprises a fiber-reinforced composite, and the method additionally comprises curing the impact support member prior to arranging the impact support member in the aperture. 
     In still another embodiment, the impact support layer is bonded to a bottom surface of the skateboard deck. 
     Certain objects and advantages of the invention are described herein. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
     All of the embodiments summarized above are intended to be within the scope of the invention herein disclosed. However, despite the foregoing discussion of certain embodiments, only the appended claims (and not the present summary) are intended to define the invention. The summarized embodiments, and other embodiments of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an assembled skateboard deck, showing truck mounting zones. 
         FIG. 2  is an exploded view showing layers to be assembled during a construction step of a skateboard deck embodiment. 
         FIG. 3  is a partially exploded bottom perspective view of a skateboard deck embodiment having impact support members. 
         FIG. 4  is a bottom view of an assembled skateboard deck embodiment. 
         FIG. 5  is a partial cross sectional view of the skateboard deck of  FIG. 4  taken along lines  5 - 5 . 
         FIG. 5A  is a partial cross sectional view of another embodiment of a skateboard deck 
         FIG. 6  is a partial bottom perspective view of the skateboard deck of  FIG. 4  with a wheel and truck assembly attached. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     With initial reference to  FIG. 1 , an embodiment of a skateboard deck  20  is illustrated. The skateboard deck  20  has a planform shape approximating an elongated oval. The deck  20  comprises an elongate body  22  having first and second opposing ends  24 ,  26 . Preferably, the skateboard deck  20  has a slightly concave upper surface  28  and a slightly convex lower surface  30  about a longitudinal axis  32  of the deck  20 . 
     In the illustrated embodiment, a first tail  34  is formed adjacent the first end  24  and a second tail  36  is formed adjacent the second end  26 . The first and second tail portions  34 ,  36  preferably are upturned, and there is a transition portion  38  between the body  22  and each upturned tail  34 ,  36 . In each of the transition portions  38 , hips  40  are formed generally along and adjacent an edge  42  of the skateboard deck  20  where the most dramatic change in curvature from the concave body  22  to the upturned tail  34 ,  36  occurs. 
     Such a skateboard deck  20  is typically configured to be attached to first and second wheeled trucks. As illustrated, first and second truck mount portions  44 ,  46  are indicated by phantom lines. The mount portions  44 ,  46  generally delineate an anticipated outline of the skateboard truck base plate  72  when such a truck would be attached to the bottom surface  30  of the deck  20 . Typically, apertures  48  are formed through the deck  20  and generally approaching the corners of the truck mount portions  44 ,  46 . Corresponding apertures typically are formed in the truck base plate. As such, bolts and/or screws extending through the mount holes  48  can secure the truck base plate  72  to the deck  20 . 
     Applicants have noted that, during use, skateboard decks are particularly vulnerable to wear and breakage along a zone or line  50  generally at or adjacent the inner apertures  48 A in each truck mount portion  34 ,  36 . The inner apertures  48 A are those generally closer to a middle portion of the deck  20  and also closest to the opposite truck mount. This vulnerability zone  50  demarcates a portion of the deck that is most likely to be exposed to the greatest stress concentrations during impacts and the like that can be expected during skateboarding, especially during high performance skateboarding in which the skateboarder becomes airborne and exerts great pressures when landing upon the deck. 
     The illustrated embodiment preferably comprises several layers of wood  55 A-G glued and pressed together to form the skateboard deck  20 . In a preferred embodiment, the skateboard deck  20  comprises seven layers  55 A-G of North American hard maple wood, each layer being generally between about 0.04 and 0.07 inches thick, and more preferably between about 0.042 inches and 0.062 inches thick, resulting in an overall deck thickness between about 0.35 and 0.45 inches, or more preferably about 0.39 inches. Of course, different thickness ranges and different materials are contemplated. 
     To construct the illustrated skateboard deck  20  embodiment, the seven layers of wood  55 A-G are arranged one on top of the other.  FIG. 2  illustrates an exploded view of seven layers of wood  55 A-G that are to be glued and pressed together to form an embodiment of a skateboard deck  20 . In the illustrated embodiment, first and second apertures  60 A,  60 B are formed through the bottom-most layer  55 A. The apertures  60  can be formed in any desired manner such as by boring, cutting, stamping, or the like. Preferably, the apertures  60  have an ovoid shape and, more preferably, the apertures  60  are circular. In the illustrated embodiment, the seven layers of wood  55 A-G preferably are bonded together with an epoxy adhesive and, before the adhesive cures, inserted into a press having a mold in the press, the bonded wood layers take on the shape of the mold and the epoxy is cured sufficient so that the molded shape is retained when the bonded layers are removed from the mold. Once the skateboard deck  20  is removed from the mold, it is cut to the desired planform shape, and the truck mount apertures  48  preferably are bored. 
     With additional reference to  FIG. 3 , in a preferred embodiment, rigid and resilient impact support members  70  are fit into the apertures  60  through the bottom-most layer of wood  55 A. The impact support members  70  preferably are shaped to complement the apertures  60  formed in the bottom layer  55 A. Preferably, the impact support members are made of a strong material, such as a fiber reinforced epoxy, a metal, or the like. In a preferred embodiment, the impact support members  70  are formed of carbon fiber material disposed in a cured epoxy matrix. Other types of fibers, such as aramid (Kevlar™) or glass, are also contemplated. 
     As indicated in  FIG. 3 , the carbon fiber impact support members  70  preferably have a thickness generally the same as a thickness of the bottom wood layer  55 A of the skateboard deck  20 . As such, preferably the bottom faces of the support members  70  are substantially flush with the bottom face of the bottom wood layer  55 A, and the overall thickness of the deck in the area of the support members  70  is about the same as the overall or average thickness of the deck. Also, the impact support members  70  have an ovoid shape that generally avoids creating substantial stress concentrations. 
       FIG. 3  illustrates the impact support members  70  being fit into the apertures  60  of the bottom-most wood layer  55 A. In one embodiment, the impact support members  70  are placed in the apertures  60  after the rest of the skateboard deck layers  55  have been bonded, pressed, and molded into the desired skateboard shape. However, in a more preferred embodiment, the impact support members  70  are placed within the apertures  60  in the bottom-most wood layer  55 A when the other layers  55  are assembled and bonded together. Thus, the entire skateboard deck  20 , including the impact support members  70 , is placed together within the mold and pressed and cured simultaneously. As such, the impact support members  70  are tightly and unitarily bonded with the rest of the skateboard deck  20  layers, and the impact support members  70  take on the curved shape of the rest of the skateboard deck  20 . Still further, preferably the impact support members  70  fit substantially flush with the bottom surface  30  of the bottom-most wood layer  55 A. 
     In a preferred embodiment, carbon fiber impact support members are cured prior to being inserted into the skateboard deck  20 . For example, in one embodiment, a flat carbon fiber sheet having the desired thickness is laid up and cured. A plurality of impact support members  70  are then cut out of the sheet such as by a die cutting method. Thus, the rigid and cured impact support members are substantially finished when inserted into the skateboard deck  20  apertures  60  during the construction process. Nevertheless, the cured impact support members still take on the desired shape when glued and molded in the press. 
     In another embodiment, a plurality of layers of a carbon fiber prepreg material is cut into a desired impact support member shape but not cured. During the skateboard deck  20  construction process the uncured impact support member is placed in the apertures. The impact support members are thus cured along with the epoxy that glues the wood layers and impact support members together into a unitary skateboard deck  20 . 
     In a preferred embodiment, during construction of the deck, epoxy is supplied between each layer of wood  55  and between the impact support members  70  and the adjacent wood layer  55 B. Preferably, distribution of epoxy throughout the deck  20  is generally consistent, except that an increased volume of epoxy is applied not only to a face of the impact support member  70  itself but also to the wood layers  55 A,  55 B in the area surrounding and adjacent each aperture  60  into which an impact support member  70  is placed. The increased density of epoxy in these areas more thoroughly ensures advantageous bonding of the impact support member  70  with the surrounding layers of wood  55 B to protect against delaminations. 
     Although the impact support members are made of carbon fiber fabric in the illustrated embodiment, other materials and configurations of fibers and layers and materials can be used. Most preferably, however, the impact support members are constructed in a manner and using materials so as to be more rigid than the wood layers that make up the majority of the skateboard deck. 
     Additionally, during construction, preferably a face of the cured impact support member is sanded or otherwise roughened prior to the bonding process to eliminate glossy spots and improve adhesion of the support member to the adjacent layer of wood and to improve interaction with the epoxy glue. 
     With next reference to  FIGS. 4-6 , embodiments of a fully constructed skateboard deck  20  having impact support member  70  formed in the bottom-most layer  55 A are illustrated. The truck mount portion  44  is shown in phantom lines on  FIG. 4 , and in  FIG. 5  a representation of a skateboard truck base plate  72  is illustrated attached to the bottom of the skateboard deck  20 .  FIG. 6  shows an example in which a skateboard truck  74  is mounted onto the embodiment of  FIG. 4 . As shown, the impact support members  70  preferably are sized to cover the entire truck mount portion  44 . Preferably the support members  70  extend or radiate outwardly beyond an anticipated footprint of a truck base plate  72 . As such, the support member  70  extends through and across the typical vulnerability zone  30  in the deck  20 , which extends as discussed above, generally across the inner truck mount apertures  48 A. 
     As discussed above, preferably the impact support members  70  are more rigid than the surrounding wood layers  55 A-G. As such, the impact support member  70  will dampen and disperse impact forces that otherwise would be focused on the most vulnerable portions  50  of the skateboard deck  20 . Durability and breakage resistance of the deck thus are dramatically improved. Specifically, the portions in and around the truck mount zone  44 ,  46  and more specifically the vulnerability zone  50  around the inner truck mount apertures  48 A. 
     Additionally, since the impact support members  70  are relatively small and unobtrusive, they have little, if any, effect on the overall performance and feel of the skateboard deck  20 . More specifically, since the extra-rigid support members  70  are quite small, and limited in size to the area generally surrounding the truck mounts  44 ,  46 , the predominantly wood deck  20  still behaves and feels like a traditional wooden deck. As such, durability is dramatically increased without substantially affecting the overall feel and performance of the skateboard deck  20 . 
     With specific reference again to  FIG. 5 , in the illustrated embodiment, the bottom-most layer  55 A of the skateboard deck  20  has a thickness tA that is less than a thickness tB of the adjacent wood layer  55 B. In fact, in the illustrated embodiment, the bottom-most layer  55 A is thinner than each of the other wooden layers  55 B-G of the skateboard  20 . In this embodiment, because of its increased strength, the impact support layer  70  can be made quite thin. Likewise, the bottom-most wood layer  55 A can be made thinner than the other layers  55 B-G of the skateboard, thus decreasing the overall weight and thickness of the skateboard  20  while still providing the increased strength and durability benefits of the impact support member. 
     In another embodiment, a skateboard deck can be constructed of wood layers of various thicknesses, including one or more very thin layers. However, preferably the bottom-most later, which includes the impact support members, has a thickness less than the average thickness of the other layers. 
     In yet another embodiment, the impact support members are disposed in an aperture formed in a wooden layer other than the bottom-most layer. As such, the support members are hidden from direct view, and completely enclosed within the wooden layers. However, most preferably the support members are disposed in the bottom-most layer so as to be closest to the interface of forces transferred between the truck mount base plate and the skateboard deck. 
     In another embodiment, as illustrated in  FIG. 5A , adjacent layers  55 A and  55 B each have an aperture, and the apertures are substantially aligned. The impact support layer  70  fits complementarily within the aligned apertures. 
     In still another embodiment, the impact support members have a thickness greater than the thickness of a single corresponding layer of wood. As such, apertures are formed through two or more adjacent layers of wood to accommodate the members. 
     In a still further embodiment, the impact support members are bonded to the bottom surface of the skateboard deck after the deck has been pressed and molded. Although the impact support member does not fit into an aperture in this embodiment, preferably it radiates outwardly beyond the truck mount zone but terminates short of the edge of the deck. In another embodiment having such construction, a thickness of one or more of the layers is reduced, or one or more layers are eliminated, so that the overall thickness of the skateboard deck including the impact support members is the same as or less than the thickness of a traditional wood skateboard. 
     In the illustrated embodiment, the impact support members  70  are circular. Such circular impact support members  70  are included in the class of ovoid shapes that also include, for example, an elongate oval. Impact support member  70  having ovoid shapes are contemplated by applicants. Applicants further contemplate even more shapes such as symmetrical and asymmetrical curvaceous shapes. Preferably, however, the impact support members  70  have shapes that avoid sharp edges that could create stress concentrations or more easily prompt delamination of the support member from the rest of the deck. 
     Additionally, although the illustrated skateboard deck has a particular shape, it is to be understood that skateboard decks having various shapes and sizes can employ the principles discussed herein. Also, although the illustrated deck is made of wood, impact support members can be used with decks comprising other materials, such as metal and plastic. 
     Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.