Abstract:
A slider resists erosion due to moisture, dirt and ultraviolet of sunlight and protects a pattern or the bonded surface from wear and tear. The slider contains a foam core, a top layer, a pattern, and a bottom layer. The foam core has a top surface, a bottom surface and edge surfaces. The top layer is a composite layer heat laminated to the top surface and edge surfaces of the foam core. The pattern is formed within the top layer and visible from outside of the top layer. The bottom layer is heat laminated to the bottom surface of the foam core.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This is a continuation application of U.S. Pat. No. 6,988,920 filed on Mar. 11, 2004, which is a continuation-in-part of U.S. Pat. No. 6,955,576 filed on Mar. 13, 2003, which is a continuation-in-part of U.S. application Ser. No. 10/040,404 filed on Jan. 9, 2002, now abandoned. 
     
    
     BACKGROUND OF INVENTION 
       [0002]    1. Field of Invention 
         [0003]    This invention relates generally to a slider, used for sliding on snow, grass, sand or the like. The slider is a foam core to which layers are laminated to protect against erosion, wear and ultraviolet light. In the context of this specification, the slider is anyone of the embodiments. The slider is a bodyboard, a snow board, a snow sled, a grass sliding board, a sand sliding board, a surfing board or the like. 
         [0004]    2. Related Prior Art 
         [0005]    The slider of the prior art is a board made of plastic that has handles attached on the surface of the board and has a design printed in a central area of the board. The plastic is typically a hard plastic in order that the board could be wear resistant. However, the solid plastic board is generally not comfortable for the user and the board is also heavy for the users, especially children to carry. Besides, the design simply printed on the surface of the board is easily worn off due to the frequent contact with the user. 
         [0006]    Another slider of the prior art is a board made of expanded foam. An outer film is generally laminated to a top surface of the foam board and several strips are laminated to edges of the foam board. The slider made of foam is more comfortable for the users to contact with and lighter for the users to carry with than a slider made of solid plastic. However, It is known that the ultraviolet damages of expanded foam; furthermore, the outer film and the strip also degrade under the sunshine after a period of time. Air-cells of the foam board fracture when abraded. Once the air-cells are broken, water retains in the open cells and erosion reduces the life of the slider. Furthermore, the design of a slider mostly is printed on the outer film and the strips; therefore, the design on the board deteriorates very quickly. 
         [0007]    The designs or patterns on the sliders are convenient means for the owners to identify their sliders. Therefore, an enduring pattern of the slider performs a useful and decorative function. 
       SUMMARY OF INVENTION 
       [0008]    It is a primary object of the invention to provide a slider whose surfaces resist accelerated erosion due to moisture, dirt and ultraviolet sunlight. 
         [0009]    It is another object of the invention that a pattern imprinted on the slider resists wear and tear. 
         [0010]    Another object of the invention is that the slider is comfortable to the touch. 
         [0011]    In one embodiment, this invention discloses a slider comprising a foam core, a top layer, a pattern, and a bottom layer. The foam core has a top surface, a bottom surface and edge surfaces. The top layer is a composite layer heat laminated to the top surface and edge surfaces of the foam core. The pattern is formed within the top layer and is visible from outside of the top layer. The bottom layer is heat laminated to the bottom surface of the foam core. 
         [0012]    In another embodiment, the top layer of this invention comprises an outer film, an inner film, a pattern, and a foam skin. The outer film has a top surface and a bottom surface on which the pattern is printed. The inner film has a top surface heat laminated to the bottom surface of the outer film and a bottom surface which is heat laminated to a top surface of the foam skin. A bottom surface of the foam skin is heat laminated to the top surface and edge surfaces of the foam core. 
         [0013]    In a further embodiment, the bottom layer of this invention comprises a foam skin and a plastic board. The foam skin has a top surface, which is heat laminated to the bottom surface of the foam core and a bottom surface, which is heat laminated to the plastic board. The plastic board is a composite board and a pattern is printed within the plastic board. 
         [0014]    Other features of the invention include bonding films that enable foam materials such as polystyrene to be heat laminated to polyethylene. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0015]    The invention will be more clearly understood after referring to the following detailed description read in conjunction with the drawings wherein: 
           [0016]      FIG. 1  is an exploded perspective view of a slider according to a first embodiment of the present invention; 
           [0017]      FIG. 2  is a cross sectional view of the slider of  FIG. 1 ; 
           [0018]      FIG. 3  is a regionally enlarged cross sectional view of the slider of  FIG. 2 ; 
           [0019]      FIG. 4  is a cross sectional view of a slider according to a second embodiment of the present invention; 
           [0020]      FIG. 5  is a cross sectional view of a slider according to a third embodiment of the present invention; 
           [0021]      FIG. 6  is a cross sectional view of a slider according to a fourth embodiment of the present invention; 
           [0022]      FIG. 7  is a cross sectional view of a slider according to a fifth embodiment of the present invention; 
           [0023]      FIG. 8  is a cross sectional view of a slider according to a sixth embodiment of the present invention; 
           [0024]      FIG. 9  is a cross sectional view of a slider according to a seventh embodiment of the present invention; and 
           [0025]      FIG. 10  is a cross sectional view of a slider according to an eighth embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    With reference to  FIGS. 1-3 , a slider in accordance with a first embodiment of the present invention comprises a foam core  1 , a top layer  4 , and a bottom layer  5 . The foam core  1  has a top surface  10 , a bottom surface  11  and edge surfaces  12 . The top layer  4  is heat laminated to the top surface  10  and edge surfaces  12  of the foam core  1 , and the bottom layer  5  is heat laminated to the bottom surface  11  of the foam core  1 . The foam core  1  is made of polyethylene foam and has a density in the range of 1.2 to 8 PCF (pounds per cubic foot) so that the foam core  1  is light and flexible. In the first embodiment, the top layer  4  is a composite layer or a patterned laminate, which includes a first outer film  41 , a first inner film  42  and a first pattern  3   a  placed in between the first outer film  41  and the first inner film  42 . Both the first outer film  41  and first inner film  42  are made of plastic. The first pattern  3   a  is pre-printed on a bottom surface  412  of the first outer film  41  and is visible from outside of the first outer film  41 . The first inner film  42  has a top surface  421  which is heat laminated to the bottom surface  412  of the first outer film  41 . The first pattern  3   a  is thereby protected from direct exposure to the outside of environment. A bottom surface  422  of the first inner film  42  is heat laminated to the top surface  10  and edge surfaces  12  of the foam core  1 . In addition, the first outer film  41  is made of a transparent material so that the first pattern  3   a  is visible from outside of the slider. 
         [0027]    A method for making the slider is described as follows: (1) extruding the first outer film  41  with a thickness in the range from 0.02 mm to 0.15 mm by an extrusion machine; (2) printing the first pattern  3   a  on the bottom surface  412  of the first outer film  41  using black and white printing or color printing techniques; (3) extruding the first inner film  42  with a thickness in the range from 0.01 mm and 0.15 mm; (4) spreading the molten first inner film  42  on the bottom surface  412  of the first outer film  41 , providing the first inner film  42  not only is heat laminated to the bottom surface  412  of the first outer film  41  but also overlays the first pattern  3   a ; and (5) heating the bottom surface  422  of the first inner film  42  to molten conditions and pressing the top layer  4  to the top surface  10  and the edge surfaces  12  of the foam core  1 . The process of combining the first outer film  41  and the first inner film  42  or combining the first inner film  42  and the foam core  1  is called heat laminating, alternatively heat fusion or heat sealing. 
         [0028]    During the process of combining the top layer  4  and the foam core  1 , the top layer  4  is placed on a hot mold (not shown). The mold surface has a plurality of embossments, when the mold surface covered by the top layer  4  is pressed against the foam core  1 , concaves  40  are formed as shown in  FIG. 3 . That is, the first outer film  41  together with the first inner film  42  is embossed to define the concaves  40  in an exterior surface  411  of the first outer film  41 . The concaves  40  are defined to enhance the area of contact between the top layer  4  and the foam core  1 , and thereby increase the strength of the seal of the top layer  4  and the foam core  1 . Furthermore, the concaves  40  enable the users to grab the slider with greater tenacity. 
         [0029]    With reference to  FIG. 4 , a slider in accordance with a second embodiment of the present invention includes the entire structure of the  FIG. 1  to  FIG. 3 , such as a foam core  1 , a top layer  4  and a bottom layer  5 . In this second embodiment, the top layer  4  includes a patterned laminate and a first polyethylene foam skin  43 . The patterned laminate includes a first outer film  41 , a first inner film  42  and a first pattern  3   a  placed in between the first outer and inner films  41 ,  42 , as disclosed in the first embodiment. The first polyethylene foam skin  43  is interposed between the first inner film  42  and the top surface  10  and edges surfaces  12  of the foam core  1 . In addition, the first polyethylene foam skin  43  has a top surface  431  being heat-laminated to the bottom surface  422  of the first inner film  42  and a bottom surface  432  being heat-laminated to the top surface  10  and edge surfaces  12  of the foam core  1 . The first polyethylene foam skin  43  has a greater density than that of the foam core  1  and has a density in the range of 1.5 to 10 PCF. The first polyethylene foam skin  43  has smoother surfaces due to the lower density, and therefore improves the bonding strength among the high-density the top layer  4 , the first foam skin  43  and the foam core  1  during the heat lamination process when compared to the case when the top layer  4  is directly bonded to the low-density foam core  1 . 
         [0030]    When subject to the heat lamination process, the first pattern  3   a  is therefore sandwiched between the first outer film  41  and the first inner film  42  with one side joined to the first outer film  41  and the other side joined to the first inner film  42 . After heat lamination is completed, the pattern  3   a  is substantially the same with the one pre-printed on the outer film  41  before the heat lamination process. Thus the slider of the present invention provides a high resolution image thereon. 
         [0031]      FIG. 5  is a slider in accordance with a third embodiment of the present invention, which includes all features of the first embodiment, such as a foam core  1 , a top layer  4  and a bottom layer  5 . In the third embodiment, the bottom layer  5  is a composite layer and comprises a second polyethylene foam skin  51  and a plastic board  52 . The second polyethylene foam skin  51  has a top surface  511  being heat laminated to the bottom surface  11  of the foam core  1  and a bottom surface  512  being heat laminated to the plastic board  52 . The second polyethylene foam skin  51  has a greater density than that of the foam core  1  and has a density in the range of 1.5 to 10 PCF. 
         [0032]    A method for making the bottom layer  5  of the third embodiment is described as follows: (1) extruding the plastic board  52  with a thickness in range from 0.3 mm to 1.5 mm; and (2) spreading the molten plastic board  52  on the bottom surface  512  of the second polyethylene foam skin  51 . Therefore, the plastic board  52  is tightly heat laminated to the second polyethylene foam skin  51 . Thereafter, heating the top surface  511  of the second polyethylene foam skin  51  to a softened state and then laminating the bottom layer  5  to the bottom surface  11  of the foam core  1 . The bottom layer  5  is tightly heat laminated to the polyethylene foam core  1 . 
         [0033]    With reference to  FIG. 6 , a slider in accordance with a fourth embodiment of the invention comprises all the elements of the second embodiment. In the fourth embodiment, the bottom layer  5  further comprises a second polyethylene foam skin  51  and a plastic board  52  having a slippery bottom surface for gliding on waters, grounds or snows. The second polyethylene foam skin  51  has a top surface  511  being heat laminated to the bottom surface  11  of the foam core  1  and a bottom surface  512  being heat laminated to a top surface of the plastic board  52 . The second polyethylene foam skin  51  has a greater density than that of the foam core  1  and has a density in the range of 1.5 to 10 PCF. 
         [0034]      FIG. 7  is a slider in accordance with a fifth embodiment of this invention, which comprises all the elements of the fourth embodiment. In the fifth embodiment, the plastic board  52  includes a plastic plate  523  and a patterned laminate having a second pattern  3   b , a second outer film  521  and a second inner film  522 . The patterned laminate of the bottom layer  5  is similar to that of the top layer  4  and is bonded to the bottom surface  512  of the second polyethylene foam skin  51 . Specifically, the second outer film  521 , second inner film  522  and the plastic plate  523  are made of plastic. The second pattern  3   b  is printed on a top surface  521   a  of the second outer film  521  and is visible from outside of the second outer film  521 . The second inner film  522  has a top surface  522   a  being heat laminated to the bottom surface  512  of the second polyethylene foam skin  51  and a bottom surface  522   b  heat laminated to the top surface  521   a  of the second outer film  521 . The second pattern  3   b  is thereby protected from direct exposure to the outside of environment. The plastic plate  523  is bonded to a bottom surface  521   b  of the second outer film  521 . In addition, the second outer film  521  and the plastic plate are both made of transparent material so the second pattern  3   b  is visible from outside of the slider. 
         [0035]    With reference to  FIG. 8 , a slider in accordance with a sixth embodiment of the invention includes a foam core  100  made of non-polyethylene materials, such as polystyrene and polypropylene materials and has a density in the range of 0.8 to 8 PCF. In the sixth embodiment, the slider further includes a top layer  4 , a first bonding film  6   a , a second bonding film  6   b  and a bottom layer  5 . Polystyrene is inexpensive and easy to be extruded as the foam core  100 . However, it is difficult to heat laminate polyethylene foam directly onto polystyrene foam. Therefore, the first bonding film  6   a  and the second bonding film  6   b  are used to overcome the lamination problems. In  FIG. 8 , the top layer  4  is heat laminated to the top and edge surfaces of the foam core  100  by the bonding film  6   a . The bottom layer  5  is heat laminated to the bottom surface of the foam core  100  by the bonding film  6   b.    
         [0036]    With reference to  FIG. 9 , a slider in accordance with a seventh embodiment of the invention comprises a foam core  1 , a top layer  4 , and a bottom layer  5 . The top layer  4  is heat laminated to the top surface of the foam core  1  and extends around the upper half of the edge surfaces  12  of the foam core  1 . The bottom layer  5  is heat laminated to the bottom surface of the foam core  1  and extends around the lower half of the edge surfaces  12  of the foam core  1 . Therefore, the top layer  4  and bottom layer  5  are sealed together at edges. The structure of the seventh embodiment also applies to the above-mentioned embodiments. 
         [0037]    With reference to  FIG. 10 , a slider in accordance with an eighth embodiment of the invention comprises a polyethylene foam core  1  having a density in the range of 1.5 to 10 PCF, a top layer  4 , and a bottom layer  5 . The polyethylene foam core  1  has a top surface  10  and a bottom surface  11 . Both the top layer  4  and the bottom layer  5  are composite layers and the elements of the composite layers are shown in the above-mentioned embodiments. Furthermore, the eighth embodiment comprises two holes  7  defined through the slider for being handhold. 
         [0038]    Accordingly, the top layer  4  and the bottom layer  5  protect the foam core  1  as well as the first pattern  3   a  and the second pattern  3   b  from erosion by exposure to ultraviolet light, moisture and abrasion. Furthermore, the first and second patterns  3   a ,  3   b  being visible from outside of the slider that attracts the users attentions. 
         [0039]    The foregoing description is for purposes of illustration only and is not intended to limit the scope of the protection accorded this invention. The scope of protection is to be measured by the following claims, which should be interpreted as broadly as the inventive contribution permits.