Patent Document

The Divisional of Copending application Ser. No. 10/431,850, filed May 7, 2003. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates in general to skateboard decks. More particularly, this invention relates to a skateboard deck with a waffled wood core for added mass, increased strength and lighter weight. 
     2. Description of the Related Art 
     Skateboarding has maintained its popularity as a recreational sport for numerous years. Skateboards typically consist of a deck with two surfaces. On the top surface, the skateboarder stands on and maneuvers the board. The bottom surface attaches to trucks and wheels to support the deck and allow for motion. 
     There is an ever-increasing demand for high-performance skateboard decks. An important consideration for high-performance is the development of decks with increased strength and reduced weight. Stronger and lighter decks allow for more aggressive maneuvers and increased responsiveness. Another consideration is manufacturing costs. It is desirable to contain the cost for manufacturing new deck designs. Thus, there is a need for skateboard decks with added mass, increased strength, increased responsiveness, decreased weight and contained manufacturing costs. 
     In U.S. Pat. No. 5,921,564, Olson discloses a snowboard comprising a flexible core element enveloped by a covering of resin impregnated fiberglass wherein the bottom surface of the core includes a plurality of parallel grooves running the longitudinal direction of the board such that in conjunction with resin impregnated fiberglass form a series of parallel integral hollow beam members increasing the strength of the board while simultaneously reducing the overall weight. 
     Instead of a core with grooves on its bottom surface only, the subject invention comprises a core with longitudinal ridges on the top, bottom or both surfaces. Forming ridges on both sides of the core substantially decreases the core weight. The longitudinal ridges also retain strength. 
     In addition, while Olson envelops a snowboard core with resin, the subject invention positions a skateboard core in between two wood portions. Wood is the preferred material for skateboard decks. The strength and impact resistance of wood are conducive to the aggressive and intricate maneuvers skateboarders perform. 
     In U.S. Pat. No. 6,460,868, Madrid discloses a corrugated skateboard deck and method of corrugating skateboard decks in the skateboard deck manufacturing process. The corrugated skateboard deck has elongated corrugations embossed into at least one of its top and bottom surfaces and generally extending between first and second ends of the skateboard deck. The elongated corrugations are made up of ridges and grooves that are pressure-formed in a method of corrugating the surfaces of skateboard decks. This method utilizes a high-density corrugated template to emboss corrugations under high pressures. 
     Instead of corrugating a top or bottom surface of the deck, the subject invention forms longitudinal grooves on a core positioned in between two wood portions. Positioning the core in between solid layers of wood reduces weight and increases board strength without exposing the grooves on an outside surface of the skateboard deck. 
     In addition, while Madrid forms the corrugations by pressure molding the skateboard deck, the subject invention forms grooves by either molding or routing the wood core. By using a router, the subject invention can mill the surface of the wood core to a desired shape and thickness. 
     SUMMARY OF THE INVENTION 
     Accordingly, one object of the present invention is to provide a skateboard deck with increased mass, increased strength, lighter weight and increased responsiveness. 
     A second object of the invention is to provide a skateboard deck with contained manufacturing costs. 
     To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention provides a skateboard deck comprising a top and bottom wood portion, each wood portion having at least one layer of wood. The skateboard deck further comprises a wood core positioned in between the top and bottom wood portions. The wood core has first and second opposed surfaces, at least one of the opposed surfaces having longitudinal grooves forming hollow areas in conjunction with the top and bottom wood portions. Each of the top and bottom wood portions further comprise a crossband layer having grain perpendicular in direction to the longitudinal grooves, each crossband layer being in contact with the wood core. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a typical skateboard as generally seen from the top. 
         FIG. 2  is a top view of a typical skateboard deck. 
         FIG. 3  is a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting a first preferred embodiment of the invention. 
         FIG. 4  is an enlarged cross-sectional view taken at ( FIG. 4 ) in  FIG. 3 . 
         FIG. 5  is a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting a second preferred embodiment of the invention. 
         FIG. 6  is an enlarged cross-sectional view taken at ( FIG. 6 ) in  FIG. 5 . 
         FIG. 7  is a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting a third preferred embodiment of the invention. 
         FIG. 8  is an enlarged cross-sectional view taken at ( FIG. 8 ) in  FIG. 7 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Before proceeding with a description of the apparatus and method of the present invention, a summary of crossband layers, which may be helpful in understanding the disclosed embodiment, is provided. 
     A crossband layer is a layer of wood having grain perpendicular in direction compared to the length of wood. The perpendicular direction of the grain in a crossband layer, as opposed to the longitudinal layers, provides structure to the wood. 
     Referring now to  FIG. 1 , a perspective view of a typical skateboard  10  as generally seen from the top is shown. The skateboard  10  includes a top surface  11  and a bottom surface  12 . A pair of trucks  15 ,  17  mount to the bottom surface  12  at mounting holes  13 ,  14 . Each pair of trucks  15 ,  17  has a pair of wheels  16 ,  18  attached to the end portion of trucks  15 ,  17 . 
     As seen in  FIG. 2 , a top view of a typical skateboard deck  10  is shown. Mounting holes  13 ,  14  are visible from top surface  11 . 
     With reference to  FIG. 3 , a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting a first preferred embodiment of the invention is shown. Skateboard deck  10  is formed with a wood core  32  positioned in between and in direct contact with a top crossband layer  34  and a bottom crossband layer  35 . The grain of crossband layers  34 ,  35  are perpendicular to the longitudinal direction of grooves  33  of wood core  32 . 
     Still referring to  FIG. 3 , wood core  32  and crossband layers  34 ,  35  are further positioned in between a top wood portion  30  and bottom wood portion  31 . Top wood portion  30  and bottom wood portion  31  may be formed with one or more plies of wood bonded together. In this embodiment, two plies of wood form top wood portion  30  and two plies of wood form bottom wood portion  31 . 
     Still referring to  FIG. 3 , wood core  32  has parallel grooves  33  running in a longitudinal direction, forming air spaces when combined with top crossband layer  34  and bottom crossband layer  35 . The grain of crossband layers  34 ,  35  are perpendicular in direction to parallel grooves  33 , thus creating I-beams with wood core  32 . This maintains the structural integrity and balance of skateboard deck  10 . 
     Still referring to  FIG. 3 , grooves  33  of wood core  32  are formed using a router and glue process. Use of a router allows for continuous thickness of wood core  32 . The router forms initial rectangular beams in wood core  32 . After being routed, moist glue is applied to wood core  32 . 
     The moist glue softens the initial rectangular edges of wood core  32 . The wood core  32  is placed in an apparatus containing an upper and lower mold capable of operating in an opened and closed position upon the wood core  32 . When said apparatus operates in a closed position, it bends and urges the initial rectangular edges of wood core  32  to a waffled shape, reshaping grooves  33 . The moist glue then dries to fix theposition of wood core  32 . 
     With reference to  FIG. 4 , an enlarged cross-sectional view taken at ( FIG. 4 ) in  FIG. 3  is shown. Two plies of wood  40 ,  41  are bonded to create wood core  32 . Parallel grooves  33  are shaped on both the top surface and bottom surface of wood core  32 . Grooves  33  are shaped in the desired manner using the routing and glue process described above. By creating grooves  33  on wood core  32 , skateboard deck  10  is thicker and has more structural mass. The added structural mass increases the strength of skateboard deck  10 , while the air in wood core  32  makes skateboard deck  10  lighter. 
     With reference to  FIG. 5 , a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting an alternative embodiment of the invention, is shown. Wood core  52  is positioned in between and in direct contact with top crossband layer  55  and bottom crossband layer  56 . Wood pieces  53   a  and  53   b  combine to form another layer. The area in between wood pieces  53   a  and  53   b  is removed to form an internal cavity for the positioning of wood core  52 . Wood core  52  and crossband layers  55 ,  56  are further positioned in between top wood portion  50  and bottom wood portion  51 . Top wood portion  50  and bottom wood portion  51  may be formed with one or more plies of wood bonded together. In this embodiment, top wood portion  50  is formed with two plies of wood and bottom wood portion  51  is formed with two plies of wood. In addition, wood core  52  has parallel grooves  54  running in a longitudinal direction. The grain of crossband layers  55 ,  56  run perpendicular to parallel grooves  54 . 
     Still referring to  FIG. 5 , grooves  54  of wood core  52  are formed using a molding press and template. The template is shaped to create grooves  54  and the molding press allows for a continuous thickness of wood core  52 . While positioned in the molding press, moist glue is applied to wood core  52 . Wood core  52  is held in the molding press until the glue cures, thus retaining the waffled shape of wood core  52 . After curing, wood core  52  is positioned and glued within the internal cavity in between wood pieces  53   a  and  53   b.    
     With reference to  FIG. 6 , an enlarged cross-sectional view taken at ( FIG. 6 ) in  FIG. 5  is shown. Two plies of wood  60 ,  61  are bonded to create wood core  52 . Parallel grooves  54  are shaped on both the top surface and bottom surface of wood core  52 . By creating grooves  54  on wood core  52 , skateboard deck  10  is thicker and has more structural mass. The added structural mass increases the strength of skateboard deck  10 , while the air in wood core  52  makes skateboard deck  10  lighter. 
     With reference to  FIG. 7 , a cross-sectional view taken along the line of A-A of  FIG. 2 , depicting another alternative embodiment of the invention, is shown. Wood core  72  is positioned in between and in direct contact with top crossband layer  74  and bottom crossband layer  75 . Wood core  72  and crossband layers  74 ,  75  are further positioned in between top wood portion  70  and bottom wood portion  71 . 
     Top wood portion  70  and bottom wood portion  71  may be formed with one or more plies of wood bonded together. In this embodiment, top wood portion  70  is formed with two plies of wood and bottom wood portion  71  is formed with two plies of wood. In addition, wood core  72  has parallel grooves  73  running in a longitudinal direction. The grain of crossband layers  74 ,  75  run perpendicular to parallel grooves  73 . 
     Still referring to  FIG. 7 , grooves  73  of wood core  72  are formed using a molding press and template. The template is shaped to create grooves  73  and the molding press allows for a continuous thickness of wood core  72 . While positioned in the molding press, moist glue is applied to wood core  72 . Wood core  72  is held in the molding press until the glue cures, thus retaining the waffled shape of wood core  72 . After curing, wood core  72  is pressed a second time in a molding press having a cavity area, or spacer. During the second pressing, wood core  72  expands into the cavity area, creating the discontinuous surface of wood core  72 . 
     With reference to  FIG. 8 , an enlarged cross-sectional view taken at ( FIG. 8 ) in  FIG. 7  is shown. Two plies of wood  80 ,  81  are bonded to create wood core  72 . Wood plies  80 ,  81  have dissimilar surfaces, forming a discontinuous surface thickness created by the mold and spacer process described above. The dissimilar surfaces provide added strength to the board. Parallel grooves  73  can be seen on both the top surface and bottom surface of wood core  72 . By creating grooves  73  on wood core  72 , skateboard deck  10  is thicker and has more structural mass. The added structural mass increases the strength of skateboard deck  10 , while the air in wood core  72  makes skateboard deck  10  lighter. 
     Other embodiments of the invention will appear to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. For example, while the subject invention has been described as applicable to a top and bottom wood layer, other raw materials such as fiberglass, plastic or resinated paper may be employed. In addition, the longitudinal grooves can run in a substantially similar direction as opposed to being parallel. It is intended that the specification and examples to be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Technology Category: 4