WO2015172202A1

WO2015172202A1 - Skateboard deck and method of manufacturing or modifying same

Info

Publication number: WO2015172202A1
Application number: PCT/AU2015/050245
Authority: WO
Inventors: Emad Tahtouh; Albert WOFFENDEN
Original assignee: The Finch Company Pty Limited
Priority date: 2014-05-16
Filing date: 2015-05-15
Publication date: 2015-11-19

Abstract

A skateboard deck and method of manufacturing the same is disclosed. The skateboard deck includes one or more grooves in the underside surface of the skateboard deck which are filled with a filling material, wherein the grooves have a profile which define a graphic; and a wearable covering material that covers the filling material and at least partially wears away during use to expose a portion of the graphic. The method of manufacturing the deck includes creating one or more grooves into an underside surface of the skateboard deck, wherein the grooves have a profile which defines a graphic; filling the one or more grooves with a filling material; and applying a wearable covering material to at least a portion of the underside surface to cover the filling material, wherein the wearable covering material at least partially wears away during use to expose a portion of the graphic.

Description

SKATEBOARD DECK AND METHOD OF MANUFACTURING OR MODIFYING

SAME

Field of Invention

[0001] The present invention relates to a skateboard deck and a method of manufacturing or modifying a skateboard deck.

Background

[0002] In some instances skateboards include a graphic, such as artwork, on the underside (i.e. the surface of the skateboard which supports the trucks) of the skateboard. When skateboard riders perform tricks with the skateboard, such as grinding a rail and the like, the graphic can be damaged, exposing the wooden surface of the board. Therefore, the more the skateboard rider uses the skateboard, the worse the graphic on the underside of the skateboard appears.

[0003] The reference in this specification to any prior publication (or information derived from the prior publication), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from the prior publication) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Summary

[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Preferred Embodiments. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0005] In a first aspect there is provided a skateboard deck including:

one or more grooves in the underside surface of the skateboard deck which are filled with a filling material, wherein the grooves have a profile which define a graphic; and

a wearable covering material that covers the filling material and at least partially wears away during use to expose a portion of the graphic.

[0006] In certain embodiments, the filling material is cured epoxy resin.

[0007] In certain embodiments, the wearable covering material includes a paint layer that covers graphic.

[0008] In certain embodiments, the wearable covering material includes a wax layer that covers the graphic, wherein the paint layer covers the wax layer.

[0009] In certain embodiments, the paint layer is an acrylic paint layer.

[0010] In certain embodiments, a varnish layer covers the graphic, wherein the paint layer covers the varnish layer.

[0011] In certain embodiments, a varnish layer covers the graphic, wherein the wax layer covers the varnish layer, and the paint layer covers the wax layer.

[0012] In certain embodiments, the filling material is substantially flush with a undersurface of a body of the deck.

[0013] In certain embodiments, the fillable material are filled within the one or more grooves having a depth of between about 0.6mm to 0.9mm.

[0014] In a second aspect there is provided a skateboard including a skateboard deck according to the first aspect. [0015] In a third aspect there is provided a method of manufacturing or modifying a skateboard deck to include a wearable underside surface for exposing a graphic during use, wherein the method includes:

creating one or more grooves in an underside surface of the skateboard deck, wherein the grooves have a profile which defines a graphic;

filling the one or more grooves with a filling material; and

applying a wearable covering material to at least a portion of the underside surface to cover the filling material, wherein the wearable covering material at least partially wears away during use to expose a portion of the graphic.

[0016] In certain embodiments, the one or more grooves are created in the underside surface of the skateboard deck using a laser cutter.

[0017] In certain embodiments, the filling material is a curable material, wherein the method includes:

filling the one or more grooves with the filling material in a viscous state; and allowing the filling material to cure.

[0018] In certain embodiments, the filling material is epoxy resin.

[0019] In certain embodiments, filling the one or more grooves includes overfilling the one or more grooves.

[0020] In certain embodiments, after the filling material has cured, the method includes removing cured overfilled filling material such that the cured filling material is substantially flush with the underside surface of the deck.

[0021] In certain embodiments, removing the cured overfilled filling material using a sander.

[0022] In certain embodiments, applying the wearable covering material includes applying a paint layer to cover the filling material. [0023] In certain embodiments, prior to applying the paint layer, the method includes applying a varnish layer to the underside surface of the deck to cover the filling material.

[0024] In certain embodiments, applying the wearable covering material includes:

applying a wax layer to cover the filling material; and

applying the paint layer over the wax layer.

[0025] In certain embodiments, the method includes:

applying a varnish later to cover the filling material;

applying a wax layer to cover the filling material; and

applying the paint layer over the wax layer.

[0026] In certain embodiments, the creating the one or more grooves in the underside surface of the deck includes creating the one or more grooves having a depth of between about 0.6mm to 0.9mm.

[0027] In certain embodiments, the one or more grooves have a substantially equal depth over the deck.

[0028] In certain embodiments, the method includes mixing a pigment colourant with the filling material prior to filling the one or more grooves.

[0029] In certain embodiments, the method includes securing trucks and wheels to the skateboard deck after the wearable covering material has been applied.

[0030] Other aspects and embodiments will be appreciated throughout the description of the preferred embodiments. Brief Description of the Drawings

[0031] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying figures.

[0032] Figure 1 is a perspective schematic of an example deck of a skateboard with grooves cut into the underside surface which depict a graphic;

[0033] Figure 2 is a perspective schematic of the deck of Figure 1 with filling material filled in the grooves;

[0034] Figure 3 is a perspective schematic of the deck of Figure 1 with a covering material covering the grooves and filling material;

[0035] Figure 4 is a perspective schematic of the deck of Figure 3 after use where a portion of the graphic is visible due to a portion of the covering material wearing away;

[0036] Figure 5 is a cross-sectional view of a portion of the deck of Figure 1;

[0037] Figure 6 is a cross-sectional view of a portion of the deck with filling material spread over the underside of the deck;

[0038] Figure 7 is a cross-sectional view of a portion of the deck of Figure 2;

[0039] Figure 8 is a cross-sectional view of the portion of the deck of Figure 7 with a varnish applied to the underside of the deck;

[0040] Figure 9 is a cross-sectional view of the portion of the deck of Figure 8 with a wax layer applied to the underside of the deck; [0041] Figure 10 is a cross-sectional view of the portion of the deck of Figure 9 with a paint layer applied to the underside of the deck;

[0042] Figure 11 is a cross-sectional view of the portion of the deck of Figure 10 after use where a portion of the filling material is exposed thereby presenting a portion of the graphic defined by the grooves;

[0043] Figure 12 is a flowchart representing a method of manufacturing or modifying a deck of a skateboard;

[0044] Figure 13 is an underside view of an example skateboard including a deck having a covering material which covers a graphic;

[0045] Figure 14 is an underside view of the example skateboard of Figure 13 after a first amount of wear from use, thereby uncovering a first portion of the graphic;

[0046] Figure 15 is an underside view of the example skateboard of Figure 13 after a second amount of wear from use, thereby uncovering a second portion of the graphic; and

[0047] Figure 16 is an underside view of the example skateboard of Figure 13 after a third amount of wear from use, thereby uncovering a third portion of the graphic.

Description of the Preferred Embodiments

[0048] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying figures.

[0049] Referring to Figures 1 to 4 there is shown an example of a skateboard deck 100. The skateboard deck 100 includes an underside surface including grooves 110 which are filled with a filling material 120. The grooves 110 define a graphic 190 on the underside surface of the deck 100. The deck 100 also includes a covering material 130, 160 which covers the grooves 110 and filling material 120.

[0050] When a skateboard rider performs tricks, such as grinds on rails and the like, using the exemplified deck 100 for a skateboard 1300, the covering material 130, 160 at least partially wears away exposing or uncovering a portion of the graphic 190 as shown in Figure 4. As the skateboard rider uses the skateboard 1300 more often, a larger portion of the graphic 190 is exposed or uncovered on the underside of the deck 100 of the skateboard 1300.

[0051] In a preferred form, the filling material 120 is a curable material such as resin like an epoxy resin. Also, in a preferred form, the covering material 130, 160 is provided in the form of paint such as acrylic paint 130 which is coated over a wax layer 160 which in turn covers the epoxy resin 120 embedded within the deck and substantially flush with the underside surface thereof.

[0052] Referring to Figures 5 to 10 there is shown a series of cross-sectional views of a portion of the deck 100 during a method 1200 of manufacturing the deck 100 or modifying the deck 100. The steps of the method 1200 are represented by the flowchart shown in Figure 12.

[0053] In particular, referring to Figure 12, step 1210 includes creating the one or more grooves 110 in the underside portion of the deck 100 as shown in Figure 5. The one or more grooves 110 can be created in the form of engravings. This step is performed using a laser cutter, which cuts or burns the grooves 110 in the planar underside surface of the deck 100. A path of the grooves 110 which are to be created in the underside of the deck 100 can be defined in a computer file such as an AutoCAD file or the like. The computer file can be transferred to the laser cutter using a portable storage medium such as a USB key or the laser cutter can be in data communication with a processing system which provides data indicative of the computer file representing the graphic 190 to be cut or burnt into the underside surface of the deck 100. It will be appreciated that the grooves that are made by the laser cutter do not fully protrude through the deck 100 but partially protrude into the undersurface of the deck. In particular, a deck is typically equal to or greater than 10mm to 15mm thick and the grooves are generally made with a depth of about 0.6mm to 0.9mm. The grooves 110 are generally created with substantially the same depth within the deck 100. In a preferable form, the grooves avoid protruding through an underside ply of the skateboard deck 100 to avoid burning adhesive which secure multiple plies of wood together. In instances where the deck 100 has a curved profile, the laser cutter operates to compensate for the curved profile to ensure that the depth of the groove is consistent over the deck 100.

[0054] At step 1220, the method 1200 includes filling the grooves 110 with the filing material 120. The filling material 120 is preferably a non-wooden material. In one form, the filling material 120 is a resin which is filled in the grooves in a substantially viscous form and then cures so as to harden and secure within the grooves. In one preferred embodiment, the filling material 120 is an epoxy resin. The epoxy resin is generally an epoxy adhesive. In particular embodiments, the epoxy resin is a two-part epoxy resin, where a wide range of co-reactants (often referred to as hardeners or curatives) can be used for cross-linking including polyfunctional amines, acids (and acid anhydrides), phenols, alcohols, and thiols.

[0055] The epoxy resin 120 can be spread over the underside surface of the deck 100 using a spreading blade or tool. In a preferred form, the epoxy resin 120 is filled in the grooves in a viscous form and then allowed to cure to secure to the wood of the deck 100 in a substantially solid and hardened form. Generally, as the epoxy material 120 is spread over the underside surface of the deck 100, a portion of the epoxy resin 120 covers portions of the deck 100 which do not have grooves 110 as shown in Figure 6 to ensure that all grooves 110 are sufficiently filled. Preferably, the epoxy resin 120 should be applied to overfill the grooves 110 relative to the underside surface of the deck 100 to avoid under-filling of the grooves 110. Epoxy resin is advantageous as it has been found to provide a similar density to the wooden board of the deck 100, thereby avoiding any substantial modifications to the balance of the board. Additionally, through testing it has - Si - been found that cured epoxy resin has a substantially similar durability to that of the wood used for manufacturing skateboard decks.

[0056] The cured epoxy resin 120 generally has a colour that substantially contrasts with the colour of the underside ply of the deck 100 in order for the graphic 190 to be easily visible. In one variation, multiple portions of the graphic 190 may depict different colours, wherein different coloured epoxy resin can be used to create the multi-coloured graphic 190. In one form, pigment colourants may be mixed with the epoxy resin 120 to create different coloured epoxy resins which can be used to fill different portions of the grooves 110 to create the multi-coloured embedded graphic 190 in the underside surface of the deck 100.

[0057] At step 1230, the method 1200 includes allowing the filling material 120 to cure. Preferably, the type of epoxy resin 120 used can be allowed to cure at ambient temperature which may take approximately twenty-four hours. Whilst other epoxy resins 120 can be used which require heat to be applied from a heat source, the heat should be quite low otherwise this may have detrimental impacts upon the integrity of the skateboard deck which may not be designed to withstand high temperatures required to cure the epoxy resin 120.

[0058] At step 1240, the method 1200 includes removing the excess filling material 120 from the underside surface of the deck 100 after curing. In particular, the removal process can be performed using a sander tool such as an orbital sander. The sander is used to cause the outer surface of the epoxy resin 120 to be substantially flush with the underside surface of the deck 100 as shown in Figure 7.

[0059] At step 1250, the method 1200 includes applying a varnish layer 150 to the underside surface of the deck 100 as shown in Figure 8. The varnish layer 150 is then allowed to dry. The varnish layer 100 protects the graphic 190 when at least a portion of the covering material 130, 160 has been uncovered through use. [0060] At steps 1260 and 1270 of method 1200, a covering material 130, 160 is applied to the deck 100 as shown in Figures 9 and 10.

[0061] In one form, at step 1260, the method 1200 includes applying a soft wearable layer 160 to the varnished surface of the underside surface of the deck 100. In one form, the soft wearable layer is a layer of wax 160. In one form, candle wax can be used although other forms of wax can also be used. The wax layer 160 provides a number of advantages. In particular, the wax layer 160 promotes the removal of the paint layer 130 from the underside surface of the deck 100 during use. Additionally, the wax layer 160 promotes sliding skateboard tricks which involve the underside surface of the deck 100 sliding over an object such as a rail. Furthermore, the wax layer 160 acts as a paint barrier layer, inhibiting the paint layer seeping into the wood of the deck 100.

[0062] At step 1270, the method 1200 includes applying a paint layer 130 over the wax layer 160 on the underside surface of the deck 100. In particular, the paint layer 130 can be provided in the form of an acrylic paint. More specifically, the acrylic paint can be thinned with a solvent such as xylene. The acrylic paint can be air brushed onto the wax layer 160 of the underside of the deck 100. Generally, the paint layer 130 covers the entire underside surface of the deck 100. The acrylic paint can also include a dye to define the colour of the acrylic paint. The acrylic paint is then left to dry.

[0063] It will be appreciated that whilst step 1260 is advantageous in certain circumstances, as discussed above, it is possible to omit step 1260 such that the paint layer 130 is directly applied over the varnish layer 150.

[0064] It will be appreciated that method 1200 is generally performed to the deck 100 when the trucks and wheels are removed from the deck 100 of the skateboard 1300.

[0065] Prior to use, the entire graphic 190 is preferably covered by the covering material 130, 160 as shown in Figure 13. As illustrated by Figures 14, 15 and 16, when a skateboard rider performs tricks, such as grinds on rails and other objects, using the exemplified deck 100 of the skateboard 1300, the covering material of the acrylic paint 130 and the wax layer 160 at least partially wear away from the underside of the deck 100 thereby exposing or uncovering a portion of the graphic 190 which is defined by the cured epoxy resin 120 which is embedded within the grooves 110 defined in the deck 100. In particular, in Figure

14 a first portion 1410 of the graphic 190 is uncovered after a first amount of use, in Figure

15 a second portion 1510 of the graphic 190, greater than the first portion 1410 of the graphic 190, is uncovered after a second amount of use, and in Figure 16 a third portion 1610 of the graphic 190, greater than the second portion 1510 of the graphic 190, is uncovered after a third amount of use. As the skateboard rider uses the skateboard 1300 more often, more of the covering material 130, 160 is removed from the underside of the deck 100 such that a larger portion of the graphic 190 is exposed. It will be appreciated that not all of the covering material 130, 160 may be uncovered during use. Advantageously, as the skateboard 1300 is used more often to perform tricks and the like, the skateboard rider is rewarded with the aesthetic changes to the underside of the skateboard 1300. The skateboard rider may be unaware of the graphic 190 which is hidden under the covering material 130, 160, such that the skateboard rider is motivated to use the skateboard 1300 more often to uncover the graphic 190.

[0066] In particular embodiments, the grooves 110 may be created in areas of the deck which wear the most during use.

[0067] In certain embodiments, the paint layer 130 may include an additional graphical design such that over time the further graphic wears away exposing the prior covered graphic 190. However, in alternate embodiments the paint layer 130 may be a single colour or a plurality of block colours.

[0068] Whilst laser cutting has been described, which is advantageous particularly for graphics such as artwork which can require tight curved grooves 110 to be created in the deck 100, it is also possible to use other cutting tools such as CNC routers and the like. [0069] It will be appreciated that the method described can be used to retrofit an existing deck with an embedded graphic 190, however it is also possible that the method described can form part of the manufacturing process for a new skateboard deck 100.

[0070] In a particular embodiment, the graphic 190 may be an advertisement. In additional or alternative forms, the graphic 190 may be artwork. It will be appreciated that the term graphic may include textual indicia.

[0071] Although a preferred embodiment has been described in detail, it should be understood that many modifications, changes, substitutions or alterations will be apparent to those skilled in the art without departing from the scope of the present invention

Claims

1. A skateboard deck including:

2. The skateboard deck according to claim 1, wherein the filling material is cured epoxy resin.

3. The skateboard deck according to claim 1 or 2, wherein the wearable covering material includes a paint layer that covers graphic.

4. The skateboard deck according to claim 3, wherein the wearable covering material includes a wax layer that covers the graphic, wherein the paint layer covers the wax layer.

5. The skateboard deck according to claim 4, wherein the paint layer is an acrylic paint layer.

6. The skateboard deck according to any one of claims 3 to 5, wherein a varnish layer covers the graphic, wherein the paint layer covers the varnish layer.

7. The skateboard deck according to claim 5, wherein a varnish layer covers the graphic, wherein the wax layer covers the varnish layer, and the paint layer covers the wax layer.

8. The skateboard deck according to any one of claims 3 to 6, wherein the filling material is substantially flush with a undersurface of a body of the deck.

9. The skateboard deck according to any one of claims 1 to 9, wherein the fillable material are filled within the one or more grooves having a depth of between about 0.6mm to 0.9mm.

10. A skateboard including a skateboard deck according to any one of claims 1 to 9.

11. A method of manufacturing or modifying a skateboard deck to include a wearable underside surface for exposing a graphic during use, wherein the method includes:

filling the one or more grooves with a filling material; and

12. The method of claim 11, wherein the one or more grooves are created in the underside surface of the skateboard deck using a laser cutter.

13. The method according to claim 11 or 12, wherein the filling material is a curable material, wherein the method includes:

14. The method according to claim 13, wherein the filling material is epoxy resin.

15. The method according to claims 13 or 14, wherein filling the one or more grooves includes overfilling the one or more grooves.

16. The method according to claim 15, wherein after the filling material has cured, the method includes removing cured overfilled filling material such that the cured filling material is substantially flush with the underside surface of the deck.

17. The method according to claim 16, wherein removing the cured overfilled filling material using a sander.

18. The method according to claim 11 to 17, wherein applying the wearable covering material includes applying a paint layer to cover the filling material.

19. The method according to claim 18, wherein prior to applying the paint layer, the method includes applying a varnish layer to the underside surface of the deck to cover the filling material.

20. The method according to claim 11 to 17, wherein applying the wearable covering material includes:

applying a wax layer to cover the filling material; and

applying the paint layer over the wax layer.

21. The method according to claim 11 to 17, wherein the method includes:

applying a varnish later to cover the filling material;

applying a wax layer to cover the filling material; and

applying the paint layer over the wax layer.

22. The method according to any one of claims 11 to 21, wherein the creating the one or more grooves in the underside surface of the deck includes creating the one or more grooves having a depth of between about 0.6mm to 0.9mm.

23. The method according to any one of claims 11 to 22, wherein the one or more grooves have a substantially equal depth over the deck.

24. The method according to any one of claims 11 to 23, wherein the method includes mixing a pigment colourant with the filling material prior to filling the one or more grooves.

25. The method according to any one of claims 11 to 24, wherein the method includes securing trucks and wheels to the skateboard deck after the wearable covering material has been applied.