Sports boards with edges

Abstract

Sports boards (100, 200) are disclosed. In one exemplary aspect, a sports board (100) can include a board body (102) having a top board surface (104) and a bottom board surface (106). The board body (102) can include a core(HO) having a front end (116), an opposing back end (118), a first core sidewall (120) and a second, opposing core sidewall (122), a first edge (112) coupled to the core (110) along a segment(132) of the first core sidewall (120), and a second edge (114) coupled to the core (110) along a segment (138) of the second core sidewall (122). Method for manufacturing the same are also disclosed.

Description

SPORTS BOARDS WITH EDGESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 642,698 filed on May 4, 2024, and entitled “Sports Board with Edges,” and U.S. Provisional Patent Application No. 63 / 639,901 filed on April 29, 2024, and entitled “Sports Board with Edges,” the disclosures of which are incorporated herein by reference in their entireties.TECHNICAL FIELD

[0002] The subject matter described herein relates to sports boards with edges and methods of manufacturing the same.BACKGROUND

[0003] Skis and snowboards are made to be used in a variety of snow conditions, ranging from loose powder to ice. Typically, these sports boards are formed of a multi-layered composite that includes a variety of materials. Unfortunately, these composites do not afford the ability to form sufficiently hard lateral edges that is desired to maintain a sufficient grip for turning the sports boards during use. As such, metal edges have been developed that attach to the lateral sides of the composite to provide the desired gripping. It is common to use one or more polymer materials to attach the metal edges to the composite. However, the one or more polymer materials are typically brittle and therefore can result in cracking of the one or more polymer materials when the sports board is exposed to change in temperature (e.g., 70 °F to 10 °F or below) or due to bending deflection during board use. Furthermore, due to the variability of the materials within the composite and the varying process parameters during manufacturing of the composite, it is quite difficult to repeatedly produce generally uniform sports boards (e.g., nominally identical within manufacturing tolerances).

[0004] Accordingly, there remains a need for improved sports boards that address current issues with at least manufacturing variability and cracking of the one or more polymer materials.SUMMARY

[0005] In certain aspects of the current subject matter, challenges associated with sports boards can be addressed by inclusion of one or more of the features described herein or comparable / equivalent approaches as would be understood by one of ordinary skill in the art.Aspects of the current subject matter relate to sports boards and methods of manufacturing the same.

[0006] In some aspects, one or more of the following features may optionally be included in any feasible combination.

[0007] Exemplary sports boards are disclosed. In one exemplary aspect, the sports board includes a board body having a top board surface and a bottom board surface. The board body includes a single, monolithic core having a front end, an opposing back end, a first core sidewall and a second, opposing core sidewall, a first edge coupled to the core along a segment of the first core sidewall, and a second edge coupled to the core along a segment of the second core sidewall. The core has a Rockwell B hardness value; the first edge has a first Rockwell C hardness value; and the second edge has a second Rockwell C hardness value.

[0008] In another exemplary aspect, the sports board includes a board body having a top board surface and a bottom board surface. The board body includes a core having a front end, an opposing back end, a first core sidewall, and a second, opposing core sidewall, a first metal edge coupled to the core along a segment of the first core sidewall, a first cured polymer interposed between the first metal edge and the core, thereby coupling the first metal edge to the core, a second metal edge coupled to the core along a segment of the second core sidewall, and a second cured polymer interposed between the second metal edge and the core, thereby coupling the second metal edge to the core. The first cured polymer has a first elastic modulus, where the first elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C, and the second cured polymer has a second elastic modulus, where the second elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C.

[0009] Exemplary methods for manufacturing sports boards are disclosed. In one exemplary aspect, the method include removing material from a blank core to form a core having a front end, an opposing back end, a first core sidewall and a second, opposing core sidewall; attaching a first edge to a segment of the first core sidewall; and attaching a second edge to a segment of the second core sidewall.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are incorporated into and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with thedescription, help explain some of the principles associated with the disclosed aspects. In the drawings:

[0011] FIG. 1 is cross-sectional view of an exemplary sports board having a board body with a core, two edges and two shims attached to the core, and a binding attached to a top surface of the board body;

[0012] FIG. 2 is cross-sectional view of the sports board in FIG. 1 taken at line 2-2 with the binding removed;

[0013] FIG. 3 is a cross-sectional view of the sports board in FIG. 2 with the two edges and the two shims removed;

[0014] FIG. 4 is cross-sectional view of an exemplary sports board having a board body with a core and a metal plate; and

[0015] FIG. 5 is cross-sectional view of the sports board in FIG. 4 taken at line 5-5.

[0016] When practical, similar reference numbers denote similar structures, features, or elements.DETAILED DESCRIPTION

[0017] Certain exemplary aspects will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the sports boards, and methods disclosed herein. One or more examples of these aspects are illustrated in the accompanying drawings. Those skilled in the art will understand that the sports boards and methods specifically described herein and illustrated in the accompanying drawings are nonlimiting exemplary aspects and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary aspect may be combined with the features of other aspects. Such modifications and variations are intended to be included within the scope of the present invention.

[0018] In general, sports boards are provided. In one exemplary aspect, a sports board can include a board body having a top board surface and a bottom board surface. The board body can have a variety of configurations. In some aspects, the board body has a core and first and second edges coupled to the core. The core can have a front end, an opposing back end, a first core sidewall, and a second, opposing core sidewall, where the first edge is coupled to the corealong a segment of the first core sidewall, and the second edge is coupled to the core along a segment of the second core sidewall.

[0019] The sports boards disclosed herein can be used by a user in a variety of different environments. In some aspects, the sports board can be used on snow, ice, sand, water, or any combination thereof. Non-limiting examples of different implementations of the sports boards described herein include a ski, a snowboard, a wakeboard, a surfboard, and the like.

[0020] In general, the first and second edges are sufficiently durable to maintain a desired edge sharpness for a desired period of time. As such, the present sports boards disclosed herein can be utilized for longer periods of time between sharpening periods. Further, the present sports boards described herein can be repeatedly manufactured with generally uniformity (e.g., nominally identical within manufacturing tolerances). Moreover, the first and second edges of the present sports boards disclosed herein are coupled to the core in a way that inhibits cracking of the one or more coupling materials used to attach the edges when the sports boards are exposed to typical changes in temperature (e.g., 70 °F to 10 °F or below).

[0021] The first and second edges can have a variety of different configurations. In some aspects, the first edge has a first Rockwell C hardness value and the second edge has a second Rockwell C hardness value. In certain aspects, the core can either have a lower Rockwell C hardness value that the first and second Rockwell C hardness values or have a Rockwell B hardness value, and therefore, in either aspect, the first and second edges can be harder than the core. As such, the difference in hardness between the first and second edges and the core can effect a desired edge durability to the sports board.

[0022] In some aspects, the first edge can have a Rockwell C hardness value from about 40 to about 60. In certain aspects, the first Rockwell C hardness value can be from about 40 to about 50. It is also contemplated herein that the first Rockwell C hardness value does not fall outside any of these recited ranges. It is further contemplated herein that the first Rockwell C hardness value can be between any of these recited ranges.

[0023] The first edge can be formed of a variety of materials. In some aspects, the first edge can be formed of one material, whereas in other aspects, the first edge can be formed of two or more materials. In some aspects, the first edge can include one or more first metals. In such instances, the first edge can be referred to as a first metal edge. Non-limiting examples ofsuitable one or more first metals include steel, titanium, or a combination thereof. In one aspect, the first edge can include carbon steel.

[0024] Alternatively, or in addition, the second edge can have a second Rockwell C hardness value can be from about 40 to about 60. In some aspects, the second Rockwell C hardness value can be from about 40 to about 50. It is also contemplated herein that the second Rockwell C hardness value does not fall outside any of these recited ranges. It is further contemplated herein that the second Rockwell C hardness value can be between any of these recited ranges. In some aspects, the first edge and the second edge can each have a Rockwell C hardness from about 40 to about 50.

[0025] The second edge can be formed of a variety of materials. In some aspects, the second edge can be formed of one material, whereas in other aspects, the second edge can be formed of two or more materials. In some aspects, the second edge can include one or more second metals. In such instances, the second edge can be referred to as a second metal edge. Nonlimiting examples of suitable one or more second metals include steel, titanium, or a combination thereof. In certain aspects, the second edge can include carbon steel. In some aspects, the first edge and the second edge both include carbon steel.

[0026] As noted above, in some aspects, the core can have a Rockwell B hardness value. In such aspects, the Rockwell B hardness value can be from about 50 to about 65. In certain aspects, the Rockwell B hardness value can be about 60. It is also contemplated herein that the Rockwell B hardness value does not fall outside any of these recited ranges. It is further contemplated herein that the Rockwell B hardness value can be between any of these recited ranges.

[0027] The core can have a variety of configurations. In some aspects, the core can be a single, monolithic structure, e.g., constructed from an isotropic material, in certain aspects, the core can be formed of one or more metals, thermoplastic polymers, or thermoset polymers. Non-limiting examples of suitable one or more metals includes aluminum, steel, titanium, or any combination thereof. In one aspect, the one or more metals include aluminum. In certain aspects, the core can be formed of a bulk composite material, such as, for example, a cured carbon fiber composite or a cured glass fiber composite. In one aspect, the one or more metals include aluminum. In one aspect, the core can include aluminum and the first edge and the second edge can each include carbon steel.

[0028] In some aspects, the core can have a top core surface and a bottom core surface, and the first edge can have a top surface and a bottom surface. In such instances, the bottom core surface and the bottom surface can define a portion of the bottom board surface. Alternatively, or in addition, the second edge can have a top surface and a bottom surface, in which the bottom surface defines another portion of the bottom board surface. In certain instances, the bottom surface of the first edge, the bottom core surface, and the bottom surface of the second edge can define respective portions of the bottom board surface. Alternatively, or in addition, the bottom board surface of the front and back ends of the board body can be defined by only the bottom core surface.

[0029] Alternatively, or in addition, the core can include a first cut-out portion defining a first recess within the core, in which the first edge is positioned within the first recess. The first recess can be spaced a distance from the top board surface and extends towards the bottom board surface.

[0030] The first recess can having a variety of configurations. In some aspects, the first recess can have a L-shaped configuration. In certain aspects, the first recess can have a rectangularshaped configuration. In other aspects, the first recess can have any suitable shape. A person skilled in the art would appreciate that the shape and size of the first recess depends at least upon the shape and size of the first edge. As such, the first recess can be tailored to effect a desired engagement between the first recess and the first edge.

[0031] The first edge can be coupled to the core in a variety of ways. In some aspects, the first edge can be coupled to the core by an interference fit. In other aspects, the core can include a first interlocking member and the first edge can include a second interlocking member that is engaged with the first interlocking member to thereby couple the first edge to the core. Alternatively, or in addition, as described in more detail below, the board body can include a first cured polymer that is interposed between the first edge and the core. In such instances, the first cured polymer can attach the first edge to the core within the first recess.

[0032] Alternatively, or in addition, the core can include a second cut-out portion defining a second recess within the core, in which the second edge is positioned within the second recess. The second recess can be spaced a distance from the top board surface and extends towards the bottom board surface.

[0033] The second recess can having a variety of configurations. In some aspects, the second recess can have a L-shaped configuration. In certain aspects, the second recess can have a rectangular- shaped configuration. In other aspects, the second recess can have any suitable shape. A person skilled in the art would appreciate that the shape and size of the second recess depends at least upon the shape and size of the second edge. As such, the second recess can be tailored to effect a desired engagement between the second recess and the second edge.

[0034] The second edge can be coupled to the core in a variety of ways. In some aspects, the second edge can be coupled to the core by an interference fit. In other aspects, the core can include a second interlocking member and the second edge can include a second interlocking member that is engaged with the second interlocking member to thereby couple the second edge to the core. Alternatively, or in addition, as described in more detail below, the board body can include a second cured polymer that is interposed between the second edge and the core. In such instances, the second cured polymer can attach the second edge to the core within the second recess.

[0035] In aspects where the core and the first edge are formed of different material, e.g., when the core is formed of aluminum and the first edge is formed of carbon steel, the difference in the coefficient of thermal expansion between these materials can lead to undesirable cracking. As such, a first cured polymer can be interposed between the core and the first edge that is configured to couple the core and the first edge and to allow, e.g., the material of the core to move (or slide) relative to the material of the first edge and vice versa. In other words, the first cured polymer would not only couple the first edge to the core, but also maintain sufficient elasticity (and tensile strength) to counterbalance the thermal expansion between the core and the edge thereby inhibiting cracking that would otherwise occur therebetween. Moreover, even in instances where the core and the first edge are made of the same material, a first polymer can still be utilized in the board body, e.g., for coupling the first edge to the core. Further, a person skilled in the art would understand the foregoing discussion is also applicable to the core and the second edge, e.g., when the core is formed of aluminum and the second edge is formed of carbon steel, and therefore alternatively, or in addition, a second cured polymer can be used in the board body.

[0036] The first cured polymer has a first elastic modulus. In some aspects, the first elastic modulus can be from about 0.1 MPa to about 45 MPa at 22 °C. In other aspects, the first elastic modulus can be from about 0.5 MPa to about 5 MPa, 0.5 MPa to about 30 MPa, or from about0.7 MPa to about 20 MPa at 22 °C. In yet other aspects, the elastic modulus can be from about 35 MPa to about 45 MPa at 22 °C. It is also contemplated herein that the first elastic modulus does not fall outside any of these recited ranges. It is further contemplated herein that the first elastic modulus can be between any of these recited ranges.

[0037] In some aspects, the first cured polymer can have a tensile failure strain from about 100% to about 300%. In other aspects, the first cured polymer can have a tensile failure strain from about 100% to about 250% or from about 100% to about 200%. It is also contemplated herein that the tensile failure strain of the first cured polymer does not fall outside any of these recited ranges. It is further contemplated herein that the tensile failure strain of the first cured polymer can be between any of these recited ranges.

[0038] The second cured polymer has a second elastic modulus. In some aspects, the second elastic modulus can be from about 0.1 MPa to about 45 MPa at 22 °C. In other aspects, the second elastic modulus can be from about 0.5 MPa to about 5 MPa, 0.5 MPa to about 30 MPa, or from about 0.7 MPa to about 20 MPa at 22 °C. In yet other aspects, the elastic modulus can be from about 35 MPa to about 45 MPa at 22 °C. It is also contemplated herein that the second elastic modulus does not fall outside any of these recited ranges. It is further contemplated herein that the second elastic modulus can be between any of these recited ranges.

[0039] In some aspects, the second cured polymer can have a tensile failure strain from about 100% to about 300%. In other aspects, the second cured polymer can have a tensile failure strain from about 100% to about 250% or from about 100% to about 200%. It is also contemplated herein that the tensile failure strain of the second cured polymer does not fall outside any of these recited ranges. It is further contemplated herein that the tensile failure strain of the second cured polymer can be between any of these recited ranges.

[0040] Alternatively or in addition, the board body can include at least one shim that is configured to aid in maintaining the position of the first metal edge within the first recess, the position of the second metal edge within the second recess, or both. The at least one shim can be formed of a variety of materials. In some aspects, the at least one shim can include steel, aluminum, one or more polymer materials, or any combination thereof In certain aspects, the one or more polymer materials can include a polymer material reinforced with glass material. In other aspects, the at least one shim can include carbon steel. In some aspects, the at least one shim can be formed of the same material as the first edge, the second edge, or both, whereas inother aspects, the at least one shim can be formed of a different material that the material of the first edge, the second edge, or both. In one aspect, the at least one shim, the first edge and the second edge are each formed of steel (e.g., carbon steel).

[0041] In some aspects, the at least one shim can include a first shim that is positioned within the first recess and interposed between the first edge and a first portion of the core. In certain aspects, the first shim is coupled to the core, in which a first cured polymer is interposed between the first shim and the core. In some instances where a cured polymer is present and interposed between the first metal edge and the core, the first cured polymer can be the same as the cured polymer. In other instances where a cured polymer is present and interposed between the first metal edge and the core, the first cured polymer can be different than the cured polymer.

[0042] Alternatively, or in addition, the at least one shim can include a second shim that is positioned within the second recess and interposed between the second edge and a second portion of the core. In certain aspects, the second shim is coupled to the core, in which a second cured polymer is interposed between the second shim and the core. In some instances where a cured polymer is present and interposed between the second metal edge and the core, the second cured polymer can be the same as the cured polymer. In other instances where a cured polymer is present and interposed between the second metal edge and the core, the second cured polymer can be different than the cured polymer.

[0043] The core can be shaped and structured to have particular mechanical properties to optimize the performance of the sports board. In some aspects, the board body can include a plurality of ribs formed in a top portion of the core to optimize the board body to have a preselected longitudinal, transverse, and torsional stiffness desirable for sliding on a surface, such as snow or ice. The plurality of ribs can he oriented or shaped in a variety of configurations to tailor the local stiffness of the board body. In some aspects, the plurality of ribs collectively can have longitudinal portions and angled portions relative to the longitudinal axis of the core each having a thickness T and a height El that are predetermined to provide the board body, and thus sports board, with desired characteristics, in certain aspects, a rib can be formed in the top portion of the core and extend along a perimeter of the core.

[0044] In some aspects, the sports board can include one or more coatings applied to the bottom board surface. The one or more coatings can be configured to reduce the coefficient offriction between the bottom board surface and a surface the sports board is applied (e.g., a snow surface or an ice surface). As such, different types of friction reducing coating can be used, for example a powder coat, paint, or other suitable material.

[0045] In some aspects, the sports board can include a binding that is coupled to the board body, where the binding is configured to attach the sports board to a boot.

[0046] FIGS. 1-3 depict an exemplary sports board 100 having a board body 102 with a top board surface 104 and a bottom board surface 106. The board body 102 has a core 100, a first edge 112, and a second edge 114. The core 110 has a front end 116 and an opposing back end 118 with a longitudinal axis L extending therebetween, and a first core sidewall 120 and a second, opposing core sidewall 122. In this illustrated aspect, the core 110 is a single, monolithic structure. Further, the sports board 100 includes a binding 154 that is coupled to the board body 102 and configured to attach the sports board 100 to a boot (not shown).

[0047] As shown, the first edge 112 has a top surface 128 and a bottom surface 130 and is coupled to the core 110 along a segment 132 of the first core sidewall 120. The second edge 114 has a top surface 134 and a bottom surface 136 and is coupled to the core 110 along a segment 138 of the second core sidewall 120. In this illustrated embodiment, the bottom surface 130 of the first edge 112, the bottom surface 136 of the second edge 114, and the bottom core surface 126 define the portion of the bottom board surface 106 that extends along a central region 140 of the core 110. As shown, the central region 140 extends between the front end 116 and the back end 118 of the core 110. As such, the bottom board surface 126 at the front end 116 of the core 110 and at the back end 118 of the core 110 is defined by only the bottom core structure 106. As a result, the first edge 112 and the second edge 114 are not present at the front end 116 or the back end 118 of the core 110.

[0048] In this illustrated aspect, as shown in detail in FIG. 3, the core 110 includes a first cutout portion defining a first recess 142 within the core 110 that is spaced a distance DI from the top board surface 104 and extends towards the bottom board surface 106. The first recess 142 has a L-shaped configuration and the first edge 112 is positioned within the first recess 142. Further, the core 110 includes a second cut-out portion defining a second recess 144 within the core 110 that is spaced a distance D2 from the top board surface 104 and extends towards the bottom board surface 106. The second recess 144 has a L-shaped configuration and the second edge 114 is positioned within the second recess 144. As shown, distance DI anddistance D2 are generally equal in value (e.g., nominally identical within manufacturing tolerances). In other aspects, distance DI and distance D2 can be difference, e.g., distance DI can be greater than D2 or vice versa.

[0049] While the first edge 112 and the second edge 114 can each be coupled to the core in a variety of ways, as shown in detail in FIG. 2, the first edge 112 is coupled to the core 110 via a first cured polymer 146, and the second edge 114 is coupled to the core 110 via a second cured polymer 148. More specifically, the first cured polymer 146 is interposed between the first edge 112 and the core 110, thereby coupling the first edge 112 within the first recess 142 to the core 110, and the second cured polymer 148 is interposed between the second edge 114 and the core 110, thereby coupling the second edge 114 within the second recess 144 to the core 110.

[0050] As further shown in FIG 2, the board body 102 includes a first shim 150 that is positioned within the first recess 142 and interposed between the first edge 112 and a portion of the core 110. In this illustrated aspect, the first shim 150 is coupled to the core 100 via the first cured polymer, 146, and therefore, the first cured polymer 146 is further interposed between the first shim 150 and the core 110 and between the first shim 150 and the first edge 112.

[0051] As further shown in FIG 2, the board body 102 includes a second shim 152 that is positioned within the second recess 144 and interposed between the second edge 114 and a portion of the core 110. In this illustrated aspect, the second shim 152 is coupled to the core 110 via the second cured polymer 148, and therefore, the second cured polymer 140 is further interposed between the second shim 152 and the core 110 and between the second shim 152 and the second edge 114.

[0052] Further, in some aspects, as shown in FIGS. 1-3, the board body 102 includes a plurality of ribs 156A, 156B, and 156C formed in a top portion 158 (see FIG. 3) of the core 110. While the number of plurality of ribs can vary, in this illustrated aspect, there is a first rib 156 A that extends along a portion of the longitudinal axis L of the core 110, one or more second ribs 156B, each extending outward from the first rib 156A, and therefore extends at an angle relative to the longitudinal axis L of the core 110, and one or more third ribs 156C. each extending outward from the first rib 156 A, and therefore extends at an angle relative to the longitudinal axis L of the core 110. As shown the one or more second ribs 156B and the one ormore third ribs 156C extend in opposing direction relative to each other. That is, the one or more second ribs 156B each extend outward from the first rib 154A and towards the second core side wall 120, and the one or more third ribs 156C each extend outward from the first rib 154A towards the second core side wall 122.

[0053] In some aspects, for example, as shown in FIGs. 4 and 5, a sports body 200 can include a board body 202 having a core 210 and a metal plate 203 that is coupled to a a bottom core surface 226 of the central region 240 of the core 210. In this illustration, the central region 240 is the region of the core 210 that extends between the core’s front end 216 and the core’s back end 218. Further, the metal plate 203 extends the width W of the bottom core surface 226 (e.g., in the Z-direction), and therefore forms a first edge 212 along a segment 232 of a first core sidewall 220 of the core 210 and an opposing, second edge 214 along a segment 238 of a second core sidewall 222 of the core 110. As shown, the metal plate 203 is not inserted into any recess within the core 100 (e.g., such as recesses 142, 144 shown in FIG. 3 with respect to sports board 100). This structural configuration can simplify the overall manufacturing process of the sports board and therefore decrease manufacturing costs.

[0054] The sports boards described herein can be formed using a variety of manufacturing methods. In some aspects, a method for manufacturing a sports board can include removing material from a blank core to form a core having a front end, an opposing back end, a first core sidewall and a second, opposing core sidewall; attaching a first edge to a segment of the first core sidewall; and attaching a second edge to a segment of the second core sidewall.

[0055] In some aspects, attaching the first edge can include forming a first recess along the segment of the first core sidewall; and inserting the first edge into the first recess thereby attaching the first edge to the first core sidewall. In one aspect, the first recess can be formed by milling the segment of the first core sidewall with a rotating cutter. In certain aspects, the method can include applying, prior to inserting the first edge into the first recess, a first polymer to at least a portion of an outer surface of the first edge, and thereafter inserting the first edge into the first recess such that the first polymer is interposed between the core and the first edge; and curing the polymer to form a first cured polymer. In other aspects, the method can alternatively include, while inserting the first edge into the first recess, concurrently inserting a first shim into the first recess thereby coupling the first shim to the first edge and the first shim to the first core sidewall.

[0056] In some aspects, the method can include, applying, prior to concurrently inserting the first shim and the first edge into the first recess, a first polymer to at least a portion of an outer surface of the first shim and of the first edge, and thereafter concurrently inserting the first edge and the first shim into the first recess such that the first polymer is interposed between the core and the first edge and further interposed between the core and the first shim; and curing the first polymer to form the first cured polymer. In certain aspects, the first cured polymer is further interposed between the first shim and the first edge.

[0057] In some aspects, attaching the second edge can include forming a second recess along the segment of the second core sidewall; and inserting the second edge into the second recess thereby attaching the second edge to the second core sidewall. In one aspect, the second recess can be formed by milling the segment of the second core sidewall with a rotating cutter. In certain aspects, the method can include applying, prior to inserting the second edge into the second recess, a second polymer to at least a portion of an outer surface of the second edge, and thereafter inserting the second edge into the second recess such that the second polymer is interposed between the core and the second edge; and curing the second polymer to form a second cured polymer. In other aspects, while inserting the second edge into the second recess, concurrently inserting a second shim into the second recess thereby coupling the second shim to the second edge and the second shim to the second core sidewall.

[0058] In some aspects, the method can include applying, prior to inserting the second shim and the second edge into the second recess, a second polymer to at least a portion of an outer surface of the second shim and of the second edge, and thereafter concurrently inserting the second edge and the second shim into the second recess such that the second polymer is interposed between the core and the second edge and further interposed between the core and the second shim; and curing the second polymer to form the second cured polymer. In certain aspects, the second cured polymer is further interposed between the second shim and the second edge.

[0059] In some aspects, the method can include forming a plurality of ribs in the core. Alternatively, or in addition, the method can include attaching a binding to the board body, where the binding is configured to attach the sports board to a boot.

[0060] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers can be read as if prefaced by the word “about”or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and / or position to indicate that the value and / or position described is within a reasonable expected range of values and / or positions. The phrase “about” or “approximately” when immediately preceding a numerical value means a range of plus or minus 10% of that value, e.g., “about 50” means 45 to 55, “about 25,000” means 22,500 to 27,500, etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “X” is disclosed the “less than or equal to X” as well as “greater than or equal to X” (e.g., where X is a numerical value) is also disclosed. It is also understood that the throughout the application, data is provided in a number of different formats, and that this data, represents endpoints and starting points, and ranges for any combination of the data points. For example, if a particular data point “10” and a particular data point “15” are disclosed, it is understood that greater than, greater than or equal to, less than, less than or equal to, and equal to 10 and 15 are considered disclosed as well as between 10 and 15. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0061] Although various illustrative aspects are described above, any of a number of changes can be made to various aspects without departing from the teachings herein. For example, the order in which various described method steps are performed may often be changed in alternative aspects, and in other alternative aspects, one or more method steps may be skipped altogether. Optional features of various package aspects may be included in some aspects and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the claims.

[0062] The examples and illustrations included herein show, by way of illustration and not of limitation, specific aspects in which the subject matter may be practiced. As mentioned, other aspects may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such aspects of the inventive subject matter may be referred to herein individually orcollectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is, in fact, disclosed. Thus, although specific aspects have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific aspects shown. This disclosure is intended to cover any and all adaptations or variations of various aspects. Combinations of the above aspects, and other aspects not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. Use of the term “based on,” herein and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0063] The subject matter described herein can be embodied in systems, apparatus, methods, and / or articles depending on the desired configuration. The aspects set forth in the foregoing description do not represent all aspects consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail herein, other modifications or additions are possible. In particular, further features and / or variations can be provided in addition to those set forth herein. For example, the aspects described herein can be directed to various combinations and subcombinations of the disclosed features and / or combinations and subcombinations of several further features disclosed herein. In addition, the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other aspects may be within the scope of the following claims.

Claims

What is claimed is:

1. A sports board, comprising: a board body having a top board surface and a bottom board surface, the board body comprising, a single, monolithic core having a front end, an opposing back end, a first core sidewall and a second, opposing core sidewall, the core having a Rockwell B hardness value; a first edge coupled to the core along a segment of the first core sidewall, the first edge having a first Rockwell C hardness value; and a second edge coupled to the core along a segment of the second core sidewall, the second edge having a second Rockwell C hardness value.

2. The sports board of claim 1, wherein the first Rockwell C hardness value is from about 40 to about 60.

3. The sports board of claim 1 or claim 2, wherein the first Rockwell C hardness value is from about 40 to about 50.

4. The sports board of any one of the preceding claims, wherein the second Rockwell C hardness value is from about 40 to about 60.

5. The sports board of any one of the preceding claims, wherein the second Rockwell C hardness value is from about 40 to about 50.

6. The sports board of any one of the preceding claims, wherein the Rockwell B hardness value is from about 50 to about 65.

7. The sports board of any one of the preceding claims, wherein the Rockwell B hardness value is about 60.

8. The sports board of any one of the preceding claims, wherein the core has a top core surface and a bottom core surface, and the first edge has a top surface and a bottom surface, wherein the bottom core surface and the bottom surface define a portion of the bottom board surface.

9. The sports board of any one of claims 1-8, wherein the second edge has a top surface and a bottom surface, wherein the bottom surface defines another portion of the bottom board surface.

10. The sports board of any one of the preceding claims, wherein the core comprises a first cut-out portion defining a first recess within the core, wherein the first edge is positioned within the first recess.

11. The sports board of claim 10, wherein the first recess is spaced a distance from the top board surface and extends towards the bottom board surface.

12. The sports board of claim 10 or claim 11, wherein the first recess has a L-shaped configuration.

13. The sports board of claim 10 or 11, wherein the first recess has a rectangular- shaped configuration.

14. The sports board of any one of the preceding claims, wherein the first edge is coupled to the core by an interference fit.

15. The sports board of any one of claims 1 to 14, wherein the core comprises a first interlocking member and the first edge comprises a second interlocking member that is engaged with the first interlocking member to thereby couple the first edge to the core.

16. The sports board of any one of the preceding claims, wherein the board body further comprises a first cured polymer that is interposed between the first edge and the core.

17. The sports board of any one of the preceding claims, wherein the core comprises a second cut-out portion defining a second recess within the core, wherein the second edge is positioned within the second recess.

18. The sports board of claim 17, wherein the second recess is spaced a distance from the top board surface and extends towards the bottom board surface.

19. The sports board of claim 17 or claim 18, wherein the second recess has a L-shaped configuration.

20. The sports board of claim 17 or 18, wherein the second recess has a rectangular- shaped configuration.

21. The sports board of any one of the preceding claims, wherein the second edge is coupled to the core by an interference fit.

22. The sports board of any one of claims 1 to 21, wherein the core comprises a second interlocking member and the second edge comprises a second interlocking member that is engaged with the second interlocking member to thereby couple the second edge to the core.

23. The sports board of any one of the preceding claims, wherein the board body further comprises a second cured polymer that is interposed between the second edge and the core.

24. The sports board of any one of the preceding claims, wherein the board body further comprises at least one shim.

25. The sports board of claim 24, wherein the at least one shim comprises a first shim that is positioned within the first recess and interposed between the first edge and a first portion of the core.

26. The sports board of claim 25, wherein the first shim is coupled to the core, wherein the first cured polymer is further interposed between the first shim and the core,27. The sports board of claim 26, wherein the first cured polymer is further interposed between the first shim and the first edge.

28. The sports board of any one of claims 24 to 27, wherein the at least one shim comprises a second shim that is positioned within the second recess and interposed between the second edge and a second portion of the core.

29. The sports board of claim 28, wherein the second shim is coupled to the core, wherein the second cured polymer is further interposed between the second shim and the core, and optionally30. The sports board of claim 29, wherein the first cured polymer is further interposed between the first shim and the first edge.

31. The sports board of any one of claims 24-30, wherein the at least one shim comprises steel, aluminum, one or more polymer materials, or any combination thereof32. The sports board of claim 31, wherein the one or more polymer materials comprises a polymer material reinforced with glass material.

33. The sports board of any one of the preceding claims, wherein the core is formed of one or more metals.

34. The sports board of claim 33, wherein the one or more metals comprise aluminum, steel, titanium, or any combination thereof.

35. The sports board of any one of the preceding claims, wherein the first edge comprises one or more first metals.

36. The sports board of claim 35, wherein one or more first metals comprise steel, titanium, or a combination thereof37. The sports board of any one of the preceding claims, wherein the second edge comprises one or more second metals.

38. The sports board of claim 37, wherein the one or more second metals comprise steel, titanium, or a combination thereof.

39. The sports board of any one of the preceding claims, wherein the board body comprises a plurality of ribs formed in a top portion of the core.

40. The sports board of any one of the preceding claims, further comprises a binding coupled to the board body, the binding configured to attach the sports board to a boot.

41. The sports board of any one of the preceding claims, wherein the core comprises aluminum and the first edge and the second edge each comprise carbon steel.

42. A sports board, comprising: a board body having a top board surface and a bottom board surface, the board body comprising, a core having a front end, an opposing back end, a first core sidewall, and a second, opposing core sidewall;a first metal edge coupled to the core along a segment of the first core sidewall, a first cured polymer interposed between the first metal edge and the core, thereby coupling the first metal edge to the core, wherein the first cured polymer has a first elastic modulus, the first elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C; a second metal edge coupled to the core along a segment of the second core sidewall, and a second cured polymer interposed between the second metal edge and the core, thereby coupling the second metal edge to the core, wherein the second cured polymer has a second elastic modulus, the second elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C.

43. The sports board of claim 42, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.5 MPa to about 5 MPa at 22 °C44. The sports board of claim 42, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.5 MPa to about 30 MPa at 22 °C.

45. The sports board of claim 42, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.7 MPa to about 20 MPa at 22 °C.

46. The sports board of claim 42, wherein the first elastic modulus, the second elastic modulus, or both is from about 35 MPa to about 45 MPa at 22 °C.

47. The sports board of any one claims 42 to 46, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 300%.

48. The sports board of any one claims 42 to 46, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 250%.

49. The sports board of any one claims 42 to 46, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 200%.

50. The sports board of any one of claims 42 to 49, wherein the core has a top core surface and a bottom core surface, and the first metal edge has a top surface and a bottom surface,wherein the bottom core surface and the bottom surface define at least a portion of the bottom board surface.

51. The sports board of any one of claims 42 to 50, wherein the second edge has a top surface and a bottom surface, wherein the bottom surface defines another portion of the bottom board surface.

52. The sports board of claim 50 or claim 51, wherein the top core surface extends a first width from the first core sidewall to the second core sidewall, and the bottom core surface extends a second width from the first core sidewall to the second core sidewall.

53. The sports board of claim 52, wherein the first width is greater than the second width.

54. The sports board of claim 53, wherein the first width is equal to the second width.

55. The sports board of any one claims 42 to 54, wherein the core comprises a first cut-out portion defining a first recess within the core, wherein the first metal edge is positioned within the first recess.

56. The sports board of claim 55, wherein the first recess is spaced a distance from the top board surface and extends towards the bottom board surface.

57. The sports board of claim 55 or claim 56, wherein the first recess has a L-shaped configuration.

58. The sports board of claim 55 or 56, wherein the first recess has a rectangular- shaped configuration.

59. The sports board of any one claims 42 to 58, wherein the core comprises a second cutout portion defining a second recess within the core, wherein the second metal edge is positioned within the second recess.

60. The sports board of claim 59, wherein the second recess is spaced a distance from the top board surface and extends towards the bottom board surface.

61. The sports board of claim 59 or claim 60, wherein the second recess has a L-shaped configuration.

62. The sports board of claim 59 or 60, wherein the second recess has a rectangular- shaped configuration.

63. The sports board of any one of the preceding claims, wherein the board body further comprises at least one shim.

64. The sports board of claim 63, wherein the at least one shim comprises a first shim that is positioned within the first recess and interposed between the first metal edge and a portion of the core.

65. The sports board of claim 64, wherein the first shim is coupled to the core, wherein the first cured polymer is further interposed between the first shim and the core.

66. The sports board of claim 65, wherein the first cured polymer is further interposed between the first shim and the first edge.

67. The sports board of any one of claims 63 to 66, wherein the at least one shim comprises a second shim that is positioned within the second recess and interposed between the second metal edge and a portion of the core.

68. The sports board of claim 67, wherein the second shim is coupled to the core, wherein the second cured polymer is further interposed between the second shim and the core.

69. The sports board of claim 68, wherein the first cured polymer is further interposed between the second shim and the second edge.

70. The sports board of any one of claims 63 to 69, wherein the at least one shim comprises steel, aluminum, one or more polymer materials, or any combination thereof71. The sports board of claim 70, wherein the one or more polymer materials comprises a polymer material reinforced with glass material.

72. The sports board of any one claims 42 to 71, wherein the core is formed of one or more metals.

73. The sports board of claim 72, wherein the one or more metals comprise aluminum, steel, titanium, or any combination thereof.

74. The sports board of any one claims 42 to 71, wherein the core is formed of a bulk composite material.

75. The sports board of any one of claims 42 to 71, wherein the bulk composite material comprises a cured carbon fiber composite.

76. The sports board of any one of claims 42 to 71, wherein the bulk composite material comprises a cured glass fiber composite.

77. The sports board of any one of claims 42 to 76, wherein the first metal edge comprises steel, titanium, or a combination thereof78. The sports board of any one of claims 42 to 77, wherein the second metal edge comprises steel, titanium, or a combination thereof79. The sports board of any one of claims 42 to 78, wherein the board body comprises a plurality of ribs formed in a top portion of the core.

80. The sports board of any one of claims 42 to 79, further comprises a binding coupled to the board body, the binding configured to attach the sports board to a boot.

81. The sports board of any one of claims 42 to 80, wherein the core comprises aluminum and the first metal edge and the second metal edge each comprise carbon steel.

82. The sports board of any one of the preceding claims, further comprising one or more coatings applied to the bottom board surface, the one or more coatings configured to reduce a coefficient of friction between the bottom board surface and a surface the sports board is applied.

83. A method for manufacturing a sports board, the method comprising: removing material from a blank core to form a core having a front end, an opposing back end, a first core sidewall and a second, opposing core sidewall; attaching a first edge to a segment of the first core sidewall; and attaching a second edge to a segment of the second core sidewall.

84. The method of claim 83, wherein attaching the first edge comprises forming a first recess along the segment of the first core sidewall; and inserting the first edge into the first recess thereby attaching the first edge to the first core sidewall.

85. The method of claim 84, further comprising, applying, prior to inserting the first edge into the first recess, a first polymer to at least a portion of an outer surface of the first edge, and thereafter inserting the first edge into the first recess such that the first polymer is interposed between the core and the first edge; and curing the polymer to form a first cured polymer.

86. The method of claim 84, further comprising, while inserting the first edge into the first recess, concurrently inserting a first shim into the first recess thereby coupling the first shim to the first edge and the first shim to the first core sidewall.

87. The method of claim 86, further comprising, applying, prior to concurrently inserting the first shim and the first edge into the first recess, a first polymer to at least a portion of an outer surface of the first shim and of the first edge, and thereafter concurrently inserting the first edge and the first shim into the first recess such that the first polymer is interposed between the core and the first edge and further interposed between the core and the first shim; and curing the first polymer to form the first cured polymer.

88. The method of claim 87, wherein the first cured polymer is further interposed between the first shim and the first edge.

89. The method of any one of claims 85, 87, or 88, wherein the first cured polymer has a first elastic modulus, the first elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C.

90. The method of any one of claims 83 to 89, wherein attaching the second edge comprises forming a second recess along the segment of the second core sidewall; and inserting the second edge into the second recess thereby attaching the second edge to the second core sidewall.

91. The method of claim 90, further comprising, applying, prior to inserting the second edge into the second recess, a second polymer to at least a portion of an outer surface of the second edge, and thereafter inserting the second edge into the second recess such that the second polymer is interposed between the core and the second edge; and curing the second polymer to form a second cured polymer.

92. The method of claim 90, further comprising, while inserting the second edge into the second recess, concurrently inserting a second shim into the second recess thereby coupling the second shim to the second edge and the second shim to the second core sidewall.

93. The method of claim 92, further comprising, applying, prior to inserting the second shim and the second edge into the second recess, a second polymer to at least a portion of an outer surface of the second shim and of the second edge, and thereafter concurrently inserting the second edge and the second shim into the second recess such that the second polymer is interposed between the core and the second edge and further interposed between the core and the second shim; and curing the second polymer to form the second cured polymer.

94. The method of claim 93, wherein the second cured polymer is further interposed between the second shim and the second edge.

95. The method of any one of claims 91, 93, or 94, wherein the second cured polymer has a first elastic modulus, the second elastic modulus is from about 0.1 MPa to about 45 MPa at 22 °C.

96. The method of claim 89 or 95, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.5 MPa to about 5 MPa at 22 °C.

97. The method of claim 89 or 95, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.5 MPa to about 30 MPa at 22 °C.

98. The method of claim 89 or 95, wherein the first elastic modulus, the second elastic modulus, or both is from about 0.7 MPa to about 20 MPa at 22 °C.

99. The method of claim 89 or 95, wherein the first elastic modulus, the second elastic modulus, or both is from about 35 MPa to about 45 MPa at 22 °C.

100. The method of any one of claims 85, 87, 88, 89, 91, 92, 94, or 95, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 300%.

101. The method of any one of claims 85, 87, 88, 89, 91, 92, 94, or 95, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 250%.

102. The method of any one of claims 85, 87, 88, 89, 91, 92, 94, or 95, wherein the first cured polymer, the second cured polymer, or both has a tensile failure strain from about 100% to about 200%.

103. The method of any one of claims 82 to 102, further comprising forming a plurality of ribs in the core.

104. The method of any one of claims 82 to 103, further comprising attaching a binding to the board body, the binding configured to attach the sports board to a boot.

Images