[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/121,216 filed on December 3, 2020, which is incorporated by reference in its entireties.

FIELD OF THE INVENTION

[0001] The disclosed invention relates generally to snow sliding devices and covers and more particularly to snow skis, snow skates and hard-pack skis and covers therefor and methods of making and using the same.

BACKGROUND

[0002] Over the thousands of years that skis have been used to travel over snow, there has been a continuing quest for skis with improved performance, durability, and longevity of life. Early skis were made exclusively from wood that was treated in various ways to achieve those ends. In the late 1800s, ski manufacturers began laminating the skis with various materials. Most present-day skis are manufactured by laminating various materials over a core material, such as foam or wood, using monocoque or cap ski shell designs, which are costly and labor-intensive processes. Other ski designs contemplating the use of plastic materials have not found commercial acceptance.

[0003] As such, while there has been great progress over the years in improving skis, there is a continuing need in the market for skis, snow skates, and other sliding devices with improved performance, durability, longevity of life and cost.

BRIEF SUMMARY OF THE INVENTION

[0004] The present invention provides inventive snow skis, skates, and other sliding devices, and covers therefor and methods of making the same. In various embodiments the skis, snow skates, and other sliding devices are molded with at least one partially integrated edge appropriately positioned along one or more edges of the device to facilitate the various actions required for the specific activity using the device, e.g., a steel edge integrated in each opposing side over some or all of the length of the device. In various embodiments, the device mold may provide for one or more fasteners, e.g., screws, to be partially integrated into the device to enable various bindings and/or boots to be used with device. [0005] In various embodiments, the device may be a hard-pack ski in which the ski is manufactured using an injection molding process in which the mold provides for the integration of edges along both sides of the ski and a plurality of fasteners in the top of the ski to enable the secure connection of various bindings or boots to the ski that provide high ankle support for the user.

[0006] For example, the ski can be formed by injecting Ultra High Molecular Weight Polyethylene (UHMWPE), other thermoplastic or a similar material with proper viscosity and attributes for use on snow and in a variety of temperatures using steel edges on both sides of the ski and threaded insert fasteners, e.g., screws, to secure bindings or boots. In this manner, the ski may be manufactured in a single molding or printing process with integrated edges and fasteners. [0007] Exemplary methods of manufacturing the device may involve the follow processes. A mold of the device structure, e.g., hard-pack ski, skate, etc., may be provided or produced as desired using various commercially available mold materials suitable for use with the molding process. The mold may be designed to produce a near finished product, except for exterior finishing, such as surface preparation, tampo printing, etc. and edge polishing and sharpening. The mold may include one or more edge portions, magnets or related retention devices to receive and retain corresponding edges and one or more fastener portion to receive and retain corresponding fasteners depending upon the design of the device. Prior to formation of the device structure, the desired number of edges and fasteners are placed into the respective edge and fastener portions of the mold. After the edges and fasteners are placed into the mold, the material that is being used to form the device structure is introduced into the mold. With injection modeling, the mold includes an injection port through which an injection machine is positioned to inject the material into the closed mold. The injection systems may employ a hot runner system to maintain the material within an appropriate temperature to achieve a desired cycle time and material consistency of the finished structure. The material may be shot into the mold, overmolding around the edges and fasteners to fix them in place and provide integrated strength in one single shot. In various embodiment, the color of the device may be varied to match the upper boot or for personal variety. After ejection of the device, e.g., ski, etc., from the mold with lifters, the edges may be finished on an edge sharpening machine to create an optimum steel edge. The end product is a short ski snow sliding device with substantially improved edge and fastener strength over other processes for manufacturing comparable device structures with a reduced number of manufacturing steps and associated cost.

[0008] In another inventive aspect, novel covers may be employed to protect sliding surfaces, i.e., base or bottom, of the devices and enable walking on the covers in various embodiments of the devices and covers. In such embodiments, a cover cooperates with the device such that the cover captures one of the front tip or backend of the device and covers the sliding surface of the device as the cover is being installed and captures the other of the front tip or back end of the device to secure the cover. In exemplary embodiments, the cover may be constructed from a hard rubber, silicon, etc, e.g., 50A+ hardness or similar for durability, elasticity and strength, having a front section that captures the front tip of a hard-pack ski and a back portion that may be stretched over the back end of the ski to secure the cover over the sliding surface and the front tip and back end of the sliding device.

[0009] Accordingly, the present inventive disclosure addresses the continuing need for skis, snow skates, and other sliding devices with improved performance, durability, longevity of life and cost.

BRIEF DESCRIPTION OF DRAWINGS

[0010] The accompanying drawings are included for the purpose of exemplary illustration of various aspects of the present invention, and not for purposes of limiting the invention, wherein: [0011] FIGS. 1A-1F show various views of exemplary embodiments of snow sliding devices. [0012] FIGS. 2 A- 5 show various views of exemplary embodiments of covers for snow sliding devices.

[0013] FIG. 6A & 6B show two perspective views of the cover positioned on a snow skate.

[0014] In the drawings and detailed description, the same or similar reference numbers may identify the same or similar elements. It will be appreciated that the implementations, features, etc. described with respect to embodiments in specific figures may be implemented with respect to other embodiments in other figures, unless expressly stated, or otherwise not possible.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention provides inventive skis, snow skates, and other snow sliding devices, and covers therefor and methods of making the same. For ease of description, reference may be made individually to skis, skates, or other sliding devices, but, unless stated explicitly or otherwise not practical or possible, the description may apply to any or all of the embodiments. [0016] In various embodiments the snow skis, skates, and other snow sliding devices may be molded as a unitary device structure made of one material with at least one partially integrated edge appropriately positioned along one or more edges of the device to facilitate the various actions required for the specific activity using the device. For example, in hard-pack snow ski embodiments, the ski may often include one steel edge on each side of the ski proximate the base, i.e., sliding surface, to facilitate turns and stops. The partial integration of the edge into the ski material structure itself may provide for a higher strength, more secure bond of the edge with material forming the ski structure, while at the same time eliminating manufacturing steps and reducing cost. Devices 10 of the present invention may be particularly well-suited for high performance hard-pack skis and snow skates, which are often less than twenty inches long and need to be durable.

[0017] A hard-pack ski may be distinguished from snow skates, ski skates, or short skis in that hard-pack skis are high performance skis that require exceptional edge retention and edge positioning, while being capable of cooperating with boots to provide high ankle support and having no loose parts. These features of hard-pack skis provide speed, edge control and optimum performance on groomed ski slopes, which is what makes them unique relative to other short snow sliding devices designed for use on cross country ski trails or recreational activities.

[0018] Similarly, in various embodiments, the device mold may provide for one or more fasteners to be partially integrated into the device to enable various bindings to be used with device. The mold may be shaped to accommodate a specific number or types of fastener, e.g., four M3 threaded fasteners. In other mold embodiments, the number and type of fastener may be changed or not included by the skilled artisan. The partial integration of the fasteners into the ski structure itself also provides a higher strength, more secure bond of the fastener with material forming the ski and further reduces manufacturing steps and cost.

[0019] One of ordinary skill in the art will appreciate that partially integrated in the context of edges and fasteners anticipates that some portion of the edge and fastener may usually extend beyond or not be integrated into the structure of the device 10, so the function of the edge and fastener may be performed.

[0020] FIGS. 1A-1E show exemplary views of various snow sliding device 10 embodiments, which may be a snow ski or snow skate or other snow sliding device. FIG. 1A is a top plan view of the device 10, which includes a front tip 12, a backend 14, opposing sides 16, a bottom sliding surface, or base, 18, and a top surface 20. In various embodiments, the entire device 10 structure is formed from the same material 22 at the same time, e.g., one shot injection molding, single compression modeling, etc. 3D printing and multi-staged modeling may also be employed to impart various features to the device 10.

[0021] In various embodiments, the top surface 20 may include textures or contours, such as depressions and/or raised surfaces 24 to improve contact with a boot in the binding (not shown), aesthetics, or otherwise. Alternatively, the top surface 20 may be smooth in the area in contact with the boot. In addition, other contours may be added, e.g., heel stops, arch supports, etc. 26, as well as raised sections proximate the sides 16 to restrain movement of the boot. The surface contour to reduce weight may be formed as part of the device 10 or added after the device 10 is formed.

[0022] In many embodiments, binding fasteners 28 and edges 30 may not made of the same material 22 as the remainder of the device 10, but may be partially integrally formed into the device 10. However, the present invention does not exclude such embodiments, if a material 22 is identified that is suitable for the fasteners 28 and edges 30. FIG. 1A embodiments show four fasteners 28, but that number and the location of the fasteners may be varied or eliminated by the practitioner.

[0023] FIG. IB depicts an exemplary cross section B-B along the front to back axis of the device 10, which is generally in the direction of forward motion. These embodiments show contours 24 as surface depressions in the top surface 20. FIG. IB also shows various dimensions that may be varied by the skilled artisan depending upon the application of the device 10. For example, for a hard-pack ski, the top-bottom thickness may be 0.5 inches or less, with contours 22 less than 0.25 inches and other contours and binding fasteners extending approximately 0.5 inches above the top surface 20. In addition, the front to back length may be varied depending upon the application. Again, for an exemplary hard-pack ski, the front to back length of the ski may varied depending upon the user, but may be more or less in the 5-15 or 15-20 inch range. The width of the ski from side to side may be uniform or varied over the front to back length. Also, the width may range over several inches to accommodate a range of foot widths of the user. [0024] FIG. 1C depicts a close up view of the front tip section of FIG. IB. The close-up shows the integration of the edge 30 with the ski structure material 22. It will be appreciated that for various devices 10, the edge 30 may extend along a portion or the entire length of the side 16. Also, the proximity of the edge 30 to the bottom 18 may be determined by one of skill in the art for the particular application.

[0025] FIG. ID shows an exemplary left side view of the device 10. While it may be generally desirable to provide some degree of curvature to the front tip 12 and backend 14, the particular shape and curvature may be decided by the skilled artisan based on a particular application, ease of manufacture, and/or ornamental considerations.

[0026] FIG. IE shows planar cross section near the bottom 18 of the device 10 in the plane of the bottom 18 to expose partially integrated edges 30. Commercial off the shelf steel edges 30 may be employed in the present invention, although non-standard sizes and other edge materials may be employed depending upon the material 22 selected for the device structure, as well as other considerations. For example, the edges 30 may be integrated with the material 22 structure to a depth of 1/3 - 1/2 inch in various embodiments. Other edge materials may include other metal and material that have comparable material properties to steel, such that the material may be manufactured as provided herein and perform the desired functions of edges on skis, skate, and other snow sliding devices 10 including being sharpened after the manufacturing of the device 10. [0027] FIG. IF shows an exemplary back to front top perspective view of the device 10. As previously noted, the particular shape, curvature, texturing, etc. of the device 10 may be decided by the skilled artisan based on a particular application, ease of manufacture, and/or ornamental considerations.

[0028] In various embodiments, the device 10 may be manufactured using various molding processes, such as an injection or compression, with or without sintering and other material treatments. The molds are designed in the shape of the finished device 10, such as a ski or a skate. The molds include edge portions to receive and retain one or more edges that are being integrated into the device 10 structure and fastener portions to receive and retain one or more fasteners being integrated into the device 10 structure. While it is not required that all edges and fasteners be integrated into the device 10, adding edges and fasteners after the device 10 is formed via molding will increase production complexity and cost.

[0029] In exemplary embodiments, the device 10 may be embodied as a hard-pack ski, where ski is formed using an Ultra High Molecular Weight Polyethylene (UHMWPE), other thermoplastic or thermoplastic-based materials and mixtures thereof with steel edges and M3 threaded insert fasteners. The desired material properties of the material for the device 10 are those that have similar or better hardness, elasticity, durability, surface viscosity and appearance, manufacturability, performance, etc. to UHMWPE over the range of temperature and stress conditions experienced during skiing, skating, and other snow sliding activities.

[0030] Exemplary methods of manufacturing the device 10 may involve the follow processes. A mold of the desired device 10 structure may be provided or produced as desired. Preferably the mold results in a device 10 that is in a near finished product state following the molding process, except for exterior finishing, such as surface preparation, tampo printing, painting, etc. and edge polishing and sharpening, so manufacturing cost and complexity can be kept as low as practical.

[0031] The mold may include one or more edge portions to receive and retain corresponding edges and one or more fastener portions to receive and retain corresponding fasteners. It will be appreciated that molds with two edge portions may be used with one or two edge designs and the number of fasteners used may be less than or equal to the faster portions in the mold.

[0032] Prior to formation of the device structure 22, the desired number of edges 30 and fasteners are placed into the respective edge and fastener portions. For example, in manufacturing embodiments, such as those shown in FIGS. 1A-1E, a robot or human operator would place the inside and outside steel edges of a ski in the mold and the four threaded insert pins into edge and fastener portions. In various mold embodiments, the edges 30 and/or fasteners 28 may be held in place within the mold by magnets or similar retention devices to keep or help keep the edges and fasteners from shifting after the mold is closed and while under molding conditions, such as high temperature and pressure. In various embodiments, the molds may hold the edges and fasteners in place via friction and/or other mechanisms.

[0033] After the edges 30 and fasteners 28 are placed, the material 22 that is being used to form the device 10 structure is introduced into the mold. With injection modeling, an injection machine is positioned to inject the material 22 into the closed model via an inject port in the mold. A hot runner system may be employed to maintain the material 22 within an appropriate operating conditions, e.g., temperature, pressure, etc., to achieve a desired cycle time and material consistency of the finished device structure.

[0034] Preferably, the material 22 may be shot into the mold, over-molding around the edges 30 and fasteners 28 to fix them in place and provide integrated strength in one single shot. After the device is formed in the mold, then removed from the mold with lifters or otherwise, the edges of the near- finished product may be finished on an edge sharpening machine to create an optimum steel edge. Similar procedures for compression modeling made be implemented by those of skill in the art.

[0035] In another inventive aspect, the devices 10 may be designed to enable covers 50 to be used to protect the sliding surface, i.e., base, 18 of the device 10 and enable a user to walk on short versions of the devices 10, such as hard-pack skis and snow skates. While it is possible for users to walk around with longer skis, it is generally not practical. Hence, the cover 50 may be employed mainly to protect long skis during transport and storage.

[0036] In various embodiments, the cover 50 cooperates with the device 10 such that the cover 50 captures one of the front tip 12 or backend 14 of the device 10 and covers the sliding surface 18 of the device 10 as it is being installed and captures the other of the front tip 12 or back end 14 of the device 10 to secure the cover 50 in place. For example, the cover 50 may have a front section 52 that captures the front tip 12 of the device 10 and a back portion 54 that may be pulled to stretch the back portion 54 over the backend 14 of the device 10 to secure the cover 50 over the sliding surface 18 and the front tip 12 and backend 14 of the sliding device 10. In exemplary embodiments, the cover 50 may be constructed from various elastomers, e.g., hard rubber with sufficient resilience, silicon, e.g., 50A+ hardness, such as 85 A, to withstand repeated stretching cycles and outdoor conditions. [0037] FIGS. 2A-2F show different views of exemplary embodiments of covers 50 for snow sliding devices 10, which may be embodied as a ski or skate. FIG. 2A is a left side view of the cover 50 showing the front section 52 for retaining the front tip 12 of the device 10, the back section 54 for retaining the backend 14 of the device 10, a bottom surface 56, and a top surface 58 for contacting and protecting the sliding surface 18 of the device 10.

[0038] The back section 54 may include a handle 60 or other retaining mechanism used to position the back section 54 to retain the backend of the device. Embodiments shown in FIGS. 2A, 2B, 2D, and 2E, may include an integrated or discrete handle 60 that is pulled to stretch the back section 54 over the backend of the device 10 in order to provide a secure fit of the cover. In these stretch fit embodiments, the choice and thickness of material used for the back section 54 should be selected to provide a secure fit, while enable the user to actually stretch the material without frustration. In various embodiments, the cover may be disassembled or rolled to fit nicely into a large pocket or bag as will be further described herein. It will be appreciated that other retaining mechanisms, such as hooks, clamps, ties, etc. may be employed by the skilled artisan in lieu of, or in combination with, the stretch fit retention.

[0039] Embodiments depicts in FIGS. 2A-2F include bottom surfaces 56 that are textured with patterns, which is useful to provide traction for covers that are designed for shorter devices 10, such as hard-pack skis and snow skates. Alternatively, the bottom surface 56 and other surfaces and shapes of the cover 50 may be smooth or textured and otherwise shaped based on a particular application, ease of manufacture, and/or ornamental preference.

[0040] FIG. 2B depicts exemplary bottom plan views of the cover 50. The handle 60 may be configured in a variety of shapes by the skilled artisan. Whether discrete or integrated, the handle 60 should be designed to withstand many stretch cycles and cold weather for stretch fit implementations .

[0041] FIGS. 2C & 2D depict exemplary front and back view, respectively, of the cover 50. While the interior surface of the cover 50 must generally correspond the curvature of the sliding surface 18 of the device 10, the outer surface curvature of the cover 50 may be shaped for aesthetics and/or ease of walking, transport, storage, etc.

[0042] FIGS. 2E & 2F depict exemplary front to back perspective top and bottom views, respectively, of the cover 50. As shown in FIG. 2E, the top surface 58 may be recessed to provide side walls or support to further protect the device 10 and/or add lateral stability to the cover 50 when it is used for walking by the user.

[0043] FIGS. 3A-3C depict other exemplary embodiments in which a portion of the cover 50 between front section 52 and back section 54, e.g., the middle section 58, is narrowed to increase the front to back elasticity of the cover, which enables a less elastic material to be used.for the cover, but the narrow middle section has less material to resist stretching of the cover by a user, thereby reducing the force necessary to stretch the cover over the front and back ends of the snow sliding device 10. FIGS. 3 A & 3B depict front and back perspective views of the cover 50. FIG. 3C depicts a side view of the cover 50. It will be appreciated that while FIGS. 3A-3C depict embodiments with one rectangular narrowed section, other geometric shapes and number of ligaments may be employed to improve the ease of putting the cover 50 on the device 10.

[0044] FIGS 4A-4F depict various embodiments in which the cover 50 comprises at least two separate connected sections, the front section 52 and back section 54 connected by the middle section 58. In these embodiments, the middle section 58 may comprise one or more ligaments that are fastened to the front and back sections, 52 and 54, respectively. The cover 50 may or may disassembled following assembly. The middle section 58 may be a different size, thickness, and/or material from the front and back sections, 52 and 54, to allow for increased elasticity for stretching the cover 50 over different sized devices 10, bendability for storage, etc.

[0045] FIG 4A depicts a top view of the cover 50 with the front section 52 and back section 54 disassembled. The middle section 58 is not shown. FIG. 4B depict side views of the front section 52. FIGS. 4C & 4D shows exemplary bottom views of the front and back sections, 52 and 54, in an assembly position and disassembled position, respectively, and connectors or fasteners 59 from the middle section 58. FIG. 4E depicts the cover 50 with two different length middle sections 58 (shown in FIG. 4F) to enable one front and back section to be used as a cover for a wide range of sliding device lengths. One of skill in the art will appreciate that by providing a middle section 58 having different lengths and mechanical properties, the front and back section of the cover 50 may be used with a wide range of sliding device lengths.

[0046] In FIG. 4A-4F embodiments, the connectors 59 are depicted as having cooperating portions, 59A and 59B, such as a button and hole, or snaps, but may include other connectors/ fasteners as desired by one of ordinary skill. The button and hole connector allows for the tension of the cover 50 being stretched over the sliding device 10 to secure the button in the hole.

[0047] FIG. 5 depicts various embodiments in which the middle section 58 spans the entire width of the cover 50 to connect the front and back section, 52 and 54. Similar to some other embodiments, the middle section 58 may be a separate section used to connect the front and back sections, 52 and 54, may be provided in different lengths to vary the length of the cover 50, and may provide different mechanical properties, e.g., tensile strength, bendability, elasticity, plasticity, hardness, toughness, brittleness, stiffness, ductility, etc., than the front and/or back sections. For example, the middle section 58 may enable the cover 50 to be more easily rolled or folded and stored by a user of the cover 50. In various embodiments, the front section and back section may be configured to cooperate, such as via the tab 60 or otherwise, to secure the cover 50 in a folded or rolled position.

[0048] FIG. 6A & 6B show two perspective views of the cover 50 positioned on a snow skate. In view of these figures and the description herein, it will be appreciated the manner of attachment to other sliding devices, such as skis.

[0049] It is to be understood that the foregoing embodiments are exemplary, and that the invention is NOT limited to only the embodiments disclosed herein. Equivalent variations not hitherto disclosed are to be understood as remaining within the scope and the spirit of the claims below. Although the present invention may have been illustrated and described herein with reference to one or more embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims. Similarly, it will be understood that a number of items and steps are disclosed. Each of these may have an individual benefit and each may also be used in conjunction with one or more, or in some cases all, of the other disclosed items. Accordingly, for the sake of clarity, this description may refrain from repeating every possible combination of the individual items in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

[0050] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Where only one item is intended, the term "one" or similar language is used. Also, as used herein, the terms "has," "have," "having," or the like are intended to be open-ended terms. Further, the phrase "based on" is intended to mean "based, at least in part, on" unless explicitly stated otherwise. [0051] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0052] Some implementations are described herein in connection with thresholds. As used herein, satisfying a threshold may refer to a value being greater than the threshold, more than the threshold, higher than the threshold, greater than or equal to the threshold, less than the threshold, fewer than the threshold, lower than the threshold, less than or equal to the threshold, equal to the threshold, etc.

[0053] Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of possible implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of possible implementations include each dependent claim in combination with every other claim in the claim set to the maximum extent possible.