Skate frame with cap construction

Abstract

Skate frame ( 20 ) for an in-line skate ( 18 ) having shoe portion ( 22 ) and a plurality of wheels ( 24 ) capable of traversing a surface. Skate frame includes an elongate structural member comprised of a structural material having a first average density, the structural member having first and second sidewalls ( 62, 68 ). Structural member also includes shoe mounting portion ( 50 ) spanning between at least a portion of the upper ends of the sidewalls. Skate frame also includes core material ( 64 ) disposed within at least one of the first and second sidewalls or within the shoe-mounting portion. In an embodiment of the invention, threaded insert ( 602 ) is embedded in the core material of one sidewall, and an aligned tubular insert is installed in the opposite sidewall, such that the wheel axle ( 612 ) can be inserted through the tubular insert to engage the embedded threaded insert. In another embodiment, protective cap ( 770 ) protects and/or enhances the appearance of the skate frame.

1 . A method of constructing a skate frame sidewall for an in-line skate comprising: 
 (a) placing a polymeric cap film sheet over the depressed portion of a frame mold wherein the cap film sheet is large enough to substantially cover the depressed portion of the frame mold;    (b) laying up a composite layer in the frame mold, on top of the polymer cap film such that the composite layer and the cap film sheet substantially fill the depressed portion of the frame mold;    (c) placing a frame cover over the composite layer;    (d) heating the frame mold to cure the composite layer whereby the polymer cap film adheres to the composite layer;    (e) removing the sidewall from the frame mold.    
   
   
       2 . The method of  claim 1  wherein the cap film sheet comprises urethane.  
   
   
       3 . The method of  claim 2 , wherein the cap film sheet further comprises a decorative design extending substantially through the thickness of the cap film sheet.  
   
   
       4 . The method of  claim 1 , wherein the composite layer comprises at least in part reinforced fiberglass.  
   
   
       5 . The method of  claim 1  wherein the composite layer comprises at least in part a graphite epoxy composite.  
   
   
       6 . A method of constructing a skate frame sidewall for an in-line skate comprising: 
 (a) placing a polymeric cap film sheet over the depressed portion of a frame first mold piece wherein the cap film sheet is large enough to substantially cover the depressed portion of the frame first mold piece;    (b) laying up a first composite layer in the frame first mold piece, on top of the polymer cap film;    (c) placing a polymeric foam core over a portion of the first composite layer;    (d) laying up a second composite layer over the polymeric foam core such that the polymeric foam core is substantially encapsulated by the first and second composite layers and further such that the composite layer and the cap film sheet substantially fill the depressed portion of the frame first mold piece;    (e) placing a frame second mold piece over the composite layer;    (f) heating the frame sidewall to cure the composite layer whereby the polymer cap film adheres to the first composite layer;    (g) removing the sidewall from the frame first and second mold pieces.    
   
   
       7 . The method of  claim 6  wherein the cap film sheet comprises an acrylic and urethane blend.  
   
   
       8 . The method of  claim 7 , wherein the cap film sheet further comprises a decorative design affixed to an inner surface of the cap film sheet.  
   
   
       9 . The method of  claim 6 , wherein the composite layer comprises a reinforced fiberglass.  
   
   
       10 . The method of  claim 6  wherein the composite layer comprises a graphite epoxy composite.  
   
   
       11 . A method of constructing a skate frame for an in-line skate comprising: 
 (a) placing a polymeric cap film sheet into the depressed portion of a frame first mold piece wherein the cap film sheet is large enough to substantially cover the depressed portion of the frame first mold piece;    (b) laying up a first composite layer in the frame first mold piece, on top of the polymer cap film;    (c) placing a polymeric foam core over a portion of the first composite layer;    (d) laying up a second composite layer over the polymeric foam core such that the polymeric foam core is substantially encapsulated by the first and second composite layers and further such that the composite layer and the cap film sheet substantially fill the depressed portion of the frame first mold piece;    (e) placing a frame second mold piece over the composite layer;    (f) heating the skate frame to cure the composite layer whereby the polymer cap film adheres to the first composite layer;    (g) removing the skate frame from the frame first and second mold pieces.    
   
   
       12 . The method of  claim 11  wherein the cap film sheet comprises an acrylic and urethane blend.  
   
   
       13 . The method of  claim 12 , wherein the cap film sheet further comprises a decorative design applied to the inner surface of the cap film sheet.  
   
   
       14 . The method of  claim 11 , wherein the composite layer comprises a reinforced fiberglass.  
   
   
       15 . The method of  claim 11  wherein the composite layer comprises a graphite epoxy composite.