Method for manufacturing professional grade skateboard decks using recycled wood fiber veneer substrate

Abstract

An environmentally friendly composite material for use in the manufacture of professional grade skateboard decks and other high quality equipment and sporting gear. In the one embodiment, a skateboard deck is manufactured from a composition of recycled hard rock maple wood fibers, a polyvinyl acetate adhesive, a cross-link catalyst and water. The malleable nature of the composite material prior to curing, allows the skateboard deck to attain virtually any desired shape. Differing composites and adhesives may be employed to achieve the a similar product when properly cured. Once cured, the composite material is light weight, strong, durable, and requires no lacquers or other sealers.

1 . A material composition for planar objects comprising:
 a range of thirty percent to fifty percent by weight of polyvinyl acetate adhesive;   a range of one percent to five percent by weight of liquid cross-link catalyst;   a range of thirty percent to fifty percent by weight of recycled hard rock maple wood fibers; and   a range of fifteen percent to twenty percent by weight of water.   
     
     
         2 . A skateboard deck comprising:
 a first structural layer comprising recycled wood;   a second structural layer comprising of an adhesive;   a bonding layer for permanently attaching said first structural layer to said second structural layer; and   a mounting means disposed to receive two or more trucks.   
     
     
         3 . The skateboard deck of  claim 2 , wherein said skateboard is from 7.5 to 8.5 inches in width. 
     
     
         4 . The skateboard deck of  claim 2 , wherein said skateboard is from 31 inches (78.74 centimeters) to 34 inches (86.36 centimeters) in length. 
     
     
         5 . The skateboard of  claim 3 , wherein said skateboard is from 4.0 inches (10.16 centimeters) to 4.2 inches (10.67 centimeters) in thickness. 
     
     
         6 . The skateboard of  claim 4 , wherein said skateboard is from 2.8 lbs. (1.27 kilograms) to 3.2 lbs. (1.45 kilograms) in weight. 
     
     
         7 . The skateboard deck of  claim 2  wherein said bonding layer further comprises polyethylene. 
     
     
         8 . The skateboard deck of  claim 2 , wherein said recycled wood is selected from the group consisting of maple wood fibers, recycled maple wood fibers, hard rock maple wood fibers, recycled hard rock maple wood fibers, maple wood dust, recycled maple wood dust, hard rock maple wood dust, and recycled hard rock maple wood dust. 
     
     
         9 . The skateboard deck of  claim 2 , wherein said adhesive is a polyvinyl acetate. 
     
     
         10 . The skateboard deck of  claim 2 , wherein said deck is from 10 centimeters to 45 centimeters in width. 
     
     
         11 . The skateboard deck of  claim 2 , wherein said deck is from sixty centimeters to one hundred centimeters in length. 
     
     
         12 . The skateboard deck of  claim 2 , wherein said deck is from six to fifteen millimeters in thickness. 
     
     
         13 . The skateboard deck of  claim 2 , wherein said deck is from one to two kilograms in weight. 
     
     
         14 . A method of manufacturing skateboard decks comprising the steps of:
 fabricating a mold;   placing recycled wood fibers onto mold;   placing a polyvinyl acetate adhesive onto the inferior side of a polyethylene sheet;   placing said inferior side of said polyethylene sheet directly onto said wood fibers;   applying pressure to the mold to form a veneer;   curing said veneer from 35 to 60 hours;   abrasing said veneer surface;   applying 4 to 5 layers of polyvinyl acetate adhesive onto veneer surface;   running said veneer through heat machine;   making perforations on veneer with a roller;   enclosing the veneer between 2 polyethylene sheets;   placing the veneer onto a mold under pressure; and   curing said veneer from 1 to 2 weeks.   
     
     
         15 . The method of  claim 14 , wherein a die is applied to render the resulting veneer colored. 
     
     
         16 . The method of  claim 14 , wherein the veneer is cured utilizing a radio frequency.