Note: Descriptions are shown in the official language in which they were submitted.
CA 02573004 2007-01-05
SPORTS BnARD APPARATUS A.NI.i METHOD
FIELD OF THE INVENTION
(0001] The present invention relates generally to the field of
sports board apparatus and methods, and more specifically to sports
board apparatus and methods for forming sports boards using roll-
formed metal materials.
BACKGROUND OF THE INVENTION
[0002] It is often necessary, be it for the purposes of the
playing of various sports, for safety, or otherwise, to surround
the perimeter of a sports surface (e.g., an ice surface, a sports
field, a ring, and a court) with a sports board apparatus. For
example, the sport of hockey requires boards, often with acrylic
plastic sheets or another substantially transparent and durable
material positioned thereabove. These boards and transparent
sheets rnay preferably serve both to define the area on which the
game is played, and to prevent any projectiles from leaving the
surface and thus disrupting the game or injuring onlookers.
[00033 Of course, hockey and other sports and entertainment may
involve body contact among the competitors and/or movement of
players and sports equipment (e.g_, pucks, balls, other
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projectiles, sticks, other sporting implements and means of
coIlvcYaincc% at cc:iiS_1Cler'a Li~ = ~ -- - w'.:e-'_t }'iGi ~~. _-oort~, _
played wearing, for example, hat'e f?et, es , _C, e sk:ates, or
inline skates. As such, in order to be effective for its intended
purpose, a sports board apparat.us must be capable of withstanding
the impact of any sports equipment and competitors that may have
occasion to collide heavily therewith. Such impacts may occur, for
example, as the result of calculated body checking, equipment
malfunction, and/or misfortune or a lack of skill in traversing the
sports surface.
[0004] It is also very common for multi-purpose use to be made
of sports surfaces. For example, the same sports surface that is
used for hockey may periodically have the ice surface removed
therefrom, so as to be capable of use for basketball, concerts,
equestrian events, and/or various other events. Sometimes, multi-
purpose uses of the sports surface may call for the disassembly of
the sports board apparatus. For these and other reasons, it may be
desirable to provide a sports board apparatus that is capable of
being quickly and easily assembled and disassembled on a regular or
as needed basis, without employing highly skilled workers, and/or
without sacrificing the structural integrity of the sport$ board
apparatus. In this regard, prior art sports board assemblies may
have been woefully inadequate, and/or may possibly have resulted in
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serious injury to such workcrs, wo the sporting competitors, and/or
Lo "iiL-
[0005] In order to provide the necessary strength, many prior
art sports board assemblies may have been constructed, at least in
part, from very heavy metal materials. While such materials may be
structurally sound, they may also be inappropriately unwieldy
and/or cumbersome. Some conventional sports board assemblies may
have included components constructed from extruded aluminum (which
has the benefit of a high resistance to corrosion) and/or hot
rolled structural steel. The use of these materials may have been
prohibitively costly, whether due to (i) the inherent cost of such
materials, (ii) the high amount of labor involved in (the possibly
quite mechanical and/or manual) manufacturing processes which may
heretofore have been used to construct the individual components of
these prior art sports board assemblies from such materials, and/or
(iii) other factors.
[0006] Notwithstanding that light gauge steel (alternately
referred to herein as "LGS") may have similar corrosion resistant
properties to those exhibited by aluminum, LGS -- which may include
coiled stainless steel and the like -- may not have been used
previously as a main structural component of prior art sports board
assemblies. This prior failure to successfully employ LGS, as a
main structural component in a sports board apparatus, may have
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CA 02573004 2007-01-05
been due in part to the shortcomings of LG5 when used in
CO[]vF't1i~10[? ~~C!1IL>U)?:~'tIC rS~UIIt l~[ 1.. . LJ : r.5 i_i n~v I'i .C
i'.i)Ci1t
ha V(- b e "! I-l1 - tllr?11'r n i;ic-~L '_17 C) ?T'1:':~ On
thicker and heavier materials mentioried above.
[0007] In addition to its anti-corrosive properties, LGS has the
further advantage of being highly formable, enabling construction
of components having relatively complex shapes from LGS, through
the use of a series of continuous roller dies. As such, the use of
LGS in a sports board apparatus -- though not previously successful
-- may afford a relatively high efficiency of manufacture (e.g., in
terms of time and money) in comparison with components formed from
prior art sports board materials, without requiring the use of
exceedingly heavy and/or otherwise cumbersome components.
Preferably, such use of LGS in a novel and inventive sports board
apparatus (e.g., according to the present invention) would also
avoid seriously sacrificing the structural integrity of the sports
board apparatus,
[0008] It is thus an object of the present invention to provide
a sports board apparatus comprising posts formed from C-shaped post
channel members nested in clusters for strength.
[0009] It is another object of the present invention to provide
posts which are joined together in a nested fashion.
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[0010] It is yer another object of the presetit invention to
rit el,~ --.r.i~~~~~~~rl
allow passage therethrough of po.1.e5 for iiolc3ing substantially
transparenL sheets of material (e.g., acrylzc plastic sheets).
[0011I It is still another object of the present invention to
provide components of a sports board apparatus in a configuration
that substantially conceals and/or reduces the prominence of all
sharp edges thereof, so as to prevent and/or reduce risk of injury.
[0012] It is also an object of this invention to obviate or
mitigate at least one of the above mentioned disadvantages of the
prior art.
SUl24ARY OF THE INVENTION
[0013] In accordance with the present invention there is
disclosed a sports board apparatus for use with a sports surface
and one or more substantially planar boards. According to the
invention, the apparatus includes a plurality of posts, at least
one web member, and at least one upper support member_ Each upper
support member, each web member, and each of the post channel
members is constructed from a roll-formed metal material. Each of
the posts has a lower end portion and an upper end portion. Each
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of the posts includes two elongate post channel members in securFly
C,fi C5iit-. rfI ]viii_
c..-~.>.7r~C lnri r7;}'i,(a~,,.al
_ ~_
upper end portion. Each of tha post channel members has a post
back wall and two post side walls extending from the post back
wall. The post back wall and the two post side walls are together
shaped to define a substantially C-shaped post channel profile.
Each web member extends substantially between and securely engages
at least two of the posts. Each web member has a web back wall and
two web side walls extending from the web back wall. The web back
wall and the two web side walls are together shaped to define a
substantially G-shaped web profile. Each upper support member
securely engages the at least two of the posts substantially
adjacent to each upper end portion of the at least two of the
posts. Each upper support member and each web member is
operatively securable relative to the boards. Each of the posts is
operatively securable relative to the boards and to the sports
surface, with the lower end portion of each of the posts
operatively positioned substantially adjacent to the sports
surface.
[0014} According to an aspect of a preferred embodiment of the
invention, the metal material may preferably, but need not
necessarily, be a light gauge steel material.
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[0015] According to an aspect of a preferred embodiment ef the
Mo.V F t' T''
.
I1P:O !'ltlt- pa~....,~=?ri .I,~;, rl~=.rc ~ _ r::.,~' ~ r-~ -.,r}~~,- n.,
~~~1~, ; . ..,V~?."1
from one of the post side walls. Each post back wall of each of
the post channeJ, members may preferably, but need not necessarily,
be shaped so as to define a retention depression. According to
this aspect of the invention, in the securely nested relation, the
retention depression of a first one of the two elongate post
channel members may preferably, but need not necessarily, receive
therewithin a substantial extent of the retention member of a
respective other one of the two elongate post channel members.
[0016] According to an aspect of a preferred embodiment of the
invention, a first member and a second member are selected from a
group that may, but need not necessarily, consist of each upper
support member, each web member, and each of the post channel
members. Each of the first member and the second member may
preferably, but need not necessarily, include one or more dimpled
portions. Each of the dimpled portions of the first member may
preferably, but need not necessarily, be in the aforesaid securely
nested relation with a respective one of the dimpled portions of
the second member, so as to form one or more nested pairs of the
dimpled portions.
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[0017] According to an aspect of a preferred embodiment of the
illi"tC1Pr 1P.( I llr'1 <9 '1~.17)":' Ti T
attaching the first member to th~- _econ,-; me:t;!De- of t~.~
mechanical fasteners may preferably, but need not iiecessarily,
extend substantially through a respective one of the nested pairs
of the dimpled portions.
[0016] According to an aspect of a preferred embodiment of the
invention, each of the mechanical fasteners may preferably, but
need not necessarily, include a head portion and a threaded
portion. Each threaded portion may preferably, but need not
necessarily, threadingly engage a respective one of the nested
pairs of the dimpled portions. A substantial extent of each head
portion may preferably, but need not necessaxily, be fully received
within the respective one of the nested pairs of the dimpled
portions.
[0019] According to an aspect of a preferred embodiment of the
invention, each of the posts and the post channel members may
preferably, but need not necessarily, extend in a substantially
upright direction.
(0020] According to an aspect of a preferred embodiment of the
invention, each one of the web member and the upper support member
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may preferably, but need'not necessarily, extend substantia.lly
[00?7.] Acccrding tn an aUpeGt of 7a pre~4r ed :,~kodj,mvi~t of th=~
invention, the web member may preferably, but need not ntcessarily,
have opposing web end portions and flanged web portions. Each of
the flanged web portions may preferably, but need not necessarily,
extend from substantially adjacent to a respective one of the
opposing web end portions, and may preferably, but need not
necessarily, securely engage a respective one of the two of the
posts.
[0022] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include a plurality of mechanical fasteners securely
attaching each of the flanged web portions to the respective one of
the two of the posts.
[0023] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further inc].ude at least one web cover extending substantially
between the two of the posts. The web cover may preferably, but
need not necessarily, securely engage the web member, and may
preferably, but need not necessarily, be constructed from the roll-
formed metal material.
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[0024) According to an aspect oF a preferred embodiment of the
r 1P
COVE'r bdCi: W311. I'}iC CU'/c'i i:idi=:i: walt and the t"v:0 t.cver :a1de:
wali.S
may preferably, but need not necessarily, be together shaped to
define a substantially C-shaped cover profile. Each of the cover
side walls may preferably, but need not necessarily, have a web
retention portion securely engaging the web member over a
respective one of the web side walls.
[0025] According to an aspect of a preferred embodiment of the
invention, the two of the posts may preferably, but need not
necessarily, include a first male end post and a first female end
post. The plurality of posts may preferably, but need not
necessarily, further include a second male end post matingly
engaginq the first female end post. The plurality of posts may
preferably, but need not necessarily, still further include a
second female end post matingly engaging the first male end post.
[0026] According to an aspect of a preferred embodiment of the
invention, one of the post channel members of each male end post
may preferably, but need not necessarily, include a post mating
protuberance. One of the post channel members of each female end
post may preferably, but need not necessarily, include a post
mating depression. Each post mating protuberance may preferably,
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but need not necessarily, matingly enqage a respective one post
1_~,~~ .1 r~~..-
[0027] According to an dspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include post securing means for securely attaching the
first male end post t.o the second female end post and for securely
attaching the first female end post to the second male end post.
[0028] According to an aspect of a preferred embodiment of the
invention, the web back wall may preferably, but need not
necessarily, have a notched web portion defining a web aperture
therethrough. The web member may preferably, but need not
necessarily, securely engage at least three of the posts. The
three of the posts may preferably, but need not necessarily,
include two end posts and a middle post. The web member may
preferably, but need not necessarily, extend substantially between
the two end posts. The middle post may preferably, but need not
necessarily, be positioned between the two end posts and may
preferably, but need not necessarily, be securely received within
the web aperture.
[0029] According to an aspect of a preferred embodiment of the
invention, the upper support member may preferably, but need not
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necessarily, have a notcher_i beam portion defining a beam aperture.
1 1 _ _-_ . . . . ) L t. _ i r - . . _ ... = . l. . . . _ . ._ . . r , __ _ .
_ . _. ~ ._. _ ~ .- . _ . _ .. . . . . .;,r,,,-,-,1 ~~ _,--r .-;-=c, +-Fc +
.~;= ,...: ~ r
support member ttiay preferably, bu', net-d not nervF-ssari'; , c
mechanically fastened to the upper end portion of each of the two
end posts. The middle post may preferably, but need not
necessarily, be securely received within the beam aperture.
[0030] According to an aspect of a preferred embodiment of the
invention, the upper support member comprises a support channel
member, and may preferably, but need not necessarily, have a
support back wall and two support side walls extending from the
support back wall. The support back wall and the two support side
walls may preferably, but need not necessarily, be together shaped
to define a substantially C-shaped support channe], profile. The
upper support member may preferably, but need not necessarily,
further include a first beam and a second beam in substantially
parallel and spaced relation with the first beam. The first beam
and the second beam may preferably, but need not necessarily,
define a beam opening therebetween. Each of the first beam and the
second beam may preferably, but need not necessarily, be positioned
substantially between the two support side walls of the support
channel member.
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[0031] According to an aspect of a preferred embodiment of the
bc'.nR1 Ss.d~ lJcills L-}:tL-P.c1ng trcm the li:'=~ ~i i;ai.'r: wall. Tliz~ bp-
~,?il bac'r:
wall and the two beam side walls may preferabJ.y, but need not
necessarily, be together shaped to define a substantially C-shaped
beam channel profile. The beam back wall of the first beam may
preferably, but need not necessarily, substantially engage a first
one of the support side walls. The beam back wall of the second
beam may preferably, but need not necessarily, substantially engage
a second one of the support side walls.
[0032] According to an aspect of a preferred embodiment of the
invention, the support back wall may preferably, but need not
necessarily, have a notched support portion defining a support
aperture therethrough. Each of the first beam and the second beam
may preferably, but need not necessarily, have a beam back wall and
two beam side walls extending from the beam back wall. Each of the
beam side walls of each of the first beam and the second beam may
preferably, but need not necessarily, have a notched beam portion
defining a beam aperture. The upper support member may preferably,
but need not necessarily, engage at least three of the posts. The
three of the posts may preferably, but need not necessarily,
include two end posts and a middle post positioned between the two
end posts_ Each of the first beam and the second beam may
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preferably, but need not necessarily, be mechanically fastened to
=,-:nst?ntially bet~veen thc two end pcst~. The middle pasz n,ay
preferably, but need not nece.ssarily, be securely received wit}-iin
the support aperture and within each the beam ap2rture.
[0033] According to an aspect of a preferred embodiment of the
invention, each one of the first beam and the second beam may
preferably, but need not necessarily, have two flanged beam
portions. Each of the flanged beam portions may preferably, but
need not necessarily, extend from a first wall that is selected
from the group consisting of the beam back wall and the beam side
walls. Each of the flanged beam portions may preferably, but need
not necessarily, be mechanically fas=tened to the upper end portion
of a respective one of the two end posts.
[0034] According to an aspect of a preferred embodiment of the
invention, the support back wall may preferably, but need not
necessax,ily, be shaped so as to define two or more pole openings
therethrough. The apparatus may preferably, but need not
necessarily, further include two or more poles and a substantially
transparent and substantially planar sheet supported between the
poles. Each of the poles may preferably, but need not necessarily,
extend through the beam opening and through a respective one of the
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pole openings. Each of the poles has a pole base tY at may
nr.-.F~r,h.l, ..=i -,~..a .,-.~ .._ _'__._._-~.. ..~ ..:..._._.:.._..
rõ..__.._.__.., ~'.. ...._..-..
.... ~-.. ..-r?I.1 ...=tt;l{'.... _
[0035] According t-o an asp~---ct of a preferred ecnbouiment of the
invention, the apparatus may prefexably, but need not necessarily,
further include at least one web cover extending substantially
between the two of the posts. The web cover may preferably, but
need not neaessarily, securely engage the web member, and may
preferably, but need not necessarily, be constructed from the roll-
formed metal material. The pole base may preferably, but need not
necessarily, be securely attached to the web cover.
[0036] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one substantially planar top cover
securely engaging the upper support member in substantially
overlying relation, preferably, but not necessarily, substantially
adjacent to each upper end portion of the at least two of the
posts. The poles may preferably, but need not necessarily, extend
through apertures shaped in the top cover.
[0037] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one bottom channel member extending
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substantial].y between and securely e-ngaging each lower end portion
- ~ !, .. , . ~ . .. , .. . . , _ ,_,,.,. :.._ ,_, _ . ... .. ;_ ... .,,
. .-. , . = ..
.._ ;.
wall and two bottorn channel side waJ.J.s evte.ndinq from the L4ott<-7
channel back wall. The bottoin channel back wall and the two bottom
channel side walls may preferably, but need not necessarily, be
together shaped to define a substantially C-shaped bottom channel
profile. The bottom channel member may preferably, but need not
necessarily, be constructed from the roll-formed metal material.
The bottom channel member may preferably, but need not necessarily,
be operatively positioned substantially adjacent to the sports
surface, and may preferably, but need not necessarily, be
operatively securable relative to the boards and to the sports
surface.
[0038] According to an aspect of a preferred embodiment of the
invention, the bottom channel member may preferably, but need not
necessarily, extend substantially horizontally.
[0039] According to an aspect of a preferred embodiment of the
invention, the bottom channel member and at least one of the post
channel members of each of the at least two of the posts may
preferably, but need not necessarily, eacb include one or more
dimpled portions. Each of the dimpled portions of the bottom
channel member may preferably, but need not necegsarily, be in
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securely nested relation with a respective one of the dimplcd
_-'. _ ._ .:.. .
1leCeSSdJ lly, iOrIll ac 1edJt tW0 I:F,c t.i-l;-, di:.r1 ~
portions.
[0040] According to an aspect of a preferred embodiment of the
invention, the apparatus may preferably, but need not necessarily,
further include at least one bottom cover having a bottom cover
back wall and two bottom cover side walls extending from the bottom
cover back wall. The bottom cover back wall and the two bottom
cover side walls may preferably, but need not necessarily, be
together shaped to define a substantially C-shaped bottom cover
profile. Each of the bottom cover side walls may preferably, but
need not necessarily, have a bottom channel retention portion
securely engaging the bottom channel member over a respective one
of the bottom channel side walls. The bottom cover back wall may
preferably, but need not necessarily, have a notched bottom cover
portion defining a bottom cover aperture therethrough. The bottom
cover may preferably, but need not necessarily, extend
substantially between the lower end portion of the two of the
posts, and may preferably, but need not necessarily, be constructed
from the roll-formed metal material. The plurality of posts may
preferably, but need not necessarily, further include a middle post
positioned between the two of the posts. The middle post may
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pr=uFerakily, but need not necessarily, be securely received within
,~. - . _ ,...
i0 0 Tn ;:'cr,:cl=n~ , a.'-h tho t.~res:~nt i:.r:n' ~h re _. ,~
- ._ ._ _
disclosed a method of forming a sports board aFipaxatus for use with
a sports surface and one or more substantially planar boards. The
method includes a post channel forming step, a web forming step,
and an upper support forming step. In the post channel forming
step, at least four post channel members are roll-formed by passing
first elongate sheets of light gauge steel material through a
series of roll-forming post channel tool sets. Passage of the
first elongate sheets through each successive one of the post
channel tool sets progressively forms the post channel members,
such that each of the post channel members has a post back wall and
two post side walls extending from the post back wall, with the
post back wall and the two post side walls being together shaped to
define a substantially C-shaped post channel profile. In the web
forming step, one or more web mernbers are roll-formed by passing
second elongate sheets of light gauge steel material through a
series of roll-forming web tool sets. Passage of the second
elongate sheets through each successive one of the web tool sets
progressively forms the web members, such that each of the web
members has a web back wall and two web side walls extending from
the web back wall, with the web back wall and the two web side
walls being together shaped to define a substantially C-shaped web
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profile. In the upper support forming step, a plurality of beams
, . , . , ,- ,. . . .. .. . .. , ~ , .
i.0ul sF'~S- PasScli-(i_ Ul -Ii__d Li-lioligh aach
successive one of the bearn tool sets progressively forms the beanis.
Each of the post channel members is adapted to be in operative
securely nested relation with another one of the post channel
members to form at least two posts, such that each of the posts has
a lower end portion and an upper end portion, with each of the post
channel members extending longitudinally upward from the lower end
portion to the upper end portion. Each of the web members and each
of the beams is adapted to operatively extend substantially between
and securely engage the two posts, with each of the beams engaging
the two posts substantially adjacent to each the upper end portion
of the two posts. Each of the beams and each of the web members is
operatively securable relative to the boards. Each of the posts is
operatively securable relative to the boards and to the sports
surface, such that the lower end portion of each of the posts is
operatively positioned substantially adjacent to the sports
surface.
[0042] According to an aspect of a preferred embodiment of the
invention, in the post channel forming step, a retention member and
a retention depression may preferably, but need not necessarily, be
roll-formed on each of the post channeJ, members. Passage of the
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CA 02573004 2007-01-05
first elongate sheets through each successive one of the post
, . - , - ._ . ~ , . , _ . .., . .. . . . .. , _ _ ; ~ .
aupF~ssiU:~, ith t-h= ..
necessarily, extending substantially inwardly fx'om one of the post
side walls, and with the retention depression preferably, but not
necessarily, formed in the post back wall, such that in the
operative securely nested relation, the retention depression of the
aforesaid each of the post channel members may preferably, but need
not necessarily, have received therewithin a substantial extent of
the retention member of the another one of the post channel
members.
[0043] According to an aspect of a preferred embodiment of the
invention, the method may preferably, but need not necessarily,
further include a mechanical fastening step of securely attaching a
first member to a second member using a mechanical fastener
extending substantially therethrough. Each of the first member and
the second member may preferably, but need not necessarily, be
selected from a group consisting of the post channel members, the
web members, and the beams.
[0044] According to an aspect of a preferred embodiment of the
invention, the method may preferably, but need not necessarily,
further include a dimpling step before the mechanical fastening
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step, and a nesting step after the dimpling step and before the
marh~.,;,-~1 f~~+-nr,=1.,~r r-+-..... T_. ~i,-. -i,_..,..~:.__ ._'__,. . . .
formed 1n each of t- 1'?r t i r-= t..
nesting step, each of the dimpled portiona of the firat menLber may
preferably, but need not necessarily, be securely nested in the
operative securely nested relation with a respective one of the
dimpled portions of the second member, so as to form one or more
nested pairs of the dimpled portions. According to this aspect of
the invention, in the mechanical fastening step, each of the
mechanical fasteners may preferably, but need not necessarily,
extend substantially through a respective one of the nested pairs
of the dimpled portions, such that a substantial extent of the
aforesaid each of the mechanical fasteners is fully received within
the aforesaid respective one of the nested pairs of the dimpled
portions.
[0045] Accordingly, this invention obviates or mitigates at
least one of the above mentioned disadvantages of the prior art.
[0046] Other advantages, features and characteristics of the
present invention, as well as methods of operation and functions of
the related elements of the structure, and the combination of parts
and economies of manufacture, will become more apparent upon
consideration of the following detailed description and the
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appended claims with refercnce to the accompanying drawings, the
_ . . . . -- = , . _
BlIilaF UE.}lilPl+VIV '~ti a.au ~i,~t1T1r..J~7
[0047] Figure 1 of the drawings appended hereto is a partially
exploded top rear left perspective view of the sports board
apparatus of the present invention, shown with a board and a sports
surface;
[0048] Figur$ 2 is a top plan view of a first post channel
member of the apparatus shown in Figure 1;
[0049] Figure 3 is a top plan view of a second post channel
member of the apparatus shown in E'igure 1;
[0050] Figure 4 is a top plan view of a third post channel
member of the apparatus shown in Figure 1;
[0051] Figure 5 is a top plan view of the middle post shown in
Figure 2;
[00521 Figtire 6 is a top plan view of a male end post in mating
engagement with a female end post, each according to the invention;
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[0053] Figure 7 is a top plan view of an alternate female end
~0 IJ5 "- j i'iCJurca a.1.:~ a tlalli -~.'
in mating engagement with an alternate post according to the
invention;
[0055] Figure 9 is a top rear side perspective view of the
member shown in Figure 2;
[0056] Figure 10 is a top rear side perspective view of the
posts shown in Figure 6;
[0057) Fs.gvre 11 is an exploded view of the posts shown in
Figure 10;
[0058] Figure 12 is a bottom perspective view of a dimpled
portion shown in Figure 1;
[0059] Figure 13 is a side elevational view of a mechanical
fastener engaging a nested pair of dimpled portions, which are
shown in section, according to the invention;
23
CA 02573004 2007-01-05
[0060] Fi.gure 14 is a top sectional view of a cage nut assembly
[0061] Figure 15 zs a left side perspective view of the web
member, and an exploded view of the end post, shown in Figure 1;
[0062] Figure 16 is a top left perspective view of the web cover
shown in Figure 1;
[0063] Figure 17 is an enlarged view of the encircled portion 17
of Figure 16;
[0064] Figure 19 is a top left perspective view of the support
channel member shown in Figure 1;
[0065] Figure 19 is an enlarged view of the encircled portion 19
of Figure 18;
[0066] Figure 20 is an exploded left side perspective view of
middle post and the first and second beams shown in Figure 1;
[0067] Figure 21 is top left perspective view of the apparatus
in Figure 1, showing the fully assembled panel;
24
CA 02573004 2007-01-05
[0068] Figure 22 is a top left perspective view of the panel of
[ ( I n t; 1 !.'s 1.,r_e 23 1 s a ?. _lay 7, C _gur , :iruc
alternate panels according to tflu invention, each adjacent to each
other.
nF,TAILED DESCRIPTION OF A pREFERRED EMBQDI2MENT
[0070] Referring now to Figure 1 of the drawings, there will be
seen a sports board apparatus 40 for use with a sports surface 30
and one or more substantially planar boards 32. As best seen in
Figure 1, the apparatus 40 includes a plurality of posts
50a,50b,50c, at least one web assembly 150, at least one upper
support member 180, and at least one bottom support member 229.
The web assembly 150 preferably includes a web member 152 and a web
cover 154 (as best seen Figure 16) that securely engages the web
member 152. The upper support member 180 preferably includes a
support channel member 181 (as best seen in Figure 1B) and first
and second beams 210,212 (as best seen in Figure 20). As best seen
in Figure 1, the bottom support member 229 preferably includes a
bottom channel member 230 and a bottom cover 240 that securely
engages the bottom channel member 230.
CA 02573004 2007-01-05
[0071] The posts 50 may preferably include at least three posts,
preferably positioned between the two end posts 50a,50c_ Each of
the posts 50a,50b,50c has a lower end 54 portion and an upper end
52 portion.
[0072] Each of the posts 50a,50b,50c includes two elongate post
channel members 60,80,100 in securely nested relation with one
another. The post channel members 60,80,100 include a first post
channel member 60 (as best seen in Figure 2), a second post channel
member 80 (as best seen in Figure 3), and a third post channel
member 100 (as best seen in Figure 4).
[0073] The post channel members 60,80,100, the web members 152,
the web covers 154, the support channel members 181, the first beam
210, the second beam 212, the bottom channel member 230, and/or the
bottom cover 240 are constructed from a roll-formed metal material.
The metal material is preferably a light gauge steel material.
[0074] As best seen in Figure 1, each of the post channel
members 60,80,100 extends longitudinally upward from the lower end
portion 54 to the upper end portion 52. Each of the posts
26
CA 02573004 2007-01-05
50a,50b,50c and the post channel rnembers 60,80,100 preferably
' ..1_. - 4 ~ _- _ ' _ = nv!-rn,..i.. . _ _ . ,::_. _ ~ ,.,~. ; = - ; , ..
= l
t:E: L~V~.:i.
-
channel membnrs 60,80,100 has a post back wall 70,90,110 and two
post side walls, 62,64, 82,84, and 102,104, extending from the post
back wall 70,90,110. As best seen in Figure 11, (i) the post back
wall 70 of the first post channel member 60 is shaped to define a
bolt aperture 122 therethrough, (ii) the post back wall 90 of the
second post channel member 80 is shaped to define a cage aperture
120 therethrough, and (iii) the post back wall 110 of the third
post channel member 100 is shaped to define an access port 124
therethrough.
[0076] As best seen in Figures 2, 3 and 4, each of the post
channel members 60,80,100 preferably has a retention member
66,86,106 extending inwardly from one of the post side walls
62,82,102. Similarly, each of the post channel members 60,80,100
preferably has a nesting member 68,88,108 extending inwardly from
another one of the post side walls 64,84,104.
[0077] Each post back wall 70,90,110 of each of the post channel
members 60,80,100 is preferably shaped so as to define a retention
depression 72,92,112 substantially adjacent to one of the post side
walls 64,84,104.
27
CA 02573004 2007-01-05
[00781 The post back wall 70,90,110 and the two post side walls,
f
, (~ = :,. :r -
fD 05~ ofil % U u
aI 1 Cj
seen in Figures 2, 3 and 4).
[0079] The two elongate post channel members 60,80,100 are
securely nested relation with one another. As best seen in Figure
6, the male end post 50a includes the second post channel member 80
and the third post channel member 100 in securely nested relation
with one another. As best seen in Figure 5, the middle post 50b
preferably includes two third post channel members 100 in securely
nested relation with one another. As best seen in Figure 6, the
female end post 50c includes the first post channel member 60 and
the third post channel member 100 in securely nested relation with
one another. An alternate embodiment of the female end post S0c is
shown in Figures 7 and 8, which includes two first post channel
members 60 in securely nested relation with one another. An
alternate embodiment of a post 50 is shown in Figure 8, which
possesses both male and female characteristics, and which includes
the fixst post channel members 60 and the second post channe7,
member 80 in securely nested relation with one another. Of course,
other nested embodiments are also possible.
28
CA 02573004 2007-01-05
[0080] In order to readi]y accommodate the aforesaid nesting,
a. L_ _ , . _ _ . ~ r ~ ! ,r _ _ - . . .. _. . . .. . _ = .. ' . . .
' . .. . I ' ' .. = ..._ , . . .. - . , . . . . . . _.,. ... - ...._ . _
JLI.iC: W:.a.i~- C) c. _S .2
[0081] In the aforesaid securely nested relation, and as best
shown in Figures 5 and 6, a substantial extent of the retention
member 66,86,106 of one of the post channel members 60, 80, 100 is
preferably received within the retention depression 72,92,112 of
another one of the two elongate post channel members 60,80,100.
[0082] In order to readily accommodate the aforesaid nesting,
the length A,A',A" of the retention member 66,86,106 is pre.ferably
less than the length B,B',B" of the retention depression 72,92,112
(as best shown in Figures 2-6). Similarly, the thickness E,E',E" of
the retention member 66,86,106 is preferably less than the depth
F,F',F" of the retention depression 72,92,112.
[00B3] Each web member 152 extends substantially between at
least two of the posts 50, and preferably extends substantially
horizontally (as best seen in Figure 1). As best seen in Figure
15, each web member 152 has a web back wall 165 and two web side
walls 166 extending from the web back wall 165. The web back wall
165 preferably has a notched web portion 156 that defines a web
aperture 158 therethrough (as best seen in Figure 1).
29
CA 02573004 2007-01-05
[0084] Preferablv, and as best seen in Figurc 1, each web member
,., ,.~õ.-_,. _ _. _ : ; ; õ ,=, .. , _ .,,. . - : :
, .. _ , .
p ~-~-'+~.~
preferably extends substantialiy between the two end posts 50a,50c,
with the middle post 50b preferably being securely received within
the web aperture 158.
[0085] As best seen in Figure 15, the web back wall 165 and the
two web side walls 166,166 are together shaped to define a
substantially C-shaped web profile 166,165,166. The web member 152
preferably has opposing web end portions 162 and flanged web
portions 160. Each of the flanged web portions 160 preferably
extends from substantially adjacent to a respective one of the
opposing web end portions 162. As best seen in Figures 1 and 15,
each of the flanged web portions 160 preferably securely engages a
respective one of the two of the posts 50 (through web flange holes
164).
[0086] As best seen in Figure 1, the web cover 154 preferably
extends substantially between the two end posts 50a,50c. As best
seen in Figure 16, the web cover 154 preferably has a cover back
wall 173 and two cover side walls 174,174 extending from the cover
back wall 173. The cover back wall 173 and the two cover side
CA 02573004 2007-01-05
walls 174,174 are preferably together shaped to define a
rnnE. - ,
cover portion 170 that defiries a caver aperture 172 therethrough
(as best seen in Figure 1). The middle post 50b is preferably
securely received within the cover aperture 172.
[0088] As best seen in Figure 17, each of the cover side walls
174,174 preferably has a web retention portion 176. As aforesaid,
and as best seen in Figure 1, the web cover 154 securely engages
the web member 152, with the web retention portions 176 preferably
securely engaging the web member 152, each over a respective one of
the web side walls 166.
[0089] As best seen in Figure 1, each upper support member 180
preferably extends substantially horizontally_ As best seen in
Figures 18 and 19, the support channel member 181 preferably has a
support back wall 187 and two support side walls 188,188 extending
from the support back wall 187. The support back wall 187 and the
two support side walls 168,1$8 are preferably together shaped to
defzne a substantially C-shaped support channel profile
188,187,188. The support back walJ. 187 is preferably shaped so as
to define two or more pole openings 186 therethrough.
31
CA 02573004 2007-01-05
[0090] As best seen in F'igure 18, the support back wall 187 also
_r=.. ~t,~ ~_.. ,wõ-r _ .-._.-. =. _ ~ . = _
. . _!..I..~y '_e ir'-1v.==!ri
[0091] As best seen in Figure 1, the support channel member 181
preferably extends substantially between the two end posts 50a,50c.
As best seen in Figure 20, the second beam 212 is preferably in
substantially parallel and spaced relation with the first beam 210,
such that the first beam 210 and the second beam 212 preferably
define a beam opening 214 therebetween. Each of the first beam 210
and the second beam 212 preferably has a beam back wall 215 and two
beam side walls 217,217 extending from the beam back wall 215. The
beam back wall 215 and the two beam side walls 217,217 are
preferably together shaped to define a substantially C-shaped beam
channel profile 217,215,217.
[0092] As best seen in Figure 1, each of the first beam 210 and
the second beam 212 is preferably positioned substantially between
the two support side walls 188 of the support channel member 181.
The beam back wall 215 of the first beam 210 preferably
substantially engages a first one of the support side walls 188.
The beam back wall 215 of the second beam 212 preferably
substantially engages a second one of the support side walls 188.
32
CA 02573004 2007-01-05
[0093] As best seeri in Figure 20, each of the beam side walls
?l '7 '.,~ t ar + n: ~ .
~ L . . . , . .. -
i.<<.__
within the beam aperture 220.
[0094] With the middle post 50b received within the beam
aperture 220, beam retention portions 189 on each of the support
side walls of the support channel member 181 act to impede
separation of the beams 210,212 from the support channel member
181.
[0095] Each one of the first beam 210 and the second beam 212
preferably has two flanged beam portions 219,219 (as best seen in
Figure 1). Each of the flanged beam portions 219,219 preferably
extends from the beam back wall 215. Each of the flanged beam
portions 219,219 is preferably mechanically fastened, through beam
flange holes 221, to the upper end 52 portion of a respective one
of the two end posts 50a,50c.
[0096] In this manner, the upper support member 180 preferably
securely engages the two end posts 50a,50c and the middle post 50b
substantially adjacent to each upper end 52 portion thereof.
33
CA 02573004 2007-01-05
[0097] As best shown in Figure 1, the bottom channel member 230
1;:i311 2 .::J. iile I
channel side walls 236,236 are preferably together shaped to define
a substantially C-shaped bottom channel profile.
[0098] As best shown in Figure 1, the bottom cover 240 has a
bottom cover back wall 241 and two bottom cover side walls 242,242
extending from the bottom cover back wall 241. The bottom cover
back wall 241 and the two bottom cover side walls 242,242 are
preferably together shaped to define a substantially C-shaped
bottom cover profile 242,241,242. The bottom cover back wall 241
preferably has a notched bottom cover portion 232 defining a bottom
cover aperture 234 therethrough.
[0099] As best shown in Figure 1, each of the bottom cover side
walls 242,242 preferably has a bottom channel retention portion 243
securely engaging the bottom channel member 230 over a respective
one of the bottom cbannel side walls 236,236.
[0100] As best shown in Figure 1, the bottom channel member 230
extends substantially horizontally and substantially between each
lower end portion 54 of the two end posts 50a,50c. The bottom
cover 240 preferably extends substantially between the lower end 54
34
CA 02573004 2007-01-05
portion of the two end posts 50a,50c. The bottom channel member
[0101] As shown in Figure 21, the exploded apparatus 40 may be
assembled into a sports board panel 140. Multiple panels
140, 140, 140 may be connected end to end, as shown in Figure 22.
Figure 23 depicts alternate panels 140',140' connected end to end,
with each of said alternate panels 140' including three middle
posts 50b.
[0102] In each of the panels 140,140' shown in Figures 21 to 23,
the posts 50a,50b,50c include a first male end post 50a and a first
female end post 50c, amongst other things. Similarly, and as best
seen in Figures 22 and 23, each of the adjacent panels 140,140'
includes a second male end post 50a' and a second female end post
50c'. As best seen in Figure 10, the second male end post 50a'
matingly engages the first female end post 50c. As best seen in
Figure 11, the second female end post 50c' matingly engages the
first male end post 50a.
[0103] One of the post channel members 80 of each male end post
50a,50a' preferably includes a post mating protuberance 96 (best
seen in Figure 6). Similarly, one of the post channel members 60
CA 02573004 2007-01-05
of each female end post 50c,50c' preferably includes a post mating
[0104] Preferably, and as best seen in Figure 14, the apparatus
40 further includes post securing means 200 (alternately referred
to herein as a caged nut assembly 200) for securely attaching the
first male end post 50a to the seeond female end post 50c' and for
securely attaching the first female end post 50c to the second male
end post 50a'. The caged nut assembly 200 includes a bolt 202, a
nut 204, and a cage 206. The cage 206, with the nut 204 secured
therein, is itself secured adjacent to the cage aperture 120 on the
third post channel member 100. The bolt 202 extends through the
bolt aperture 122 of the second post channel member 80, and is
tightened against the nut 204, such that the third post channel
member 100 and the second post channel member 80 are securely
attached to one another. In this manner, the first male end post
50a may be tightened against the second female end post 50c', and
the first female end post 50c may be tightened against the second
male end post 50a'
[0105] The apparatus 40 preferably further includes two or more
poles 226 and a substantially transparent and substantially planar
sheet 224 supported between the poles 226. Each of the poles 226
36
CA 02573004 2007-01-05
preferably extends through the beam opening 214 and through a
- . -- .. -i _ , -- _
C; :CL .!.._ . ? .;1 S Gc L3
_ . ., - _ .A-
[0J.06] According to one aspect of the invention, a first member
and a second member are selected from a group that preferably
consists of the posts 50, the upper and lower end pork,ions 52,54 of
the two end posts 50a,50a',50c,50c', the post channel members
60,80,100, the web member 152, the flanged web portions 160, the
upper support member 180, the first beam 210, the second beam 212,
the flanged beam portions 219,219, and the bottom channel member
230.
[0107] The apparatus 40 preferably further includes a plurality
of mechanical fasteners 190 (as best seen in Figure 13) securely
attaching the first member to the second member. Each of the
mechanical fasteners 190 preferably includes a head portion 192, a
threaded portion 196, an underside ridge portion 194, and a self-
drilling portion 198.
[0108] As best shown in Figures 12 and 13, each of the first
member and the second member pxeferably includes one or more
dimpled portions 130. Each of the dimpled portions 130 preferably
37
CA 02573004 2007-01-05
includes a downset portion 132, an underside matirig portion 134,
13~
130 of the first member is preierably in securely nested relation
with a respective one of the dimpled portions 130 of the second
member, so as to form one or more nested pairs 138 of the dimpled
portions 130. Each of the mechanical fasteners 190 preferably
extends substantially through a respective one of the nested pairs
138 of the dimpled portions 130. Each threaded portion 196
preferably threadingly engages a respective one of the nested pairs
138 of the dimpled portions 130. The underside ridge portion 194
engages the undezside mating portion 134 adjacent the downset
portion 132, and the self-drilling portion 198 may preferably
create the dimple opening 136. A substantial extent of each head
portion 192 is preferably fully received within the respective one
of the nested pairs 138 of the dimpled portions 130.
[0110] Mechanical fastening may also occur without the presence
of dimpled portions 130. For example, mechanical fasteners 190 are
preferably used to securely attach each of the flanged web portions
160 to a respective one of the two end posts 50a,50c (as
aforesaid). In another example, mechanical fasteners 190 are
preferably used to securely attach each of the flanged beam portion
38
CA 02573004 2007-01-05
219 to a r2spective one of the two end posts 50a,50c (as
further includes at least one substantially planar top cover 222
securely engaging the upper support member 180 in substantially
overlying relation, preferably substantially adjacent to each upper
end 52 portion of the two end posts 50a,50c. The poles 226
preferably extend through apertures 223 shaped in the top cover
222.
[0112] As best seen in Figure 1, each post 50a,50b,50c, each web
member 152, each web cover 154, each upper support member 180,
and/or each bottom support member 229 is operatively securable
relative to the boards 32. The lower end portion 54 of each post
50a,50b,50c, each bottom channel member 230, and each bottom cover
240 is operatively positioned substantially adjacent to the sports
surface 30. Each post 50a,50b,50c, each bottom channel member 230,
and/or each bottom cover 240 is operatively securable relative to
the sports surface 30.
[0113] In accordance with the present invention there is also
disclosed a method of forming a sports board apparatus 40 for use
with a spoxts surface 30 and one or more substantially planar
boards 32. The method includes a post channel forming step, a web
39
CA 02573004 2007-01-05
forming step, an upper support forming step, and a mechanical
. _,,,~ , _ ,.. _,.- ,=. . ..
iiirlivg ii.C_1 i.:..:1~~:1_ i.~.[0114] In the post channel forming step, at
least four of the
post channel members 60,80,10p are roll-formed by passing first
elongate sheets (not shown) of light gauge steel matexial through a
serzes of roll-forming post channel tool sets (not shown). Passage
of the first elongate sheets through each successive one of the
post channel tool sets progressively forms the post channel members
60,80,100.
[0115] In the post channel forming step, the retention member
66,86,106 and the retention depression 72,92,112 are preferably
roll-formed on each of the post channel members 60,80,100. Passage
of the first elongate sheets (not shown) through each successive
one of the post channel tool sets (not shown) preferably
progressively forms the retention member 66,86,106 and the
retention depression 72,92,112_
[0116] In the web forming step, one or more of the web members
152 is roll-formed by passing one or more second elongate sheets
(not shown) of light gauge steel material through a series of roll-
forming web tool sets (not shown). Passage of the second elongate
CA 02573004 2007-01-05
sheets thxough each successive one of the web tool sets
beams 210,212 is xoJ..7.-tormed by passing one or more third elongate
sheets (not shown) of light gauge steel material through a series
of roll-forming beam tool sets (not shown). Passage oi the third
elongate sheets through each successive one of the beam tool sets
progressively forms =the beams 210,212.
[0118] The method may also include other roll-forming steps,
e.g., a web cover roll-forming step, a support channel roll-forming
step, bottom channel roll-forming step, and/or a bottom cover roll-
forming step. These other roll-forming steps are not further
described herein, but fall generally within the scope of the
invention.
[0119] The method may also include bending steps, e.g., a beam
flange bending step and/or a web flange bending step. These bending
steps are not further described hexei.n, but fall generally within
the scope of the invention.
[0120] In the dzmpling step, one or more of the dimpled portions
130 is preferably formed in each of the first member and the second
member.
41
CA 02573004 2007-01-05
[0121] The method may also include aperture p.inchind steps,
_,.._. ~... ~~~_- ~;~,~~ r:_,.._..-= _ _ --_ --=-~- . _---- -~=~ --_ - -.-_
~_._.:....
invention.
[0122] In the nesting step, each of the post channel members
60,80,100 is positioned in operative securely nested relation with
another one of the post channeJ, members 60,80,100 to form at least
two posts 50a,50b,50c. The aforesaid securely nested relation is
such that each of the post channel members 60,80,100 extends
longitudinally upward from the lower end portion 54 to the upper
end portion 52. The retention depression 72,92,112 of each of the
post channel members 60,80 preferably has received therewithin a
substantial extent of the retention member 66,86,106 of a nesting
one of the post channel members 60,80,100. Each of the dimpled
portions 130 of the first member is also preferably securely nested
in the aforesaid operative securely nested relation with a
respective one of the dimpled portions 130 of the second member.
In this manner, one or more of the nested pairs 138 of the dimpled
portions 130 are assembled.
[0123] In the mechanical fastening step, the first member
(described in greater detail hereinabove) is securely attached to
the second member (described in greater detail hereinabove) using a
42
CA 02573004 2007-01-05
mechanical fastener 190 extendirig substantially therethrough_ Each
[0124] In the mechanical fastening step, each of the mechanical
fasteners 190 preferably extends substantially through a respective
one of the nested pairs 138 of the dimpled portions 130. Tihxs
mechanical fastening is such that a substantia7. extent of each of
the mechanical fasteners 3.90 is fully received within the aforesaid
respective one of the nested pairs 138 of the dimpled portions 130.
[0125] Operatively, each of the web members 152 and each of the
beams 210,212 extends substantially between and securely engages
the at least two posts 50a,50b,50c. Each of the beam members
operatively engages the at least two posts 50a,50b,50c
substantially adjacent to the upper end portion 52 thereof. Each
of the beams 210,212 and each of the web members 152 is operatively
secures relative to the boards 32. Each of the posts 50 is
operatively secured relative to the boards 32 and to the sports
surface 30, such that the lower end portion 54 of each of the posts
50 is operatively positioned substantially adjacent to the sports
surface 30.
43
CA 02573004 2007-01-05
[0126] As aforesaid, Che sports boaxd apparatus 40 includPs
. , -, _~,=,_ -, _. _ _ , =
-- ___ _~.- _ = .
together in a nested fashion. The first and second beams 210,212
are provided, as aforesaxd, in spaced relation from one another so
as to define an elongate beam opening 214 therebetween, which
allows passage therethrough of the poles 225 for securely holding
the transparent planar sheet 224 (e.g., an acrylic plastic sheet).
The configuration of the components of the sports board apparatus
40 according to the present invention in such as to substantially
conceal and/or reduce the prominence of sharp edges thereon, so as
to prevent and/or reduce risk of injury.
[0127] It should be additionally appreciated (i.e., from all of
the foregoing, from the claims, and from the drawings) that the use
of LGS in the sports board apparatus 40 according to the invention
provides significant anti-corrosive properties. The use of LGS
according to the present invention provides a highly formable
material and enables construction of components having relatively
complex shapes from LGS, through the use of a series of continuous
roller dies. As such, the components of the sports board apparatus
40 according to the present invention allow for a relatively high
efficiency of manufacture (e.g., in terms of both time and moneX)
over components formed from prior art sports board materials. The
44
CA 02573004 2007-01-05
present invention does not require the use of exceedingly heavy
[01281 Other modifications and alterations may be used in the
design and manufacture of other embodiments according to the
present invention without departing from the spirit arad scope of
the invention, which is limited only by the accompanying Glaims.
