EP0394835B1 - Process of manufacture for ski and ski manufactured by this process - Google Patents

Abstract

A simple and cost-effective process of manufacturing a ski is to be made available. For this purpose, an upper part (10) of the ski, consisting at least of a covering layer (12), is formed in a mould (18, 20) in such a way that flange-type edges (22) are moulded onto the covering layer (12). A bottom part of the ski is placed on the top part (10) of the ski in such a way that it is flush in the edge region with the flange-shaped edges (22) and finally the bottom part of the ski and the top part (10) of the ski are joined together. <IMAGE>

Description

The invention relates to a ski manufacturing method according to the first part of claim 1 and a ski that is manufactured according to this method.

While skis were previously made from several layers of wood, today they consist of layers of very different materials, mostly plastic, metal and possibly also wood.

When making skis, these layers have to be connected in a suitable manner. The individual layers are connected to each other in mostly very complex processes that are cumbersome and expensive.

A generic method is already known from CH-A-483,851.

Based on this state of the art, the task arises to simplify or rationalize the manufacturing process and in particular the storage of ski tops.

This object is achieved on the basis of a generic method according to the invention by the features of the characterizing part of patent claim 1. Overall, in the first process step, a ski upper part is manufactured in a form specifically provided for it, which is then connected in a second process step to a ski lower part of the common type.

The ski top manufactured in the molding process consists, for. B. from a cover layer, a core and laterally inserted side damper layers. The cover layer is shaped during the molding process in such a way that it forms flange-like edges which rest on the lower part of the ski during assembly, so that in the second process step, connecting the lower part of the ski to the upper part of the ski, an additional connection of the two parts via the flange-like edges is possible is. The flange-like edges are formed in a constant width and are only brought to their final shape after removal from the mold, the excess being able to be milled away, for example. This results in the solution according to the invention for the production process, which consists in the fact that for skis which have a different profile in plan view, i. H. for their manufacture each would have to have its own molds with differently designed edge regions, only one mold with a constant straight edge must be present. Through the previously described milling of the flange-like edges, the upper part of the ski is then adapted to the respective shape of the lower part of the ski. This ski base can be of any type. For example, it consists of a polyethylene tread bordered by steel edges, over which a lower flange is arranged.

The ski top can also be prefabricated without a core and side damper layers. In this case, the individually prefabricated upper part of the ski and lower part of the ski can be connected in an advantageous manner by foaming the core region of the upper part of the ski that is left free, for example with polyurethane or a similar material. In this way, the prefabricated upper part of the ski is connected to the prefabricated lower part of the ski and the enclosed empty space thus formed is foamed to form the core of the ski.

Another advantage results from the fact that a decorative layer is placed in the mold box of the mold below the cover layer which has a supporting function and which, of course, lies on the surface of the upper part after the upper part has been removed from the mold box. The decorative layer can either cover only the surface of the upper part of the ski or the surface as well as the side edges of the upper part of the ski.

The process step of ski top shaping can be designed in an advantageous manner in that the cover layer consists of one or more layers which are flexible at ambient pressure and ambient temperature before the final molding process. With these flexible layers, the shape can be designed before the core and side damper layers are inserted. Covering layers made of an epoxy prepreg or a polyester prepreg of the usual commercial form are suitable for this procedure.

After the individual parts of the upper part of the ski have been arranged in the mold and the molding box has been closed with the mold cover, the upper part of the ski is connected to a stable molded body at suitable temperature and pressure by polymerization.

An alternative embodiment of the method according to the invention consists in the fact that the cover layer consists of a thermoplastic shell inserted into the mold.

It proves to be advantageous to also place the decorative layer optionally provided in addition to the cover layer as flexible layers in the molding box before the final molding process at ambient pressure and temperature. Epoxy prepregs or polyester prepregs can in turn be used here.

Alternatively, however, the decorative layer can also be designed as a thermoplastic layer or thermoplastic shell.

Finally, improved damping properties compared to longitudinal vibrations can advantageously be achieved if a damper layer made of the most entropy-elastic material, for example an elastomer, is inserted in the binding region of the ski between the cover layer and the core. By means of the previously described method for shaping the upper part of the ski, a ski can be produced in a simple manner which has a upper part of the ski which is trapezoidal in cross-section, the side surfaces being inclined at a constant angle.

Fig. 1:

Einen Querschnitt durch den Skioberteil, der nach dem erfindungsgemäßen Verfahren hergestellt wird, in der geschlossenen Form;

Fig. 2:

Einen Längsschnitt entlang der Schnittlinie A-A gem. Fig. 1;

Fig. 3:

Eine andere Ausführungsform eines gem. des erfindungsgemäßen Verfahrens geformten Skioberteils innerhalb der Form im Querschnitt und

Fig. 4:

Einen Längsschnitt entlang der Schnittlinie B-B gem. Fig. 3.

Further details and features result from the description of exemplary embodiments shown in the drawing. Show it:

Fig. 1:

A cross section through the upper part of the ski, which is produced by the method according to the invention, in the closed form;

Fig. 2:

A longitudinal section along the section line AA acc. Fig. 1;

Fig. 3:

Another embodiment of a gem. of the method according to the invention molded ski top within the shape in cross section and

Fig. 4:

A longitudinal section along the section line BB acc. Fig. 3.

In Fig. 1, the molding step of the ski top 10 is shown in a form consisting of a mold box 18 and a mold cover 20. Before closing the molding box 18 with the molding lid 20, a decorative layer 24 is placed on the bottom of the molding box 18. This decorative layer 24 is flexible at ambient pressure and ambient temperature. It consists of an epoxy prepreg or alternatively, for example, of a polyester prepreg.

A cover layer 12 is placed on this decorative layer, which is also flexible at ambient pressure and temperature. This cover layer is also laid along the side walls which are inclined at an angle α with respect to the vertical. At the upper end of the molding box 18, the still flexible cover layer 12 is then bent in such a way that it forms a flange-shaped edge 22. Since the cover layer 12 is a load-bearing layer, it is reinforced. For this purpose, fiber-proven mats or carbon inserts are used.

A core 14 is placed on this cover layer, which can consist of any ski building material customary for cores. For example, a foamed plastic. Between the core 14 and the laterally raised cover layer 12, triangular side damper layers 16 are inserted into the mold in cross section. These side damper layers 16 are, for example Made of an elastomer and serve to protect the core from the side.

After all of these ski components have been introduced, the mold is closed with the mold cover 20 and, under suitable pressure and at a suitable temperature, the individual layers are polymerized with one another, so that a dimensionally stable ski upper part 10 is produced.

From the longitudinal section of FIG. 2 it can be seen how the molding box 18 is shaped according to the thickness distribution over the length of the upper part of the ski. The core 14 of the upper part 10 of the ski is made thicker from the longitudinal center of the ski, i.e. exactly in the area in which the ski binding will be arranged later. Towards the center of the ski and towards the ski shovel, the thickness of the core decreases, as shown in FIG. 2.

After a shape-retaining ski upper part has been obtained by the molding process, this is removed from the molding box 18 and the flange-shaped side edges 22 are milled in accordance with the final shape of the ski.

The upper ski part prepared in this way is applied to a lower ski part of a conventional design (not shown) and glued to it in the usual way. In addition, for a better connection, the upper ski part 10 can be connected to the lower ski part, not shown, along the flange 22 using conventional fastening means. The lower ski part can consist, for example, of a polyethylene tread which is bordered by means of steel edges, a lower flange usually being arranged above the polyethylene tread. However, it can also be any other lower ski part with a ski upper part 10, which according to the previously described sequence of processes was connected.

3 and 4, a ski upper part 10 is also shown in the mold 18, 20 during the molding process. According to this exemplary embodiment, however, a further substep is added to the method for producing the ski during the method step of assembling the upper ski part 10. After the covering layer 12 has been applied and before the core 14 has been inserted, the bond area, i.e. in the area on which the bond is later applied, an entropy-elastic damper layer as possible. This advantageously consists of an elastomer. The length of the damping element 26 is designated by L in FIG. 4. L can typically vary in a range of 500-700 mm. The length of the area L depends on on the total length of the ski.

As an alternative to the manufacturing method for the upper part of the ski explained in the figures, this can also be formed by leaving a corresponding empty space in place of the inserted core 14 and optionally the side damper layers 16. For this purpose, the mold cover 20 can have a corresponding bulge (not shown in the figures). This modified upper part of the ski is then connected to a lower part of the ski, at the same time the empty core area is foamed, for example with polyurethane or a similar material.

Claims (16)

1. Process for the manufacture of a ski, comprising the following steps:

   - forming a ski upper part (10) comprising at least a cover layer (12) in a die such that flange-like rims (22) are moulded integral with the cover layer (12);

   - placement of a ski lower part onto the ski upper part (10) such that it is covered in the rim area by the flange-like rims (24); and

   - joining of the ski upper part (10) with the ski lower part,

   characterised in that,
   the flange-like rims (22) are formed with a constant rim width, and that the rims (22) on removal of the ski upper part (10) from the die box (18) are worked to their final shape.
2. Process according to Claim 1, characterised in that a decorative layer (24) is inserted in the die box (18) below the cover layer (12).
3. Process according to claims 1 or 2, characterised in that the cover layer (12) is inserted in the die box (18), said cover layer (12) prior to the final forming process comprising flexible layers at ambient pressure and ambient temperature.
4. Process according to Claim 3, characterised in that the cover layer (12) comprises an epoxy prepreg with inlaid reinforcement material.
5. Process according to Claim 3, characterised in that the cover layer (12) comprises a polyester prepreg with inlaid reinforcement material.
6. Process according to one of claims 4 or 5, characterised in that the reinforcement material is carbon.
7. Process according to claims 1 or 2, characterised in that the cover layer (12) is inserted in the die as a thermoplastic shell.
8. Process according to one of claims 2 to 7, characterised in that the decorative layer (24) is inserted in the die box (18), said decorative layer prior to the final forming process comprising flexible layers at ambient pressure and ambient temperature.
9. Process according to Claim 8, characterised in that the decorative layer comprises an epoxy prepreg.
10. Process according to Claim 8, characterised in that the decorative layer comprises an epoxy prepreg or a polyester prepreg.
11. Process according to one of claims 1 to 8, characterised in that the decorative layer (24) is inserted in the die as a thermoplastic shell.
12. Process according to one of claims 1 to 11, characterised in that the ski upper part (10) during the separate forming process is composed of a core (14) and lateral damping layers (16) in addition to the cover layer (12).
13. Process according to one of claims 1 to 11, characterised in that the core (14) is only formed once the ski upper part has been joined to the ski lower part, and then by foam-filling for example with polyurethane or a similar substance.
14. Process according to one of claims 1 to 13, characterised in that, prior to process continuation in the die (18, 20) a damping layer (26) is inserted or fixed at the binding area (L) between the cover layer (12) and core (14) or between the cover layer (12) and the space which is later to be filled as the core.
15. Process according to Claim 13, characterised in that a layer of material exhibiting maximum possible entropic elasticity is inserted as the damping layer (26).
16. Ski manufactured in accordance with one of claims 1 to 15, characterised in that the ski upper part (10) is of trapezoidal cross section, the lateral faces of which are inclined at a constant angle.

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