EP0729769A1 - Method of fabrication a structure by injection molding - Google Patents

Method of fabrication a structure by injection molding Download PDF

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Publication number
EP0729769A1
EP0729769A1 EP96102251A EP96102251A EP0729769A1 EP 0729769 A1 EP0729769 A1 EP 0729769A1 EP 96102251 A EP96102251 A EP 96102251A EP 96102251 A EP96102251 A EP 96102251A EP 0729769 A1 EP0729769 A1 EP 0729769A1
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Prior art keywords
molded structure
manufacturing
structure according
mold
section
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP96102251A
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German (de)
French (fr)
Inventor
Pierre Garcin
Benoît Saillet
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Salomon SAS
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Salomon SAS
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Publication of EP0729769A1 publication Critical patent/EP0729769A1/en
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    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63C—SKATES; SKIS; ROLLER SKATES; DESIGN OR LAYOUT OF COURTS, RINKS OR THE LIKE
    • A63C5/00—Skis or snowboards
    • A63C5/12—Making thereof; Selection of particular materials

Definitions

  • the invention relates to a method of manufacturing a molded structure in the form of an elongated beam. More particularly, it relates to the manufacture of skis, snowboards and other similar machines suitable for sliding on snow and on ice.
  • the 'in situ' injection technique is frequently used. It consists, generally initially, to have against or near the walls of the cavity of a mold, the peripheral elements of the structure, more particularly; the sliding sole, the side edges, the upper and lateral protective casing, the reinforcing elements and other elements. Then, the components thus formed are injected with the constituents of a hardenable foam such as a polyurethane or phenolic foam which expands and ensures both the plating of the peripheral elements against the walls of the mold and the assembly of a at least part of the elements between them.
  • a hardenable foam such as a polyurethane or phenolic foam
  • the document FR 2 679 780 overcomes the use of bonding films and proposes replacing the reinforcing elements by a tubular sheet in the form of a mesh network in order to delimit a closed interior compartment in which are injected the constituents of the foam.
  • the foam passes through the trunks of the tube to coat the latter, and to press the upper face and the lateral faces of a covering layer of flexible thermoplastic material against the walls of the mold.
  • a tube does not provide optimal reinforcement of the structure taking into account its own structure and its approximate placement inside the ski after injection.
  • the tube must have a thickness which adapts to the thickness distribution of the ski. A given size and thickness distribution corresponds to a particular tube reference. The reference number is multiplied and therefore the production costs are higher.
  • the mesh tube remains relatively flexible and therefore plays a minor role in maintaining the peripheral elements before foaming. It also does not participate in the formation of the covering layer which must therefore be flexible enough to be able to be deformed by the pressure of the foam.
  • Document FR-A-2 700 479 relates to an improvement which consists in adding an additional reinforcement in dry fabric reinforced with metallic weft threads in order to obtain a remanent curvature in the shape of an inverted U in the area of the pad only.
  • Japanese document (B2) n ° 63-63233 relates to a method of manufacturing skis by injecting synthetic foam inside a structure using openwork reinforcements based on fibers and resin arranged on the surface of the sole and on the underside of the upper decoration layer.
  • the upper reinforcement is supported by several sections of corrugated plates of elastic material spaced longitudinally over the entire length of the ski.
  • the process applies to the manufacture of 'sandwich' skis; that is to say comprising a stack of flat plates of different elements comprising the sole, the lower reinforcement, the core, the upper reinforcement and the decoration top.
  • the foam is only used for bonding the different elements because it can penetrate through the mesh of the reinforcements.
  • Document DE-A1-43 19 245 relates to a process for manufacturing a ski by injecting a foam.
  • the upper reinforcement may be a perforated steel plate held in position across its width by several spacer pieces. These parts, however, have the sole function of keeping the perforated plate in contact with the lower surface of the outer layer of the ski without providing determined space for sufficient passage of the foam to ensure perfect adhesion and good forming the outer layer.
  • the outer layer is in a flat configuration and held in a sliding air gap of the mold. It is the pressure of the foam which deforms the outer layer and forms it against the walls of the mold. The positioning of the reinforcing plate during injection is therefore done in a fairly random manner since it is simply kept under pressure by the spacer pieces against the external layer which is deformed.
  • the object of the present invention is to provide an improvement to the existing injection methods for producing a ski in good shape and economically.
  • One of the objects is therefore to carry out the assembly, the bonding of the elements and the forming of the outer covering sheet by the foam injected 'in situ' during a single main injection cycle.
  • Another object of the invention is the possibility of dispensing with any additional bonding interface.
  • Another object of the invention is to be able to vary the mechanical characteristics of the ski easily in a modular manner as required and economically.
  • Another object of the invention is to keep a wide choice of materials used to form the reinforcing elements, compatible with bonding with the foam.
  • Another object of the invention is to ensure excellent positioning of the reinforcing elements during injection in order to ensure reproducible and controlled mechanical characteristics.
  • Another object of the invention is to facilitate the implementation of the elements by the manipulator thereby saving time and productivity.
  • the foam is used both for forming the structure, and in particular for the covering sheet and for bonding the essential elements of the structure to one another.
  • the lateral spacing of small width reinforcements allows the foam to circulate more freely and promotes the cohesion of the entire structure.
  • the bracing pieces locally support the covering sheet; and hold local reinforcement elements in place at a predetermined distance from the lower surface of said cover sheet to promote the passage of the foam between the reinforcement elements and said cover sheet.
  • the formation and cohesion of the structure is even more improved.
  • the foam completely traps the local reinforcing elements, which prevents any risk of delamination.
  • the bracing pieces are obtained from one or more plastic or metallic profiles produced by injection, by extrusion or pultrusion, then cut into sections of length. determined. Thus, these parts can therefore be obtained very economically.
  • each spacer piece is presented as a flattened tube section, the wall of which comprises, at least, a series of open housings, of concave cross section, and which extend substantially in the direction longitudinal of the molded structure, into which the local reinforcing elements are inserted.
  • the prepositioning of the reinforcements is facilitated without any particular adjustment on the part of the manipulator. It also ensures the predetermined distance required between the reinforcing elements and the cover sheet.
  • the reinforcements are always inside the structure in the same configuration; which guarantees good reproducibility of the mechanical characteristics from one ski to another.
  • each housing includes a narrowing zone to allow engagement by clipping of each local reinforcement element.
  • the fixing of each reinforcement is done quickly, simply and without gluing.
  • the reinforcements can thus be slightly bent and prestressed to adapt to the particular geometry of the structure, while remaining firmly retained in their housing. Time is also saved in the prepositioning operation.
  • each bracing piece is presented as a profile section having a series of holes which extend substantially in the longitudinal direction of the molded structure, and whose cross section is slightly greater than the cross section of each local reinforcement element. Pre-positioning is very fast in this case too. The reinforcement elements can be held in place without bonding.
  • the bracing pieces are made of a deformable semi-rigid material to adapt to the variation in thickness of the cross section as a function of the length of the molded structure.
  • the number of part references used along the molded structure is advantageously limited since a single reference can adapt to the thickness profile of the molded structure, within a certain given thickness range.
  • the bracing pieces are made of a rigid material resistant to crushing.
  • the spacer part participates in the preforming of the cover sheet when the mold is closed.
  • the local reinforcing elements are rods with a circular, oval or polygonal full section.
  • the rods are more economical.
  • their use makes it possible to more easily modulate the mechanical characteristics of bending and torsion of the beam.
  • a flat sole (3) is deposited flat and at the bottom of a lower part (1), for example made of polyethylene, two lateral edges (4) which border on each side the gliding sole.
  • the sole is then covered by a first lower reinforcing element, such as a metal plate (5).
  • the plate extends longitudinally continuously over a large part of the length of the structure to be produced. It advantageously comprises pins (50) regularly distributed over its lower surface which allow the plate to be placed on the sole while leaving a space between the sole and the lower surface of the plate. At the location of the pins, the upper surface of the plate also includes recesses made by punching, for example.
  • Several local spacer pieces (6) are then placed on the plate (5); separated longitudinally from each other over the entire length of the structure to be produced.
  • each piece (6) is in the form of a section of hollow tube, the lower part of which comprises pins (60) of shape complementary to that of the hollows (51) of the plate (5), to allow easy prepositioning of local parts relative to the plate (5).
  • the wall In the upper part of the tube, the wall comprises a series of laterally spaced apart openings (62) which have a concave cross section. These upper open openings (62) extend over the entire length of each part in the longitudinal direction of the molded structure.
  • each rod is preferably inserted, a rod with a full section.
  • the rods are made of material chosen from the group consisting of a metal of the steel, aluminum or aluminum alloy type, a reinforced plastic material.
  • each rod has a section of substantially circular shape, but one can imagine other sections of oval or polygonal shape, for example.
  • each local reinforcing element (7) in its respective housing To facilitate the maintenance in position of each local reinforcing element (7) in its respective housing; it is expected that the cross section of each housing includes a narrowing zone of width slightly less than the diameter of the reinforcing element.
  • the engagement is therefore done by elastic clipping by simple manual pressure.
  • a plastic covering sheet (8) monolayer or multilayer.
  • a plastic covering sheet is generally chosen from flexible or semi-rigid thermoplastic materials at room temperature. This sheet is lightly tiled by hand and then prepositioned so that its lateral ends can take position in longitudinal grooves (10) of the lower part of the mold. Compressible silicone seals (11) are provided to improve the seal after closing the mold. Then, the upper part (2) of the mold is lowered to form a sealed closed enclosure by compression of the seals (11). When closing the mold, the lateral edges of the cover sheet (8) are pinched firmly in the air gap formed in the vicinity of the joint plane of the mold (100); without possibility of sliding the sheet ( Figure 3).
  • the part of the sheet located inside the mold to have a developed surface equivalent to the surface of the imprint of the corresponding part of the mold; in this case the imprint of the upper part (2), in the illustrated case.
  • This avoids any defect of off-center of the cover sheet (8) relative to the rest of the structure, which can constitute a major cause of scrap when the sheet is predecorated before being molded, for example.
  • the spacer pieces (6) can be slightly deformed by crushing and they thus adapt to the variation in thickness of the cross section as a function of the length of the molded structure. It is thus possible to use only a limited series of parts of different thickness by providing to produce each part in a semi-rigid deformable material of plastic or metal produced by injection or by extrusion, for example.
  • the spacer piece locally supports the covering sheet by bosses (63) for example, and thus keeps in place the local reinforcing elements (7) at a predetermined distance from the lower surface of the covering sheet (8).
  • the next step illustrated in FIG. 4 consists in injecting into the closed volume, the constituents of a foam (9), of the polyurethane type for example, namely an isocyanate constituent and a polyol constituent which react 'in situ' causing a heat release and foam expansion. Sufficient injection of the components is provided so that the foam (9) can completely fill the defined volume.
  • a foam (9) of the polyurethane type for example, namely an isocyanate constituent and a polyol constituent which react 'in situ' causing a heat release and foam expansion.
  • the foam thus fills the space between the lower plate (5) and the gliding sole (3) and the space provided between each local reinforcement element or rod (7) and the covering sheet (8).
  • a homogeneous structure with strong cohesion is obtained in which the elements serving to reinforce the structure are trapped in the foam, after it has hardened.
  • the foam also repels and presses the cover sheet evenly against the walls of the upper part of the hill.
  • the sheet thus takes its final shape in the mold.
  • the forming of the sheet can be promoted by heating the mold to a temperature and for a sufficient time, depending on the nature of the material used.
  • the material constituting the layer (s) of the covering sheet is chosen from the group of aliphatic polyamides, polyether amide block, polyether ester block, polycarbonates, ABS (Acrylonitrile Butadiene Styrene), AS (Acrylonitrile Styrene) pure or mixed with TPU (thermoplastic urethane elastomer), polyethylene terephthalates (PET), polybutadienes terephthalates (PBT), polyurethanes, polyolefins, as well as mixtures and copolymers of some of these constituents.
  • ABS Acrylonitrile Butadiene Styrene
  • AS Acrylonitrile Styrene
  • TPU thermoplastic urethane elastomer
  • PET polyethylene terephthalates
  • PBT polybutadienes terephthalates
  • polyurethanes polyolefins, as well as mixtures and copolymers of some of these constituents.
  • the local reinforcing elements or rods are made of material chosen from the group consisting of: a metal of the steel, aluminum or aluminum alloy type, a reinforced plastic material. In the latter case, when being molded, the rods are based on glass fibers, carbon or aramid and on a matrix of thermosetting or thermoplastic resin.
  • FIG. 5 illustrates, in cross section, the structure after injection of the foam and molding between two local bracing pieces. Thanks to the spacer pieces, a predetermined gap (d) is ensured between each local reinforcing element (7) and the covering sheet (8).
  • Figure 6 shows the longitudinal arrangement of the local reinforcing elements (7) and the regular distribution of the bracing pieces (6) along the molded structure.
  • the structure has the shape of a ski which schematically has a wasp-shaped shape.
  • the width of each piece (6) can be variable to adapt to the particular variation in width of the ski.
  • the local reinforcing elements (7) extend longitudinally forming a bundle with high flexural and torsional reinforcement characteristics. These characteristics can be easily modulated longitudinally and laterally by modifying the number and / or the length of the elements (7).
  • One can, for example, increase the mechanical characteristics of the ski in the central area by adding several additional elements (7) of limited length in the area to be reinforced.
  • the molded structure can be entirely reinforced by local elements or upper rods (70) and lower (71) as shown in FIG. 7.
  • the bracing piece (6) comprises both a series of upper housings (620) and a series of lower housings (621). By bosses (631) the bracing piece keeps the lower rods (71) in place at a certain distance from the sliding sole (3) so as to allow the foam to circulate freely for perfect cohesion of the structure.
  • reliefs (80) or recesses (81) can easily be obtained on the surface of the covering sheet (8). These shapes are produced by the deformation of the sheet (8) in contact with corresponding recesses or reliefs in the mold cavity and under the pressure exerted by the expansion of the foam during the injection step.
  • the bracing piece (6) comprises upper housings (62) which are open towards the inside of the structure.
  • the elastic compressibility of the part is increased by lugs (64) which act as springs inside the structure.
  • the lower reinforcement element (50) is held in contact with the sole (3) by the tabs (64).
  • It can be a plate made of fibrous material pre-impregnated with an epoxy resin, for example. With heat, during injection molding, we obtain crosslinking of the resin and simultaneously bonding of the plate to the sole and with the foam.
  • the bracing piece (6) can also be presented as a profile section having a series of holes (65) which extend substantially in the direction of the molded structure, and the cross section of which transverse is slightly greater than the cross section of each upper reinforcing element (7).
  • the upper elements (7) are pre-positioned by simple sliding in their corresponding adapted section hole.
  • molded structure is not limited to the examples described and one can imagine other structures without departing from the scope of the present invention.
  • FIG. 10 thus illustrates another variant in which the lateral reinforcement can be increased by an edge element (82) positioned on each lateral edge (4) and extending over a large part of it.
  • the cover sheet forms only part of the edge of the molded structure, the lateral edges of which rest on each edge element (82).
  • the forming of the cover sheet is carried out by the foam itself. It may be otherwise in the case where, for example, the material used for the sheet is not easily deformable or when the final shape to be produced is relatively complex. In this case, it may be necessary to apply a step of 'preforming the upper cover sheet, prior to the step of molding.

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  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

Mfr. of a moulding in the form of an elongated beam involves (a) arranging in a mould a lower sub-assembly comprising a slide bed (3) edged on both sides by lateral corners (4), and opt. with a lower reinforcement (5,50), (b) covering the sub-assembly with a film (8) to form a closed vol., intended to form the top and (part of) the sides of the moulding, (c) closing the mould, (d) injecting into the vol. the reactants for a foam which expands in situ, and (e) opening the mould to remove the complex moulding. At the time of placement in the mould, several local cross-pieces (6) are placed between the sub-assembly (3,4,5,50) and the covering film (8). These cross-pieces are spread over (part of) the length of the moulding, are spaced apart from each other, rest on the lower sub-assembly and hold in place several short local reinforcing units (7) spaced laterally from each other over the width of the structure to be moulded.

Description

L'invention se rapporte à un procédé de fabrication d'une structure moulée ayant la forme d'une poutre allongée. Plus particulièrement, elle concerne la fabrication des skis, surfs des neiges et autres engins similaires adaptés à la glisse sur la neige et sur la glace.The invention relates to a method of manufacturing a molded structure in the form of an elongated beam. More particularly, it relates to the manufacture of skis, snowboards and other similar machines suitable for sliding on snow and on ice.

Les structures moulées actuelles regroupent généralement différents éléments assemblés de manière homogène et dont le rôle est d'assurer les fonctions essentielles de résistance mécanique, de glissement, d'accrochage et de protection de la structure. Pour obtenir ces fonctions, on fait appel à des matériaux très divers qui ont des affinités ou des compatibilités de collage très différentes entre eux. Le problème général consiste à réussir à obtenir une cohésion parfaite de la structure, qui vise à satisfaire aux exigences de résistance en raison des contraintes mécaniques imposées par l'utilisation, tout en diminuant le nombre et la durée des étapes de fabrication. De plus, aux structures sont associées des formes extérieures de plus en plus complexes pour augmenter la valeur d'attrait des produits.Current molded structures generally group together various elements assembled in a homogeneous manner and whose role is to ensure the essential functions of mechanical resistance, sliding, attachment and protection of the structure. To obtain these functions, very diverse materials are used which have very different affinities or compatibilities of bonding to one another. The general problem consists in succeeding in obtaining perfect cohesion of the structure, which aims to satisfy the resistance requirements due to the mechanical constraints imposed by the use, while reducing the number and the duration of the manufacturing steps. In addition, structures are associated with increasingly complex exterior shapes to increase the attractiveness of the products.

Pour répondre à ce problème, on utilise fréquemment la technique d'injection 'in situ'. Elle consiste, généralement dans un premier temps, à disposer contre ou à proximité des parois de la cavité d'un moule, les éléments périphériques de la structure, plus particulièrement ; la semelle de glissement, les carres latérales, l'enveloppe supérieure et latérale de protection, les éléments de renforcement et autres éléments. Puis, on injecte dans le volume ainsi formé, les constituants d'une mousse durcissable telle qu'une mousse polyuréthane ou phénolique qui s expanse et assure à la fois le plaquage des éléments périphériques contre les parois du moule et l'assemblage d'une partie au moins des éléments entre eux. Un tel procédé est décrit indifféremment dans les demandes françaises n° 2 654 645 ou 2 654 670 par exemple. Comme l'enseigne ces demandes, il est cependant nécessaire d'utiliser, une gaine tubulaire à base de films de collage dont le rôle est d'une part, de réaliser un écran étanche entre la mousse et les constituants de la résine des renforts et d'autre part, d'assurer l'adhérence de la mousse avec la résine des renforts périphériques pour éviter un délaminage de la structure. Les renforts utilisés se présentent sous la forme de nappes textiles préimprégnées de résine thermodurcissable ou de plaques métalliques préencollées. On obtient des structures finales très homogènes et résistantes mais qui sont aussi très coûteuses compte-tenu des matériaux et de la technique de fabrication employée.To address this problem, the 'in situ' injection technique is frequently used. It consists, generally initially, to have against or near the walls of the cavity of a mold, the peripheral elements of the structure, more particularly; the sliding sole, the side edges, the upper and lateral protective casing, the reinforcing elements and other elements. Then, the components thus formed are injected with the constituents of a hardenable foam such as a polyurethane or phenolic foam which expands and ensures both the plating of the peripheral elements against the walls of the mold and the assembly of a at least part of the elements between them. Such a process is described indifferently in French applications No. 2,654,645 or 2,654,670 for example. As these applications teach, it is however necessary to use a tubular sheath based on bonding films, the role of which is on the one hand, to produce a sealed screen between the foam and the constituents of the resin of the reinforcements and on the other hand, to ensure the adhesion of the foam with the resin of the peripheral reinforcements to avoid delamination of the structure. The reinforcements used are in the form of textile sheets pre-impregnated with thermosetting resin or pre-glued metal plates. We obtain very homogeneous and resistant final structures but which are also very expensive taking into account the materials and the manufacturing technique used.

Le document FR 2 679 780 s'affranchit de l'utilisation de films de collage et propose de remplacer les éléments de renfort par une feuille tubulaire en forme de réseau maillé afin de délimiter un compartiment intérieur fermé dans lequel sont injectés les constituants de la mousse. Ainsi, la mousse traverse les malles du tube pour enrober celui-ci, et pour faire plaquer la face supérieure et les faces latérales d'une couche de recouvrement en matériau thermoplastique souple contre les parois du moule. Il est évident qu'un tel tube n'apporte pas un renforcement optimal de la structure compte-tenu de sa structure propre et de son placement approximatif à l'intérieur du ski après injection. De plus, le tube doit posséder une épaisseur qui s'adapte à la distribution d'épaisseur du ski. A une taille et une distribution d'épaisseur donnée correspond une référence de tube particulière. Le nombre de référence est multiplié et donc les coûts de production sont plus élevés.The document FR 2 679 780 overcomes the use of bonding films and proposes replacing the reinforcing elements by a tubular sheet in the form of a mesh network in order to delimit a closed interior compartment in which are injected the constituents of the foam. Thus, the foam passes through the trunks of the tube to coat the latter, and to press the upper face and the lateral faces of a covering layer of flexible thermoplastic material against the walls of the mold. It is obvious that such a tube does not provide optimal reinforcement of the structure taking into account its own structure and its approximate placement inside the ski after injection. In addition, the tube must have a thickness which adapts to the thickness distribution of the ski. A given size and thickness distribution corresponds to a particular tube reference. The reference number is multiplied and therefore the production costs are higher.

De plus, le tube maillé reste relativement souple et joue donc un rôle mineur dans le maintien des éléments périphériques avant moussage. Il ne participe pas davantage au formage de la couche de recouvrement qui doit donc être suffisamment souple pour pouvoir être déformée par la pression de la mousse.In addition, the mesh tube remains relatively flexible and therefore plays a minor role in maintaining the peripheral elements before foaming. It also does not participate in the formation of the covering layer which must therefore be flexible enough to be able to be deformed by the pressure of the foam.

Le document FR-A-2 700 479 concerne un perfectionnement qui consiste à rajouter un renfort supplémentaire en tissu sec armé de fils de trame métallique pour obtenir une courbure rémanente en forme de U renversé dans la zone du patin seulement.Document FR-A-2 700 479 relates to an improvement which consists in adding an additional reinforcement in dry fabric reinforced with metallic weft threads in order to obtain a remanent curvature in the shape of an inverted U in the area of the pad only.

Sa fonction est d'améliorer le renforcement et la transmission des appuis sur les carres dans la zone du patin. Dans cette zone, il favorise le maintien en place des éléments. Cependant, une telle structure conserve dans les autres parties du ski les inconvénients précités de la gaine ajourée.Its function is to improve the reinforcement and the transmission of support on the edges in the skate area. In this area, it helps keep the elements in place. However, such a structure retains in the other parts of the ski the aforementioned drawbacks of the perforated sheath.

Le document japonais (B2) n° 63-63233 concerne une méthode de fabrication de skis par injection d'une mousse synthétique à l'intérieur d'une structure utilisant des renforts ajourés à base de fibres et de résine disposés sur la surface de la semelle et sur la face inférieure de la couche supérieure de décoration. Le renfort supérieur est supporté par plusieurs tronçons de plaques ondulées en matériau élastique espacés longitudinalement sur toute la longueur du ski. Le procédé s'applique à la fabrication des skis 'sandwich' ; c'est-à-dire comprenant un empilement de plaques planes de différents éléments comprenant la semelle, le renfort inférieur, le noyau, le renfort supérieur et le dessus de décoration. La mousse ne sert simplement qu'au collage des différents éléments car elle peut pénétrer à travers les mailles des renforts.Japanese document (B2) n ° 63-63233 relates to a method of manufacturing skis by injecting synthetic foam inside a structure using openwork reinforcements based on fibers and resin arranged on the surface of the sole and on the underside of the upper decoration layer. The upper reinforcement is supported by several sections of corrugated plates of elastic material spaced longitudinally over the entire length of the ski. The process applies to the manufacture of 'sandwich' skis; that is to say comprising a stack of flat plates of different elements comprising the sole, the lower reinforcement, the core, the upper reinforcement and the decoration top. The foam is only used for bonding the different elements because it can penetrate through the mesh of the reinforcements.

Le document DE-A1-43 19 245 concerne un procéde de fabrication d'un ski par injection d'une mousse. Le renfort supérieur peut être une plaque ajourée en acier maintenue en position sur sa largeur par plusieurs pièces d'entretoise. Ces pièces n'ont toutefois pour seule fonction que de maintenir la plaque ajourée au contact de la surface inférieure de la couche externe du ski sans ménager d'espace déterminé pour un passage suffisant de la mousse permettant d'assurer une parfaite adhésion et un bon formage de la couche externe. La couche externe est dans une configuration plane et maintenue dans un entrefer glissant du moule. C'est la pression de la mousse qui déforme la couche externe et réalise son formage contre les parois du moule. Le positionnement de la plaque de renfort lors de l'injection se fait donc de façon assez aléatoire puisqu'elle est simplement maintenue en pression par les pièces d'entretoise contre la couche externe qui se déforme.Document DE-A1-43 19 245 relates to a process for manufacturing a ski by injecting a foam. The upper reinforcement may be a perforated steel plate held in position across its width by several spacer pieces. These parts, however, have the sole function of keeping the perforated plate in contact with the lower surface of the outer layer of the ski without providing determined space for sufficient passage of the foam to ensure perfect adhesion and good forming the outer layer. The outer layer is in a flat configuration and held in a sliding air gap of the mold. It is the pressure of the foam which deforms the outer layer and forms it against the walls of the mold. The positioning of the reinforcing plate during injection is therefore done in a fairly random manner since it is simply kept under pressure by the spacer pieces against the external layer which is deformed.

Le but de la présente invention est d'apporter un perfectionnement aux procédés d'injection existants pour la réalisation d'un ski en forme et de façon économique.The object of the present invention is to provide an improvement to the existing injection methods for producing a ski in good shape and economically.

L'un des objets est donc de réaliser l'assemblage, le collage des éléments et le formage de la feuille extérieure de recouvrement par la mousse injectée 'in situ' au cours d'un seul cycle principal d'injection.One of the objects is therefore to carry out the assembly, the bonding of the elements and the forming of the outer covering sheet by the foam injected 'in situ' during a single main injection cycle.

Un autre objet de l'invention est la possibilité de s'affranchir de toute interface de collage supplémentaire.Another object of the invention is the possibility of dispensing with any additional bonding interface.

Un autre objet de l'invention est de pouvoir faire varier les caractéristiques mécaniques du ski facilement de façon modulable en fonction des besoins et de façon économique.Another object of the invention is to be able to vary the mechanical characteristics of the ski easily in a modular manner as required and economically.

Un autre objet de l'invention est de conserver un large choix de matériaux employés pour former les éléments de renfort, compatibles au collage avec la mousse.Another object of the invention is to keep a wide choice of materials used to form the reinforcing elements, compatible with bonding with the foam.

Un autre objet de l'invention est d'assurer un excellent positionnement des éléments de renfort lors de l'injection pour assurer des caractéristiques mécaniques reproductibles et contrôlées.Another object of the invention is to ensure excellent positioning of the reinforcing elements during injection in order to ensure reproducible and controlled mechanical characteristics.

Un autre objet de l'invention est de faciliter la mise en oeuvre des éléments par le manipulateur permettant ainsi un gain de temps et de productivité.Another object of the invention is to facilitate the implementation of the elements by the manipulator thereby saving time and productivity.

Pour cela l'invention se rapporte à un procédé de fabrication d'une structure moulée ayant la forme d'une poutre allongée consistant :

  • à disposer dans un moule un sous-ensemble inférieur comprenant une semelle de glisse bordée de part et d'autre par des carres latérales ; éventuellement un élément de renfort inférieur ;
  • à recouvrir le sous-ensemble inférieur d'une feuille de recouvrement, pour former un volume fermé, destinée à constituer le dessus et une partie au moins des faces latérales de ladite structure ;
  • à fermer le moule ;
  • puis à injecter dans le volume ainsi défini les réactifs d'une mousse qui s'expanse 'in situ' ;
  • puis à ouvrir le moule pour retirer la structure moulée complexe, caractérisé en ce qu'au moment de la mise en moule, l'on intercale entre ledit sous-ensemble inférieur et ladite feuille de recouvrement, plusieurs pièces locales d'entretoisement, longitudinalement réparties sur une partie au moins de la longueur de la structure moulée ; lesdites pièces étant espacées l'une de l'autre, reposant sur le sous-ensemble inférieur et maintenant en place plusieurs éléments de renfort locaux de faible largeur, espacés latéralement l'un de l'autre sur la largeur de ladite structure à mouler ;
For this, the invention relates to a method of manufacturing a molded structure having the shape of an elongated beam consisting of:
  • placing in a mold a lower sub-assembly comprising a gliding sole bordered on either side by lateral edges; possibly a lower reinforcing element;
  • covering the lower sub-assembly with a covering sheet, to form a closed volume, intended to constitute the top and at least part of the lateral faces of said structure;
  • closing the mold;
  • then injecting the reagents of a foam which expands 'in situ' into the volume thus defined;
  • then to open the mold to remove the complex molded structure, characterized in that at the time of setting in the mold, there are interposed between said lower sub-assembly and said cover sheet, several local parts bracing, longitudinally distributed over at least part of the length of the molded structure; said parts being spaced from one another, resting on the lower sub-assembly and holding in place several local reinforcement elements of small width, laterally spaced from one another over the width of said structure to be molded;

Ainsi, la mousse sert à la fois au formage de la structure, et en particulier de la feuille de recouvrement et au collage des éléments essentiels de' la structure entre eux.Thus, the foam is used both for forming the structure, and in particular for the covering sheet and for bonding the essential elements of the structure to one another.

L'espacement latéral de renforts de faible largeur permet à la mousse de circuler plus librement et favorise la cohésion de l'ensemble de la structure.The lateral spacing of small width reinforcements allows the foam to circulate more freely and promotes the cohesion of the entire structure.

Selon une autre caractéristique de l'invention, les pièces d'entretoisement supportent localement la feuille de recouvrement ; et maintiennent en place des éléments de renfort locaux à une distance prédéterminée de la surface inférieure de ladite feuille de recouvrement pour favoriser le passage de la mousse entre les éléments de renfort et ladite feuille de recouvrement. Le formage et la cohésion de la structure s'en trouve encore plus améliorée. La mousse emprisonne entièrement les éléments de renfort locaux, ce qui prévient tout risque de délaminage.According to another characteristic of the invention, the bracing pieces locally support the covering sheet; and hold local reinforcement elements in place at a predetermined distance from the lower surface of said cover sheet to promote the passage of the foam between the reinforcement elements and said cover sheet. The formation and cohesion of the structure is even more improved. The foam completely traps the local reinforcing elements, which prevents any risk of delamination.

Selon une autre caractéristique de l'invention, les pièces d'entretoisement sont obtenues à partir d'un ou plusieurs profilés en matière plastique ou métallique réalisé(s) par injection, par extrusion ou pultrusion, puis découpé(s) en tronçons de longueur déterminée. Ainsi, ces pièces peuvent donc être obtenues de façon très économique.According to another characteristic of the invention, the bracing pieces are obtained from one or more plastic or metallic profiles produced by injection, by extrusion or pultrusion, then cut into sections of length. determined. Thus, these parts can therefore be obtained very economically.

Selon une autre caractéristique de l'invention, chaque pièce d'entretoisement se présente comme un tronçon de tube aplati dont la paroi comprend, au moins, une série de logements ouverts, de section transversale concave, et qui s'étendent sensiblement dans la direction longitudinale de la structure moulée, dans lesquels sont insérés les éléments de renfort locaux. Ainsi, le prépositionnement des renforts est facilité sans ajustement particulier de la part du manipulateur. On assure également la distance prédéterminée nécessaire entre les éléments de renfort et la feuille de recouvrement.According to another characteristic of the invention, each spacer piece is presented as a flattened tube section, the wall of which comprises, at least, a series of open housings, of concave cross section, and which extend substantially in the direction longitudinal of the molded structure, into which the local reinforcing elements are inserted. Thus, the prepositioning of the reinforcements is facilitated without any particular adjustment on the part of the manipulator. It also ensures the predetermined distance required between the reinforcing elements and the cover sheet.

Les renforts se trouvent toujours à l'intérieur de la structure dans la même configuration ; ce qui garantit une bonne reproductibilité des caractéristiques mécaniques d'un ski à l'autre.The reinforcements are always inside the structure in the same configuration; which guarantees good reproducibility of the mechanical characteristics from one ski to another.

Selon une caractéristique complémentaire, la section transversale de chaque logement comprend une zone de rétrécissement pour permettre un engagement par clipsage de chaque élément de renfort local. La fixation de chaque renfort se fait rapidement, de façon simple et sans collage. Les renforts peuvent ainsi être légèrement pliés et précontraints pour s'adapter à la géométrie particulière de la structure, tout en restant fermement retenus dans leur logement. On obtient également un gain de temps dans l'opération de prépositionnement.According to an additional characteristic, the cross section of each housing includes a narrowing zone to allow engagement by clipping of each local reinforcement element. The fixing of each reinforcement is done quickly, simply and without gluing. The reinforcements can thus be slightly bent and prestressed to adapt to the particular geometry of the structure, while remaining firmly retained in their housing. Time is also saved in the prepositioning operation.

Selon une autre caractéristique de l'invention, chaque pièce d'entretoisement se présente comme un tronçon de profil ayant une série de trous qui s'étendent sensiblement dans la direction longitudinale de la structure moulée, et dont la section transversale est légèrement supérieure à la section transversale de chaque élément de renfort local. Le prépositionnement est dans ce cas très rapide également. Le maintien en place des éléments de renfort peut se faire sans collage.According to another characteristic of the invention, each bracing piece is presented as a profile section having a series of holes which extend substantially in the longitudinal direction of the molded structure, and whose cross section is slightly greater than the cross section of each local reinforcement element. Pre-positioning is very fast in this case too. The reinforcement elements can be held in place without bonding.

Selon une autre caractéristique, les pièces d'entretoisement sont réalisées dans un matériau semi-rigide déformable pour s'adapter à la variation d'épaisseur de la section transversale en fonction de la longueur de la structure moulée. Ainsi, on limite avantageusement le nombre de références de pièces utilisées le long de la structure moulée puisqu'une seule référence peut s'adapter au profil d'épaisseur de la structure moulée, dans une certaine plage d'épaisseur donnée.According to another characteristic, the bracing pieces are made of a deformable semi-rigid material to adapt to the variation in thickness of the cross section as a function of the length of the molded structure. Thus, the number of part references used along the molded structure is advantageously limited since a single reference can adapt to the thickness profile of the molded structure, within a certain given thickness range.

Selon une alternative, les pièces d'entretoisement sont réalisées dans un matériau rigide résistant à l'écrasement. Dans ce cas, au contraire, la pièce d'entretoisement participe au préformage de la feuille de recouvrement lors de la fermeture du moule.According to an alternative, the bracing pieces are made of a rigid material resistant to crushing. In this case, on the contrary, the spacer part participates in the preforming of the cover sheet when the mold is closed.

Selon une autre caractéristique de l'invention, les éléments de renfort locaux sont des joncs à section pleine circulaire, ovale ou polygonale. Par rapport à des renforts traditionnels en plaque, les joncs sont plus économiques. De plus, leur utilisation permet de moduler plus facilement les caractéristiques mécaniques de flexion et de torsion de la poutre.According to another characteristic of the invention, the local reinforcing elements are rods with a circular, oval or polygonal full section. Compared to traditional plate reinforcements, the rods are more economical. In addition, their use makes it possible to more easily modulate the mechanical characteristics of bending and torsion of the beam.

D'autres caractéristiques et avantages du procédé de l'invention se dégageront de la description qui va suivre au regard des dessins annexés qui ne sont donnés qu'à titre d'exemples non limitatifs :

  • Les figures 1 à 5 illustrent par des coupes transversales, un premier mode de réalisation du procédé de fabrication de la structure moulée selon l'invention ;
  • la figure 6 montre une vue longitudinale schématique de la structure moulée ;
  • la figure 7 montre une coupe transversale d'une variante d'une structure moulée selon le procédé de l'invention ;
  • la figure 8 montre une coupe transversale d'une seconde variante d'une structure moulée ;
  • la figure 9 montre une coupe transversale d'une troisième variante d'une structure moulée ;
  • la figure 10 montre une coupe transversale d'une quatrième variante d'une structure moulée.
Other characteristics and advantages of the process of the invention will emerge from the description which follows with regard to the appended drawings which are given only by way of nonlimiting examples:
  • Figures 1 to 5 illustrate by cross sections, a first embodiment of the manufacturing process of the molded structure according to the invention;
  • Figure 6 shows a schematic longitudinal view of the molded structure;
  • Figure 7 shows a cross section of a variant of a molded structure according to the method of the invention;
  • Figure 8 shows a cross section of a second variant of a molded structure;
  • Figure 9 shows a cross section of a third variant of a molded structure;
  • Figure 10 shows a cross section of a fourth variant of a molded structure.

Selon un mode particulier de réalisation du procédé de l'invention appliqué à la fabrication d'un ski, on dépose à plat et au fond d'une partie inférieure (1) d'un moule, respectivement une semelle de glisse (3), par exemple réalisée en polyéthylène, deux carres latérales (4) qui bordent de chaque côté la semelle de glisse. La semelle est ensuite recouverte par un premier élément de renfort inférieur, telle qu'une plaque métallique (5). De préférence, la plaque s'étend longitudinalement de façon continue sur une grande partie de la longueur de la structure à réaliser. Elle comprend avantageusement des picots (50) régulièrement répartis sur sa surface inférieure qui permettent un posage de la plaque sur la semelle tout en ménageant un espace entre la semelle et la surface inférieure de la plaque. A l'endroit des picots, la surface supérieure de la plaque comprend également des creux réalisés par poinçonnage, par exemple. On dispose ensuite sur la plaque (5), plusieurs pièces locales d'entretoisement (6) ; séparées longitudinalement l'une de l'autre sur toute la longueur de la structure à réaliser.According to a particular embodiment of the method of the invention applied to the manufacture of a ski, a flat sole (3) is deposited flat and at the bottom of a lower part (1), for example made of polyethylene, two lateral edges (4) which border on each side the gliding sole. The sole is then covered by a first lower reinforcing element, such as a metal plate (5). Preferably, the plate extends longitudinally continuously over a large part of the length of the structure to be produced. It advantageously comprises pins (50) regularly distributed over its lower surface which allow the plate to be placed on the sole while leaving a space between the sole and the lower surface of the plate. At the location of the pins, the upper surface of the plate also includes recesses made by punching, for example. Several local spacer pieces (6) are then placed on the plate (5); separated longitudinally from each other over the entire length of the structure to be produced.

Dans le cas illustré, chaque pièce (6) se présente sous forme d'un tronçon de tube creux dont la partie inférieure comprend des picots (60) de forme complémentaire à celle des creux (51) de la plaque (5), pour permettre un prépositionnement aisé des pièces locales par rapport à la plaque (5). Dans la partie supérieure du tube, la paroi comprend une série de logements (62) espacés latéralement, ouverts vers le haut, et qui présentent une section transversale concave. Ces logements supérieurs (62) ouverts vers le haut s'étendent sur toute la longueur de chaque pièce dans la direction longitudinale de la structure moulée.In the illustrated case, each piece (6) is in the form of a section of hollow tube, the lower part of which comprises pins (60) of shape complementary to that of the hollows (51) of the plate (5), to allow easy prepositioning of local parts relative to the plate (5). In the upper part of the tube, the wall comprises a series of laterally spaced apart openings (62) which have a concave cross section. These upper open openings (62) extend over the entire length of each part in the longitudinal direction of the molded structure.

On insère ensuite, dans chaque logement, ou dans certain d'entre eux seulement, selon les cas, un élément de renfort local (7), de préférence, un jonc à section pleine. Les joncs sont réalisés en matériau choisi dans le groupe constitué par un métal du type acier, aluminium ou alliage d'aluminium, une matière plastique renforcée. Dans l'exemple illustré, chaque jonc a une section de forme sensiblement circulaire, mais on peut imaginer d'autres sections de forme ovale ou polygonale, par exemple.Then, in each housing, or in some of them only, depending on the case, a local reinforcing element (7) is preferably inserted, a rod with a full section. The rods are made of material chosen from the group consisting of a metal of the steel, aluminum or aluminum alloy type, a reinforced plastic material. In the example illustrated, each rod has a section of substantially circular shape, but one can imagine other sections of oval or polygonal shape, for example.

Afin de faciliter le maintien en position de chaque élément de renfort local (7) dans son logement respectif ; on prévoit que la section transversale de chaque logement comprend une zone de rétrécissement de largeur légèrement inférieure au diamètre de l'élément de renfort. L'engagement se fait donc par clipsage élastique par simple pression manuelle.To facilitate the maintenance in position of each local reinforcing element (7) in its respective housing; it is expected that the cross section of each housing includes a narrowing zone of width slightly less than the diameter of the reinforcing element. The engagement is therefore done by elastic clipping by simple manual pressure.

Comme le montre la figure 2, après mise en place des éléments de renfort locaux, on recouvre la structure par une feuille de recouvrement plastique (8), monocouche ou multicouche. Une telle feuille est généralement choisie parmi les matériaux thermoplastiques souples ou semi-rigides à température ambiante. Cette feuille est légèrement tuilée à la main puis prépositionnée de sorte que ses extrémités latérales puissent prendre position dans des gorges longitudinales (10) de la partie inférieure du moule. Des joints en silicone (11), comprimables sont prévus pour améliorer l'étanchéité après fermeture du moule. Puis, la partie supérieure (2) du moule est abaissée pour former une enceinte fermée étanche par compression des joints (11). Lors de la fermeture du moule, les bords latéraux de la feuille de recouvrement (8) sont pincés fermement dans l'entrefer ménagé au voisinage du plan de joint du moule (100) ; sans possibilité de glissement de la feuille (figure 3). Ainsi, il faut prévoir que la partie de la feuille se trouvant à l'intérieur du moule ait une surface développée équivalente à la surface de l'empreinte de la partie du moule correspondante ; en l'occurrence de l'empreinte de la partie supérieure (2), dans le cas illustré. On évite ainsi tout défaut de décentrage de la feuille de recouvrement (8) par rapport au reste de la structure pouvant constituer une cause importante de rebut lorsque la feuille est prédécorée avant la mise en moule, par exemple.As shown in FIG. 2, after the local reinforcement elements have been put in place, the structure is covered with a plastic covering sheet (8), monolayer or multilayer. Such a sheet is generally chosen from flexible or semi-rigid thermoplastic materials at room temperature. This sheet is lightly tiled by hand and then prepositioned so that its lateral ends can take position in longitudinal grooves (10) of the lower part of the mold. Compressible silicone seals (11) are provided to improve the seal after closing the mold. Then, the upper part (2) of the mold is lowered to form a sealed closed enclosure by compression of the seals (11). When closing the mold, the lateral edges of the cover sheet (8) are pinched firmly in the air gap formed in the vicinity of the joint plane of the mold (100); without possibility of sliding the sheet (Figure 3). Thus, provision must be made for the part of the sheet located inside the mold to have a developed surface equivalent to the surface of the imprint of the corresponding part of the mold; in this case the imprint of the upper part (2), in the illustrated case. This avoids any defect of off-center of the cover sheet (8) relative to the rest of the structure, which can constitute a major cause of scrap when the sheet is predecorated before being molded, for example.

Après fermeture, les pièces d'entretoisement (6) peuvent être légèrement déformées par écrasement et elles s'adaptent ainsi à la variation d'épaisseur de la section transversale en fonction de la longueur de la structure moulée. On peut ainsi n'utiliser qu'une série limitée de pièces d'épaisseur différente en prévoyant de réaliser chaque pièce dans un matériau semi-rigide déformable en plastique ou métal réalisé par injection ou par extrusion, par exemple.After closing, the spacer pieces (6) can be slightly deformed by crushing and they thus adapt to the variation in thickness of the cross section as a function of the length of the molded structure. It is thus possible to use only a limited series of parts of different thickness by providing to produce each part in a semi-rigid deformable material of plastic or metal produced by injection or by extrusion, for example.

La pièce d'entretoisement supporte localement la feuille de recouvrement par des bossages (63) par exemple, et maintient en place ainsi les éléments de renfort locaux (7) à une distance prédéterminée de la surface inférieure de la feuille de recouvrement (8).The spacer piece locally supports the covering sheet by bosses (63) for example, and thus keeps in place the local reinforcing elements (7) at a predetermined distance from the lower surface of the covering sheet (8).

L'étape suivante illustrée à la figure 4 consiste à injecter dans le volume fermé, les constituants d'une mousse (9), du type polyuréthane par exemple, à savoir un constituant isocyanate et un constituant polyol qui réagissent 'in situ' provoquant un dégagement calorifique et une expansion de mousse. On prévoit une injection suffisante des constituants pour que la mousse (9) puisse remplir entièrement le volume défini.The next step illustrated in FIG. 4 consists in injecting into the closed volume, the constituents of a foam (9), of the polyurethane type for example, namely an isocyanate constituent and a polyol constituent which react 'in situ' causing a heat release and foam expansion. Sufficient injection of the components is provided so that the foam (9) can completely fill the defined volume.

La mousse vient remplir ainsi l'espace compris entre la plaque inférieure (5) et la semelle de glisse (3) et l'espace ménagé entre chaque élément de renfort local ou jonc (7) et la feuille de recouvrement (8). On obtient une structure homogène et de forte cohésion dans laquelle les éléments servant à renforcer la structure sont emprisonnés dans la mousse, après son durcissement. La mousse repousse et plaque également la feuille de recouvrement de façon régulière contre les parois de la partie supérieure du morne. La feuille prend ainsi sa forme définitive dans le moule. On peut favoriser le formage de la feuille en chauffant le moule à une température et pendant un temps suffisant, en fonction de la nature du matériau utilisé.The foam thus fills the space between the lower plate (5) and the gliding sole (3) and the space provided between each local reinforcement element or rod (7) and the covering sheet (8). A homogeneous structure with strong cohesion is obtained in which the elements serving to reinforce the structure are trapped in the foam, after it has hardened. The foam also repels and presses the cover sheet evenly against the walls of the upper part of the hill. The sheet thus takes its final shape in the mold. The forming of the sheet can be promoted by heating the mold to a temperature and for a sufficient time, depending on the nature of the material used.

Le matériau constituant la (les) couche (s) de la feuille de recouvrement est choisi parmi le groupe des polyamides aliphatiques, polyether bloc amide, polyether bloc ester, les polycarbonates, les ABS (Acrylonitrile Butadiène Styrène), les AS (Acrylonitrile Styrène) purs ou mélangés à un TPU (Elastomère thermoplastique uréthane), les polyethylènes téréphtalates (PET), les polybutadiènes téréphtalates (PBT), les polyuréthanes, les polyoléfines, ainsi que les mélanges et copolymères de certains de ces constituants.The material constituting the layer (s) of the covering sheet is chosen from the group of aliphatic polyamides, polyether amide block, polyether ester block, polycarbonates, ABS (Acrylonitrile Butadiene Styrene), AS (Acrylonitrile Styrene) pure or mixed with TPU (thermoplastic urethane elastomer), polyethylene terephthalates (PET), polybutadienes terephthalates (PBT), polyurethanes, polyolefins, as well as mixtures and copolymers of some of these constituents.

De même, les éléments de renfort locaux ou joncs sont réalisés en matériau choisi dans le groupe constitué par : un métal du type acier, aluminium ou alliage d'aluminium, une matière plastique renforcée. Dans ce dernier cas, lors de la mise en moule, les joncs sont à base de fibres de verre, carbone ou aramide et d'une matrice de résine thermodurcissable ou thermoplastique.Likewise, the local reinforcing elements or rods are made of material chosen from the group consisting of: a metal of the steel, aluminum or aluminum alloy type, a reinforced plastic material. In the latter case, when being molded, the rods are based on glass fibers, carbon or aramid and on a matrix of thermosetting or thermoplastic resin.

La figure 5 illustre, en coupe transversale, la structure après injection de la mousse et de moulage entre deux pièces locales d'entretoisement. Grâce aux pièces d'entretoisement, on assure un écart prédéterminé (d) entre chaque élément de renfort local (7) et la feuille de recouvrement (8).FIG. 5 illustrates, in cross section, the structure after injection of the foam and molding between two local bracing pieces. Thanks to the spacer pieces, a predetermined gap (d) is ensured between each local reinforcing element (7) and the covering sheet (8).

La figure 6 montre la disposition longitudinale des éléments de renfort locaux (7) et la répartition régulière des pièces d'entretoisement (6) le long de la structure moulée. A titre d'exemple, la structure a la forme d'un ski qui présente schématiquement une forme en taille de guêpe. La largeur de chaque pièce (6) peut être variable pour s'adapter à la variation de largeur particulière du ski. Les éléments de renfort locaux (7) s'étendent longitudinalement formant un faisceau aux caractéristiques de renforcement en flexion et torsion élevées. Ces caractéristiques peuvent être facilement modulées longitudinalement et latéralement en modifiant le nombre et/ou la longueur des éléments (7). On peut, par exemple, augmenter les caractéristiques mécaniques du ski dans la zone centrale en ajoutant plusieurs éléments (7) supplémentaires de longueur limitée dans la zone à renforcer.Figure 6 shows the longitudinal arrangement of the local reinforcing elements (7) and the regular distribution of the bracing pieces (6) along the molded structure. For example, the structure has the shape of a ski which schematically has a wasp-shaped shape. The width of each piece (6) can be variable to adapt to the particular variation in width of the ski. The local reinforcing elements (7) extend longitudinally forming a bundle with high flexural and torsional reinforcement characteristics. These characteristics can be easily modulated longitudinally and laterally by modifying the number and / or the length of the elements (7). One can, for example, increase the mechanical characteristics of the ski in the central area by adding several additional elements (7) of limited length in the area to be reinforced.

Selon une variante de l'invention, la structure moulée peut être entièrement renforcée par des éléments locaux ou joncs supérieurs (70) et inférieurs (71) comme le montre la figure 7. Dans ce cas, la pièce d'entretoisement (6) comprend à la fois une série de logements supérieurs (620) et une série de logements inférieurs (621). Par des bossages (631) la pièce d'entretoisement maintient en place les joncs inférieurs (71) à une certaine distance de la semelle de glisse (3) de façon à permettre à la mousse de circuler librement pour uné cohésion parfaite de la structure.According to a variant of the invention, the molded structure can be entirely reinforced by local elements or upper rods (70) and lower (71) as shown in FIG. 7. In this case, the bracing piece (6) comprises both a series of upper housings (620) and a series of lower housings (621). By bosses (631) the bracing piece keeps the lower rods (71) in place at a certain distance from the sliding sole (3) so as to allow the foam to circulate freely for perfect cohesion of the structure.

Grâce au procédé selon l'invention, on peut obtenir facilement des reliefs (80) ou creux (81) sur la surface de la feuille de recouvrement (8). Ces formes sont réalisées par la déformation de la feuille (8) au contact de creux ou relief correspondants dans l'empreinte du moule et sous la pression exercée par l'expansion de la mousse lors de l'étape d'injection.Thanks to the method according to the invention, reliefs (80) or recesses (81) can easily be obtained on the surface of the covering sheet (8). These shapes are produced by the deformation of the sheet (8) in contact with corresponding recesses or reliefs in the mold cavity and under the pressure exerted by the expansion of the foam during the injection step.

Dans le cas de la figure 8, la pièce d'entretoisement (6) comprend des logements (62) supérieurs qui sont ouverts vers l'intérieur de la structure. La compressibilité élastique de la pièce est accrue par des pattes (64) qui agissent comme des ressorts à l'intérieur de la structure. L'élément de renfort inférieur (50) est maintenu au contact de la semelle (3) par les pattes (64). Il peut être une plaque en matériau fibreux préimprégné d'une résine époxyde, par exemple. Avec `la chaleur, lors du moulage par injection, on obtient la réticulation de la résine et simultanément le collage de la plaque sur la semelle et avec la mousse.In the case of FIG. 8, the bracing piece (6) comprises upper housings (62) which are open towards the inside of the structure. The elastic compressibility of the part is increased by lugs (64) which act as springs inside the structure. The lower reinforcement element (50) is held in contact with the sole (3) by the tabs (64). It can be a plate made of fibrous material pre-impregnated with an epoxy resin, for example. With heat, during injection molding, we obtain crosslinking of the resin and simultaneously bonding of the plate to the sole and with the foam.

Comme l'illustre la figure 9, la pièce d'entretoisement (6) peut aussi se présenter comme un tronçon de profil ayant une série de trous (65) qui s'étendent sensiblement dans la direction de la structure moulée,et dont la section transversale est légèrement supérieure à la section transversale de chaque élément supérieur de renfort (7). On obtient le prépositionnement des éléments supérieurs (7) par simple glissement dans leur trou de section adaptée correspondante.As illustrated in FIG. 9, the bracing piece (6) can also be presented as a profile section having a series of holes (65) which extend substantially in the direction of the molded structure, and the cross section of which transverse is slightly greater than the cross section of each upper reinforcing element (7). The upper elements (7) are pre-positioned by simple sliding in their corresponding adapted section hole.

Bien entendu, la structure moulée n'est pas limitée aux exemples décrits et l'on peut imaginer d'autres structures sans pour autant sortir du cadre de la présente invention.Of course, the molded structure is not limited to the examples described and one can imagine other structures without departing from the scope of the present invention.

La figure 10 illustre ainsi une autre variante dans laquelle, le renforcement latéral peut être augmenté par un élément de chant (82) positionné sur chaque carre latérale (4) et s'étendant sur une grande partie de celle-ci. La feuille de recouvrement ne forme qu'une partie seulement du chant de la structure moulée, dont les bords latéraux repose sur chaque élément de chant (82).FIG. 10 thus illustrates another variant in which the lateral reinforcement can be increased by an edge element (82) positioned on each lateral edge (4) and extending over a large part of it. The cover sheet forms only part of the edge of the molded structure, the lateral edges of which rest on each edge element (82).

Dans le procédé décrit, le formage de la feuille de recouvrement est effectué par la mousse elle-même. Il peut en être autrement dans le cas où, par exemple, le matériau utilisé pour la feuille n'est pas facilement déformable ou lorsque la forme finale à réaliser est relativement complexe. Dans ce cas, il peut être nécessaire d'appliquer une étape de' préformage de la feuille supérieure de recouvrement, préalablement à l'étape de mise en moule.In the described method, the forming of the cover sheet is carried out by the foam itself. It may be otherwise in the case where, for example, the material used for the sheet is not easily deformable or when the final shape to be produced is relatively complex. In this case, it may be necessary to apply a step of 'preforming the upper cover sheet, prior to the step of molding.

Claims (17)

Procédé de fabrication d'une structure moulée ayant la forme d'une poutre allongée consistant ; - à disposer dans un moule un sous-ensemble inférieur comprenant une semelle de glisse (3) bordée de part et d'autre par des carres latérales (4) ; éventuellement un élément de renfort inférieur (5, 50) ; - à recouvrir le sous-ensemble inférieur d'une feuille de recouvrement (8), pour former un volume fermé, destinée à constituer le dessus et une partie au moins des faces latérales de ladite structure ; - à fermer le moule ; - puis à injecter dans le volume ainsi défini les réactifs d'une mousse (9) qui s'expanse 'in situ' ; - puis à ouvrir le moule pour retirer la structure moulée complexe,
caractérisé en ce qu'au moment de la mise en moule, l'on intercale entre ledit sous-ensemble inférieur (3, 4, 5, 50) et ladite feuille de recouvrement (8), plusieurs pièces locales d'entretoisement (6), longitudinalement réparties sur une partie au moins de la longueur de la structure moulée ; lesdites pièces étant espacées l'une de l'autre, reposant sur le sous-ensemble inférieur et maintenant en place plusieurs éléments de renfort locaux (7, 70, 71) de faible largeur, espacés latéralement l'un de l'autre sur la largeur de ladite structure à mouler. A method of manufacturing a molded structure in the form of a substantial elongated beam; - To have in a mold a lower sub-assembly comprising a gliding sole (3) bordered on either side by lateral edges (4); possibly a lower reinforcing element (5, 50); - to cover the lower sub-assembly with a covering sheet (8), to form a closed volume, intended to constitute the top and at least part of the lateral faces of said structure; - to close the mold; - Then to inject into the volume thus defined the reagents of a foam (9) which expands 'in situ'; - then open the mold to remove the complex molded structure,
characterized in that at the time of setting in the mold, there is interposed between said lower sub-assembly (3, 4, 5, 50) and said cover sheet (8), several local bracing pieces (6) , longitudinally distributed over at least part of the length of the molded structure; said parts being spaced from each other, resting on the lower sub-assembly and now holding several local reinforcement elements (7, 70, 71) of small width, spaced laterally from each other on the width of said structure to be molded. Procédé de fabrication d'une structure moulée selon la revendication 1, caractérisé en ce que les pièces d'entretoisement (6) supportent localement la feuille de recouvrement (8) ; et maintiennent en place des éléments de renfort locaux (7, 70) à une distance prédéterminée de la surface inférieure de ladite feuille de recouvrement (8) pour favoriser le passage de la mousse (9) entre les éléments de renfort (7, 70) et ladite feuille de recouvrement (8).A method of manufacturing a molded structure according to claim 1, characterized in that the spacer pieces (6) locally support the cover sheet (8); and hold in place local reinforcing elements (7, 70) at a predetermined distance from the lower surface of said covering sheet (8) to promote the passage of the foam (9) between the reinforcing elements (7, 70) and said cover sheet (8). Procédé de fabrication d'une structure moulée selon la revendication 1 ou 2, caractérisé en ce que les pièces d'entretoisement (6) sont obtenues à partir d'un ou plusieurs profilés en matière plastique ou métallique réalisé(s) par injection, par extrusion ou pultrusion, puis découpé(s) en tronçons de longueur déterminée.Method of manufacturing a molded structure according to claim 1 or 2, characterized in that the bracing pieces (6) are obtained from one or more plastic or metallic profiles produced by injection, by extrusion or pultrusion, then cut into sections of determined length. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que chaque pièce d'entretoisement (6) se présente comme un tronçon de tube aplati dont la paroi comprend, au moins, une série de logements ouverts (62, 620, 621), de section transversale concave, et qui s'étendent sensiblement dans la direction longitudinale de la structure moulée, dans lesquels sont insérés les éléments de renfort locaux (7, 70, 71).Method of manufacturing a molded structure according to any one of the preceding claims, characterized in that each spacer piece (6) is in the form of a flattened tube section, the wall of which comprises, at least, a series of open housings (62, 620, 621), of concave cross section, and which extend substantially in the longitudinal direction of the molded structure, into which the local reinforcing elements (7, 70, 71) are inserted. Procédé de fabrication d'une structure moulée selon la revendication 4, caractérisé en ce que la section transversale de chaque logement (62, 620, 621) comprend une zone de rétrécissement pour permettre un engagement par clipsage de chaque élément supérieur de renforts locaux.Method of manufacturing a molded structure according to claim 4, characterized in that the cross section of each housing (62, 620, 621) includes a narrowing zone to allow engagement by clipping of each upper element of local reinforcements. Procédé de fabrication d'une structure moulée selon la revendication 1, 2 ou 3, caractérisé en ce que chaque pièce d'entretoisement (6) se présente comme un tronçon de profil ayant une série de trous (65) qui s'étendent sensiblement dans la direction longitudinale de la structure moulée, et dont la section transversale est légèrement supérieure à la section transversale de chaque élément de renforts locaux (7)Method of manufacturing a molded structure according to claim 1, 2 or 3, characterized in that each spacer piece (6) is in the form of a profile section having a series of holes (65) which extend substantially in the longitudinal direction of the molded structure, the cross section of which is slightly greater than the cross section of each element of local reinforcements (7) Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que les pièces d'entretoisement (6) sont réalisées dans un matériau semi-rigide déformable pour s'adapter à la variation d'épaisseur de la section transversale en fonction de la longueur de la structure moulée.Method of manufacturing a molded structure according to any one of the preceding claims, characterized in that the spacer parts (6) are made of a semi-rigid material which can be deformed to adapt to the variation in thickness of the cross section depending on the length of the molded structure. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications 1 à 6, caractérisé en ce que les pièces d'entretoisement (6) sont réalisées dans un matériau rigide résistant à l'écrasement.A method of manufacturing a molded structure according to any one of claims 1 to 6, characterized in that the bracing pieces (6) are made of a rigid material resistant to crushing. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que les éléments de renfort locaux (7, 70, 71) sont des joncs à section pleine circulaire, ovale ou polygonale.Method of manufacturing a molded structure according to any one of the preceding claims, characterized in that the local reinforcing elements (7, 70, 71) are rods with a circular, oval or polygonal full section. Procédé de fabrication d'une structure moulée selon la revendication 9, caractérisé en ce que les joncs sont réalisés en matériau choisi dans le groupe constitué par un métal du type acier, aluminium ou alliage d'aluminium, une matière plastique renforcée.A method of manufacturing a molded structure according to claim 9, characterized in that the rods are made of material chosen from the group consisting of a metal of the steel, aluminum or aluminum alloy type, a reinforced plastic. Procédé de fabrication d'une structure moulée selon la revendication 10, caractérisé en ce que lors de la mise en moule, les joncs sont à base de fibres de verre, carbone ou aramide et d'une matrice de résine thermodurcissable ou thermoplastique.A method of manufacturing a molded structure according to claim 10, characterized in that during the molding, the rods are based on glass, carbon or aramid fibers and a matrix of thermosetting or thermoplastic resin. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que l'on applique une étape de préformage de la feuille supérieure de recouvrement (8), préalablement à l'étape de mise en moule.A method of manufacturing a molded structure according to any one of the preceding claims, characterized in that a step of preforming the upper cover sheet (8) is applied, prior to the step of forming the mold. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que lors de la fermeture du moule, les bords latéraux de la feuille de recouvrement sont pincés fermement dans l'entrefer ménagé au voisinage du plan de joint (100) du moule ; sans possibilité de glissement, et en ce que l'on prévoit que la partie de la feuille se trouvant à l'intérieur du moule ait une surface développée équivalente à la surface de l'empreinte de la partie du morne correspondante.Method of manufacturing a molded structure according to any one of the preceding claims, characterized in that when the mold is closed, the lateral edges of the cover sheet are clamped firmly in the air gap in the vicinity of the joint plane (100) of the mold; without possibility of sliding, and in that it is expected that the part of the sheet located inside the mold has a developed surface equivalent to the surface of the imprint of the corresponding part of the dreary. Procédé de fabrication d'une structure moulée selon l'une quelconque des revendications précédentes, caractérisé en ce que la feuille de recouvrement (8) comprend une seule couche ou plusieurs couches de matière plastique préassemblées.Method of manufacturing a molded structure according to any one of the preceding claims, characterized in that the cover sheet (8) comprises a single layer or several layers of preassembled plastic. Procédé de fabrication d'une structure moulée selon la revendication 14, caractérisé en ce que le matériau constituant la(les) couche(s) de la feuille de recouvrement est choisi parmi le groupe des polyamides aliphatiques, polyether bloc amide, polyether bloc ester, les polycarbonates, les ABS (Acrylonitrile Butadiène Styrène), les AS (Acrylonitrile Styrène) purs ou mélangés à un TPU (Elastomère thermoplastique uréthane), les polyéthylènes téréphtalates (PET), les polybutadiène téréphtalates (PBT), les polyuréthanes, les polyoléfines, ainsi que les mélanges et copolymères de certains de ces constituants.Process for manufacturing a molded structure according to claim 14, characterized in that the material constituting the layer (s) of the covering sheet is chosen from the group of aliphatic polyamides, polyether block amide, polyether block ester, polycarbonates, ABS (Acrylonitrile Butadiene Styrene), AS (Acrylonitrile Styrene) pure or mixed with a TPU (Thermoplastic Urethane Elastomer), polyethylene terephthalates (PET), polybutadiene terephthalates (PBT), polyurethanes, polyolefins, as well as mixtures and copolymers of some of these constituents. Procédé de fabrication d'un ski selon l'une quelconque des revendications 1 à 15.Method for manufacturing a ski according to any one of Claims 1 to 15. Procédé de fabrication d'un surf des neiges selon l'une quelconque des revendications 1 à 15.A method of manufacturing a snowboard according to any one of claims 1 to 15.
EP96102251A 1995-03-03 1996-02-15 Method of fabrication a structure by injection molding Withdrawn EP0729769A1 (en)

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FR9502855 1995-03-03
FR9502855A FR2731160B1 (en) 1995-03-03 1995-03-03 PROCESS FOR THE MANUFACTURE OF A MOLDED STRUCTURE, IN PARTICULAR FOR SKIING OR SNOW SURFING, BY INJECTION OF AN IN SITU EXPANSION FOAM

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2773999A1 (en) * 1998-01-28 1999-07-30 Rossignol Sa Injection-molding procedure for ski or snowboard with upper and lower assemblies and inner reinforcement
WO2004045727A1 (en) * 2002-11-19 2004-06-03 Sportstec Gesellschaft Zur Entwicklung Innovativertechnologien Uwe Emig, Prof. Reinhold Geilsdörfer, Markus Gramlich Gbr Downhill ski
EP1736293A1 (en) * 2005-06-23 2006-12-27 Proseat Method for producing a part comprising an isocyanate based element adhered to a thermoplastic element and part produced thereby
AT501312B1 (en) * 2005-02-04 2009-05-15 Hexcel Holding Gmbh METHOD FOR PRODUCING A SLIDING EQUIPMENT AND SLIDING DEVICE
DE102009022506A1 (en) * 2009-05-25 2010-12-09 Scharr, Gerhard, Prof. Dr.-Ing. Lightweight-ski i.e. cross country ski, has supporting structure comprising bars in bar/framework structure while connecting elements fix bars at defined distance from each other and are spaced from each other
EP3632513A1 (en) * 2018-10-05 2020-04-08 Skis Rossignol Glideboard with injected core provided with longitudinal reinforcing elements
WO2022034099A1 (en) * 2020-08-12 2022-02-17 Hutchinson Method for manufacturing a mechanical part, the resulting part and a suspension triangle

Citations (3)

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Publication number Priority date Publication date Assignee Title
FR2405075A1 (en) * 1977-10-07 1979-05-04 Karhu Titan Oy Forming ski by densifying foamed envelope at surface - dispensing with laminated sections for sole, sides, and top
FR2684012A1 (en) * 1991-11-22 1993-05-28 Rossignol Sa Shaped ski of non-rectangular cross-section
WO1994028984A1 (en) * 1993-06-09 1994-12-22 Kästle Aktiengesellschaft Ski

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2405075A1 (en) * 1977-10-07 1979-05-04 Karhu Titan Oy Forming ski by densifying foamed envelope at surface - dispensing with laminated sections for sole, sides, and top
FR2684012A1 (en) * 1991-11-22 1993-05-28 Rossignol Sa Shaped ski of non-rectangular cross-section
WO1994028984A1 (en) * 1993-06-09 1994-12-22 Kästle Aktiengesellschaft Ski

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2773999A1 (en) * 1998-01-28 1999-07-30 Rossignol Sa Injection-molding procedure for ski or snowboard with upper and lower assemblies and inner reinforcement
WO2004045727A1 (en) * 2002-11-19 2004-06-03 Sportstec Gesellschaft Zur Entwicklung Innovativertechnologien Uwe Emig, Prof. Reinhold Geilsdörfer, Markus Gramlich Gbr Downhill ski
US7185908B2 (en) 2002-11-19 2007-03-06 Sportstec Gesellschaft Zur Entwicklung Innovativer Technologien Uwe Emig, Prof. Reinhold Geilsdorfer, Markus Gramlich Gbr Downhill ski
AT501312B1 (en) * 2005-02-04 2009-05-15 Hexcel Holding Gmbh METHOD FOR PRODUCING A SLIDING EQUIPMENT AND SLIDING DEVICE
EP1736293A1 (en) * 2005-06-23 2006-12-27 Proseat Method for producing a part comprising an isocyanate based element adhered to a thermoplastic element and part produced thereby
DE102009022506A1 (en) * 2009-05-25 2010-12-09 Scharr, Gerhard, Prof. Dr.-Ing. Lightweight-ski i.e. cross country ski, has supporting structure comprising bars in bar/framework structure while connecting elements fix bars at defined distance from each other and are spaced from each other
EP3632513A1 (en) * 2018-10-05 2020-04-08 Skis Rossignol Glideboard with injected core provided with longitudinal reinforcing elements
FR3086868A1 (en) * 2018-10-05 2020-04-10 Skis Rossignol SKI INJECTED HYBRID CORE
WO2022034099A1 (en) * 2020-08-12 2022-02-17 Hutchinson Method for manufacturing a mechanical part, the resulting part and a suspension triangle
FR3113380A1 (en) * 2020-08-12 2022-02-18 Conseil Et Technique Process for manufacturing a mechanical part, the part obtained and a suspension wishbone.

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FR2731160B1 (en) 1997-05-16

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