ITUA20164146A1 - SKI MANUFACTURING PROCEDURE, AND TYPICAL TOOLS FOR SLIDING ON THE SNOW, WITH THERMOFORMABLE MATERIALS WITH CARBON FIBER-BASED STRUCTURES, AND THERMOFORMING MOLDS OF SUCH PRODUCTS, AS WELL AS SKI AND SLIP TOOLS ON THE SNOW SO OBTAINED - Google Patents

Description

"PROCESS FOR MANUFACTURING SKIS, AND EQUIPMENT OF VARIOUS KIND FOR SLIDING ON THE SNOW, WITH THERMOFORMABLE MATERIALS WITH CARBON FIBER-BASED CARBON FIBER-BASED CARBON STRUCTURES, AND MOLDS OF THERMOFORMING OF THESE PRODUCTS, AS WELL AS 'SKIS, AND EQUIPMENT FOR SLIDING' OBTAINED "

The invention refers to a process for manufacturing skis and various kinds of tools for sliding on snow, with thermoformable materials having carbon fiber-based bearing structures, and also refers to the thermoforming molds of these products as well as to a ski, and tool thus obtained.

For the manufacture of skis, and tools of various kinds for different uses, and in particular but not exclusively of piste and / or off-piste skis and for ski mountaineering, it is known that a manufacturing technology of the type is widely used. sandwich, using a series of components with traditional materials, such as metal alloys, glass fibers, elastomeric materials and multi-layer wood cores, shaped with the shape of the respective product to be obtained, which components are superimposed and glued between them with epoxy resins to make them structural. These skis and tools have good mechanical resistance, however a very high weight that does not allow for universal application, but limits their use exclusively in particular sectors of application.

Another widely used technology for the manufacture of the aforementioned products for sliding on snow involves the use of polyurethane, which is injected into the component materials of the products themselves as a structural element. The chemical reaction of the polyol with the isocyanate, which make up the polyurethane, determines the bonding of all the component materials of the ski (steel plates, thermosetting polymeric plastic laminates and carbon fibers), and of the other tools for sliding on the ski. snow, which materials are previously superimposed on each other and the aforementioned polyurethane is injected between them. Although this manufacturing technology involves low processing costs, it requires long and difficult processing, and also does not give the products a mechanical strength such as to ensure a long life of these products. As a consequence of this, the products thus manufactured have a limited duration in time.

The present invention has the purpose of making skis and tools of various kinds with component materials other than those used in the manufacturing technologies specified above, and such as to give the skis and tools the best structural characteristics with greater mechanical resistance, which allow to obtain superior performance and greater safety and considerable elasticity during their use.

A further important object of the present invention is to produce skis and tools with load-bearing structures always based on carbon fibers, which are combined with materials with a thermoplastic matrix, so as to allow the assembly thus obtained to be thermoformed, i.e. before heated to a high softening temperature and then printed using specific molds, to obtain skis and tools with the desired shapes and sizes, which have high mechanical strength and high elasticity and after their shaping and cooling assume a rigid solid state.

These objects are achieved, according to the present invention, by means of a manufacturing process of skis and various kinds of tools for sliding on the snow, with thermoformable materials with carbon fiber-based load-bearing structures, and with a series of processing steps that will be described in detail, and through the use of specific thermoforming molds of these combined materials. The invention also refers to the thermoforming molds for products of this kind, as well as to the skis and snow gliding tools thus obtained.

The invention will be better understood from the following description, by way of non-limiting example only, of the present manufacturing process of skis and tools for sliding on snow, as well as of the thermoforming molds used and of a ski or tool thus made, with reference to the attached claims and the following drawings, in which:

Figure 1 shows a front perspective view of some rigid laminates, separated from each other, and each formed by carbon fibers intertwined with each other and used in the manufacturing process of skis and tools according to the present invention;

Figure 2 shows an exploded front perspective view of the different component parts separated from each other of a ski made with the process according to the present invention;

- figure 3 shows a schematic front perspective and exploded view of a central detail of the ski of fig. 1, and its various component parts;

- figure 4 shows a plan view of the ski of fig. 2 ;

- figures 5, 6, 7 and 8 show the cross sections of the ski of fig. 4, carried out respectively along the lines A-A, B-B, C-C and D-D of fig. 4;

Figure 9 shows a front view of a press, arranged to mount each time a forming mold provided for molding one or more component parts of the ski manufactured in accordance with the present invention;

- fig. 10 shows a side view of the press of fig. 1;

- figure 11 shows a plan view of the press of fig. 9;

- Figure 12 shows a front view of the component parts of one of the molds conforming to the invention;

figure 13 shows a plan view of the component parts of the mold of fig. 12;

figure 14 shows a front perspective view of the upper punch and of the lower die of the forming mold of fig. 12;

figure 15 shows an enlarged view of the component parts of the forming mold of figs.

12 and 13;

- figure 16 shows an enlarged front perspective view of the upper part of the mold of fig. 14, with a different angle;

figure 17 shows an enlarged front perspective view of the lower part of the mold of fig. 14, with a different angle;

- Figure 18 shows a front view of the component parts of the gluing mold constituting another of the molds conforming to the invention;

figure 19 shows a side view of the component parts of the mold of fig. 18;

figure 20 shows a plan view of the component parts of the mold of fig. 18;

- figure 21 shows an exploded front perspective view of the upper punch and the lower die of the gluing mold of fig. 18;

- figure 22 shows an exploded and enlarged front perspective view of the upper part of the mold of fig. 21;

- figure 23 shows an exploded and enlarged front perspective view of the lower part of the mold of fig. 21;

- figures 24-30 schematically show various processing steps of one of the rigid laminates according to fig. 1, constituting one of the component parts of the ski of fig. 2 ;

- Figure 31 shows a schematic front perspective view of a mold for assembling the various component parts of the ski, to form the ski;

figure 32 shows a schematic front perspective view of the two main component parts of the mold of fig. 31;

- Figures 33-37 show with respective schematic front views in cross section, performed in the central part of the ski according to the invention, of the mold of fig. 31 in different assembly phases;

- figure 38 shows a schematic and enlarged front view of a construction detail of fig. 37.

The present invention refers to a process for manufacturing skis and various kinds of tools for sliding on snow, with thermoformable materials having carbon fiber-based bearing structures, and also refers to the thermoforming molds of these products as well as to a ski and a tool thus obtained.

In particular, skis to be manufactured include in particular but not exclusively on-piste and / or off-piste skis and ski mountaineering skis, as well as skis normally used by general skiers as well as skiers for sports competitions.

The structure of a ski with its various component parts, and the related component materials used, as well as the mutual arrangement of these component parts, and all the processing steps envisaged by this manufacturing process for assembling such component parts of the skis.

However, before carrying out the description of what is specified above, the essential and innovative component materials that are used to manufacture the skis, in accordance with the present invention, will be described, whose structural composition and technical characteristics will be claimed below, which component materials are used in combination with further component materials, known per se and used for some time in the field.

The essential component materials that are used in accordance with the present invention are carbon fibers, which as known are obtained by pyrolysis of acrylic PAN (polyacrylonitrile) fibers, of which carbon fibers for general uses are obtained at

1200 ° C, while those with high modulus are obtained at 2800 ° C, and are classified as HM (high modulus) at 500 GPa, and as IM (intermediate modulus) at 300 GPa.

These carbon fibers have an extremely low weight, despite having high toughness and considerable mechanical properties such as high compressive strength, excellent rigidity and good fatigue behavior, due to the particular crystalline structure of graphite.

Furthermore, the use of these carbon fibers gives the skis exceptional characteristics, in terms of both performance and aesthetic and image aspects that can be obtained.

The further essential component materials that are used in accordance with the present invention will also be described below, together with the carbon fibers, with which they are combined with the processing steps in accordance with the invention, which will also be described in detail. According to the present invention, carbon fibers with an intermediate modulus of 300 GPa are used to manufacture the skis.

Before describing the various processing steps to manufacture the skis, we describe the different processing steps that are performed on the carbon fibers, to allow to obtain a rigid laminate formed by the set of these carbon fibers, and the materials that will be described below, and which serve to make one of the component parts of the skis, and in particular the body of the skis themselves.

For this purpose, in a first phase of processing the carbon fibers are stretched at a temperature above 2500 ° C, up to limit temperatures of 3000 ° C, and this operation is carried out using a pyrolysis oven, on which the carbon fibers are deposited and pulled by computerized modular tensors, until a macromolecular alignment along the longitudinal axis of the fibers themselves is obtained, with a maximum value of 2/3%.

This processing step on the carbon fibers allows to obtain anisotropic carbon fibers with high rigidity, with stiffness values between 150 GPa and 500 GPa, and preferably 300 GPa. Then, the carbon fibers thus pulled are joined together to form carbon fiber rovings, whose skeins are made up of about 12,000 threads per skein, thus being ready to be woven.

These yarns are then woven on particular looms of the electronic type, which are made by the Applicant and are not described in the present description, and such weaving takes place at room temperature, until different and complex textile configurations of the relative skeins are obtained, which configurations are suitable to be subsequently subjected, after the treatment of the hanks to the steps that will be described, to a thermoforming step.

The different yarns thus obtained are interconnected with each other, by twill-weave weaving with looms appropriate at an ambient temperature and for the times necessary to obtain a complete interconnection of the yarns themselves, verifiable by checks on the loom display.

The most common weaving is characterized by warp and weft threads that are interconnected in a regular way, in equal measure of weft and warp threads, or even with a prevalence of warp threads of 70%, and therefore with threads weft of 30%. The threads of this weaving are heat-sealed together, making it possible to obtain a bonded fabric that has an excellent ability to cover with drapes. These weaves can be carried out in different ways, to obtain different visible effects depending on the customers' requests, and in any case always allow the carbon fiber fabrics thus obtained to be subjected to the processing steps that will be described. The interconnections made in this way of the different yarns used produce a continuous woven fabric with a grammage of 280 gr / m2. and with a variable thickness preferably between 0.25 and 0.30 mm. A high degree of interconnection between the threads of the fabric can favor a better adaptation to the shape of the mold of the presses that are used during this processing phase, so that some types of these fabrics can also adapt perfectly to the relative thermoforming phase that is carried out. together with the material that will be described, and can give rise to better aesthetic aspects and mechanical characteristics.

The continuous carbon fiber fabrics that are obtained from the loom are deposited on particular steel platforms of these presses, and a thermoplastic polymeric material is then sprayed on the fabrics at a temperature of 25 ° C with relative humidity of 65%, preferably comprising powders. polymeric PPS (polyphenylene sulfide), which consist of a linear-chain crystalline aromatic thermoplastic polymer, formed by benzene rings connected by sulfur atoms. Polyphenylene sulfide is used for prolonged use at 280 ° C, resists chemicals, is insoluble and is considered a superpolymer.

This thermoplastic polymeric material is flame retardant with high resilience, and is mainly used in the aeronautical sector, and these PPS polymeric powders are contained within steel tanks of the rolling plant, and according to the present invention these two materials are used with a percentage ranging from 30% to 40% by weight of PPS powders and a percentage ranging from 60 to 70% by weight of continuous carbon fiber fabrics. At the end of the spraying of the PPS polymeric powders on the different carbon fiber fabrics, which are separated from each other, several layers of carbon fiber fabrics covered in this way are superimposed on each other, in such a way as to obtain a desired quantity of structural laminates formed by these fabrics of coated carbon fibers, depending on the product to be obtained, and these layers of coated carbon fiber fabrics are superimposed on each other through the use of translators with tension activators. During this operational phase, the platforms supporting the fibrous material are moved under a traditional heated press (not indicated) subjected to heating up to 350 ° C, with a temperature tolerance of / - 10 ° C, and with a pressure of 30-35 tons for a period of time ranging from 20 to 30 minutes, and this movement of the platforms is carried out through the use of pneumatic systems with a slow unidirectional movement, in order to subject in succession all the fibrous material to the same conditions of temperature and pressure described above.

At the end of this operational phase, in which all the fibrous material has been subjected to these conditions of temperature and pressure, the semi-crystalline polymeric powders are melted and saturate the weaving meshes of carbon with a percentage of 30-40% by weight.

Subsequently, a cooling phase of all the fibrous material is carried out, up to the temperature between 15 ° C and 20 ° C, and this cooling is carried out in a natural way through the use of a chiller that cools the water passing through the floors. of steel, so that at the end of this cooling phase a rigid laminate with continuous fiber thermoplastic characteristics and with spatial or three-dimensional orientation is formed, which laminate can be thermoformed to obtain the desired products and has a high elasticity, and such laminate also becomes rigid when each thermoformed product is subsequently cooled. The thickness of the rigid laminate thus formed will depend on the number of overlapping fabrics on the processing platform.

In fig. 1 schematically shows on an enlarged scale some rigid laminates 5, separated from each other, and each formed by series of carbon fibers constituted by respective wefts 6 of carbon fibers and by warps 7 of carbon fibers, intertwined with each other by means of the frames above described, with the configuration shown in the same figure 1.

The carbon fiber laminate thus obtained is then ready to be thermoformed with the processing steps and under the conditions that will be described shortly, to obtain the skis and tools for sliding on the snow with the desired shapes, aesthetic aspects and dimensions. . These skis and tools can also be remodeled by thermoforming, to obtain other skis and tools with different aesthetic aspects, shapes and sizes, leaving the continuous fiber carbon structure intact, without the emanation of polluting residual gases, as the process of thermoforming, which will be described shortly, takes place without chemical reactions and polluting discharges. The thermoforming of the rigid carbon fiber laminates thus obtained will be described below, with particular reference to Figures 24-30.

Referring now to FIG. 2, the different component parts of the ski 8 according to the present invention are shown, comprising the following separate component parts, which are then joined together as will be described:

- a closed box-like load-bearing structure 9, applied to the upper part of the ski and consisting of a body or upper load-bearing element 10 and a further body or lower load-bearing element 11, separated and spaced vertically from each other;

- a first and a second additional reinforcement element 12 and 13 ed

at least one central body or filling core 14, all of which are associated with the aforementioned closed box-like bearing structure 9;

- a series of lower closing elements, which are applied under said closed box-like bearing structure 9 and are identified as a whole with the numerical reference 15 and are formed both by at least two metal sheets 16, identical and arranged parallel and slightly spaced between them in the direction of the width of the ski, both from at least one shock-absorbing element 17 and from a lower sole 18.

In fig. 4 shows a plan view of the ski 8 according to the present invention, with all its component parts joined and superimposed on each other as will be described, from which it can be seen that in the example described here of the present ski 8, it is shaped both with a first widened end 19 and slightly curved and raised, constituting the front part of the ski, both by a second flat end 20 and slightly raised, constituting the rear part of the ski, and by an elongated central portion 21, connected with said front end 19 and rear 20 and shaped with side edges 22 and 23 symmetrical to each other and with a slightly concave shape for the whole length of the central portion itself, from one to the other of these front 19 and rear 20 ends. Of course, the ski can also be made with shapes and sizes different from those illustrated here by way of example, provided that it is always made up of the same component parts above a described and manufactured with the processing steps that will be described, without thereby departing from the scope of protection of the present invention.

The upper body 10 and the lower body 11 of the aforementioned supporting structure 9 are each made up of a rigid laminate with continuous fiber thermoplastic characteristics, formed as described above, or of carbon fibers and PPS polymeric powders, which rigid laminate is thermoformed by arranging the same in one or more corresponding molds of the traditional type of a thermoforming plant, in which each rigid laminate is obtained with the operating steps that will be described later, with particular reference to figures 24-30. These upper 10 and lower 11 bodies have the same shape and length and can be superimposed and connected together as will be described, and are also shaped respectively with the same front 19 and rear 20 ends of the ski 8 illustrated in fig. 4.

This thermoforming plant comprises one or more presses 24 of the traditional type, an example of which is illustrated with reference to figures 9-11, while in figs. 12-23 describes by way of example different types of molds used, with the relative component parts of the molds themselves, which will be described below and are mounted on one or more presses 24, to join together the different component parts of the ski 8 , with the reciprocal arrangements and with the processing steps envisaged by this process, which will be described below.

In turn, said first and second additional reinforcing elements 12 and 13 are shaped with the same shape and length as the upper 10 and lower 11 bodies and with their front 19 and rear 20 ends as those of the corresponding ends of the bodies themselves, and these reinforcing elements 12 and 13 are interposed between said bodies 10 and 11, in positions such that the first reinforcement element 12 is applied in contact under the lower surface of the upper body 10, and that the second reinforcement element 13 is applied to contact above the upper surface of the lower body 11, and that the aforementioned central filling body 14 is interposed and in contact between said first and second reinforcing elements 12 and 13.

The first and second additional reinforcing elements 12 and 13 are each made up of at least one layer (not indicated) of discontinuous reinforcing fibers of a per se known type, and oriented in a random way for the entire extension of the relative reinforcing element. .

In the present example of skis, discontinuous fibers are understood to be fibers having a length comprised between 0.1 cm. and 10 cm., and preferably between 1 cm. and 2 cm. According to an embodiment, the fiber layer of each of the additional reinforcing elements 12 and 13 consists of melt spun liquid crystal polymer (LCP fiber) fibers, preferably fibers of the type marketed under the "vectran" brand.

According to another embodiment, each additional reinforcement element is a non-woven fabric with the fibers oriented in a random way with respect to each other.

According to a further embodiment, the discontinuous and randomly oriented fibers of each additional reinforcement element are compacted by needle punch.

According to a further embodiment, each additional reinforcement element provides at least one layer of discontinuous and randomly oriented fibers, which layer has a thickness of between 0.1 mm. and 0.5 mm., and preferably between 0.2 and 0.25 mm.

According to a further embodiment, each additional reinforcement element has a thickness of between 0.1 mm. and 3 mm. and preferably comprised between 0, 2 and 1 mm.

According to yet another embodiment, each additional reinforcement element provides at least one layer of randomly oriented discontinuous fibers, which has a weight per surface between 80 and 400 g / m2.

According to yet another embodiment, the thickness of each additional reinforcement element is not uniform along the entire longitudinal axis K (see fig. 4) of the ski. For example, each additional reinforcement element can have a greater thickness, for example a thickness between two and six times the minimum thickness of the additional element itself.

For example, this greater thickness can be provided in the additional reinforcement element 12 in correspondence with a first portion P1 provided at the front end 19 of the ski, in which said first portion extends for example from said front end 19 towards the center of the ski, for a portion having a length comprised between 20 and 70 cm., and preferably comprised between 30 and 50 cm.

Furthermore, this greater thickness can also be provided in correspondence with a second portion P 2 of the ski, provided in correspondence with a central line J (see fig. 4) of the ski, which second portion extends upstream and downstream of the line. J, for example for a section having a length of between 10 and 50 cm. and preferably comprised between 15 and 25 cm., so that the overall length of the second portion P 2 is comprised between 20 and 100 cm. and preferably between 30 and 50 cm. This greater thickness can be further provided also in correspondence with a third portion P 3 of the ski, provided at the rear end 20 of the ski itself, in which this first portion extends for example from said rear end 20 towards the center of the ski. , for a section having a length between 10 and 70 cm. and preferably comprised between 20 and 50 cm. For example, in the first portion P 1 and between the lower surface of the upper body 10 and the upper surface of the filling body 14 there can be provided from two to six layers and preferably four layers of discontinuous and randomly oriented reinforcing fibers, and again in the first central portion P1 and between the lower surface of the upper body 10 and the upper surface of the filling body 14 there can be provided from two to four layers and preferably two layers of such reinforcing fibers, while in the remaining portions of the ski it can be provided a layer of such fibers. Preferably, a layer of these fibers is also provided in the other areas of the filling body 14, so that the latter is completely covered by said layer / layers of discontinuous and randomly oriented reinforcing fibers. According to another embodiment, each additional reinforcing element is provided both between at least a portion of the internal surface of the upper body 10 and the upper surface of the central filling body 14 and between at least a portion of the upper surface of the lower body 11 and a lower surface of the central filling body 14. According to a further embodiment, each additional reinforcing element entirely covers the central filling body 14.

According to yet another embodiment, each additional reinforcing element is bonded, by means of an adhesive substance, to at least a portion of the internal surface of the upper body 10 and to an upper surface of the filling body 14 and / or to at least a portion of the internal surface of the lower body 11 and to a lower surface of the filling body 14. It has surprisingly been experimentally verified that the presence of the additional reinforcing element, comprising discontinuous and randomly oriented fibers, and in particular of fibers of the "Vectran" type, it allows to significantly reduce the vibrations of the ski and to considerably increase the breaking load of the ski, as well as to improve the dimensional stability of the upper 10 and lower 11 bodies made as described above.

It should also be noted that the presence of each additional reinforcement element may not be foreseen, since it is not essential for the manufacture and assembly of the ski.

Referring again to FIG. 2, it is noted that the aforementioned central filling body 14 of the ski 8 is interposed, as already described, between the aforementioned additional reinforcing elements 12 and 13 and consists of natural wood-based materials or plastic materials, and preferably of closed cell synthetic expanded foam, with density between 50 and 90 Kg / m3, such as closed cell PVC, this filling body being shaped with the same shape and with slightly smaller dimensions than those of the bodies 10 and 11 and of the additional reinforcing elements 12 and 13, and also its front 19 and rear 20 ends are also shaped like the corresponding ends of the other component parts already described

Preferably, the ski 8 provides at least one reinforcing plate 25, and advantageously two reinforcing plates 25 of rigid material, suitable for increasing the thickness of the supporting structure 9 of the ski in the portions of the ski in which the traditional bindings are usually constrained (not shown ) for ski boots, in order to allow a more secure and reliable connection of the screws of the specified bindings.

The reinforcing plates 25 preferably have a thin flat shape and each of them is housed and fixed in a corresponding seat 26 made for a certain depth in the central filling body 14, so that in their housing position the plates 25 are flush of the upper wall 27 of the central body itself.

Referring again to FIG. 2, the lower closing elements of the ski are briefly described, which are applied under said supporting structure 9 and which include, as already specified, the two metal plates 16, the shock-absorbing element 17 and the lower sole 18.

These metal foils 16 preferably made of steel are inserted into identical sidecuts (not indicated), made along the two concave lateral edges 22 and 23 of the ski 8, and extend from the front contact line 28 of the relative lateral edges of the ski and up to the rear contact line 29 of the edges themselves, thereby delimiting along the ski the relative regions G 1, G 2 and G 3 shaped with different shapes and sizes.

In turn, the shock-absorbing element 17 is enclosed between the metal plates 16 and the lower sole 18 and serves to dampen the stresses and vibrations of the ski, and is made for example of Kevlar, wood or other traditional plastic material, or in a synthetic fiber suitable for the purpose, also of the traditional type. This shock-absorbing element 17 has the same shape and length as the said component parts of the ski forming the box-like supporting structure 9 and also its front 19 and rear 20 ends are shaped like those of the said component parts of the box-like supporting structure 9.

Finally, the lower insole 18 is preferably made of a high or very high density polyethylene, for example of HDPE or UHMWPE, preferably filled with graphite. and also has the same shape and length as the said component parts of the ski forming the box-like supporting structure 9, and also its front 19 and rear 20 ends are shaped like those of the said component parts of the box-like supporting structure 9.

Referring now to FIG. 3, the mutual arrangements of the different component parts of the ski described above are shown in detail, of which only the relative central portions are shown, and from this figure it can be seen that the upper body 10 has an upper wall 30, which in the example is of flat shape, and of the short side walls 31 and 32 inclined outwards in opposite directions, each for example with an inclination angle between 92 ° and 120 ° with respect to the upper wall, and said inclined walls 31 and 32 define a cavity 33 between them to house the underlying first and second reinforcing elements 12 and 13 and the central filling body 14, in the positions to be described. In turn, the first upper reinforcement element 12 also has an upper wall 34, which in the example is flat in shape, and short side walls 35 and 36 inclined outwards in opposite directions, which delimit between them a cavity 37 adaptable on the underlying central filling body 14.

This central filling body 14 is thinly shaped with a flat upper wall 38 and, in the example indicated, also with the seat 26 in which the corresponding reinforcing plate 25 is inserted flush, and it is also shaped with inclined side walls 39 and 40 connected to a flat lower wall 41 of the filling body itself, and the body 14 thus shaped is adapted for insertion into the cavity 37 of the above first upper reinforcement element 12.

In turn, the second lower reinforcement element 13 is thinly shaped and parallelepiped in shape, with a flat upper wall 42 and a flat lower wall 43, parallel to the latter. In this way, the central filling body 14 can be superimposed on the second lower reinforcing element 13 by placing the lower flat wall 41 of the filling body 14 in contact with the upper flat wall 42 of the second reinforcing element 13. To enclose the filling body. filling 14 in the space between the first and the second reinforcing element 12 and 13, this body is made with a height greater than that of this space, so that when the material of the body 14 is introduced into the aforementioned space, this material it is compressed by gluing itself against the internal walls of the reinforcing elements 12 and 13, thus ensuring better adhesion against these internal walls.

In turn, the lower body 11 is thinly shaped and parallelepiped in shape, with a flat upper wall 44 and a flat lower wall 45. In this way, the second reinforcing element 13 can be superimposed on the lower body 11, arranging the wall flat bottom 43 of this reinforcing element 13 in contact with the underlying flat upper wall 44 of the lower body 11. In turn, the metal sheets 16 are rectilinear shaped, in order to be able to be inserted, as already described, within the sidecuts of the two concave lateral edges 22 and 23 of the ski 8, while finally the shock-absorbing element 17 and the lower sole 18 are both shaped in parallelepiped shape with respective upper surfaces 46 and 47 and lower 48 and 49 which are flat, and in which the shock-absorbing element 17 is positioned as described above, while the lower sole 18 is applied and fixed in the lower position of the ski.

Referring now to FIGS. 5-8, all the component parts of the ski 8 are shown assembled together, with cross sections made respectively through the lines A-A, B-B, C-C, D-D of fig. 4, and all these sectioned component parts consist of the closed box-like supporting structure 9, arranged in the upper part of the ski and formed by the upper body 10 and the lower body 11 joined together, advantageously supporting the inclined walls 31 and 32 of the upper body 10 (see fig. 3) on the flat upper surface 44 of the lower body 11 and rigidly binding these bodies by means of an adhesive substance, as will be discussed in detail later, and in this way in the chamber defined between the upper body 10 and the lower body 11 they are enclosed hermetically from top to bottom the upper reinforcement element 12, the central filling body 14 and the lower reinforcement element 13. In this condition, as visible in fig. 6, the width L 1 of the lower body 11 is preferably greater than the width L 2 between the points of union of the inclined walls 31 and 32 of the upper body 10 with the lower body 11. As can be seen from these figures 5-8, moreover, the the thickness of the closed supporting structure 9 is variable in the various longitudinal positions of the ski provided in correspondence with the aforementioned transverse section lines, while the upper body 10 has the same width, and the flat upper surface 30 of the upper body 10 has the same width in figs. . 5, 6 and 8 and a smaller width in fig. 7, in which it is connected with two upper inclined surfaces 50 and 51 symmetrical to each other, and in turn the lower body 11 also has the same width along the entire length of the ski.

Said closed box-like supporting structure 9 is manufactured by thermoforming the upper 10 and lower 11 bodies in suitable molds, while the component parts enclosed by this supporting structure are first manufactured by molding in corresponding molds and then they are glued inside the supporting structure 9 with special molds, with the processing steps that will be described below.

In turn, also all the lower closing elements of the ski are first manufactured by molding in corresponding molds, and then they are arranged superimposed on each other and glued together and under the supporting structure 9, by means of a special mold and with the processing steps that will be described, with the same arrangement shown in fig. 2, i.e. with the metal sheets 16 applied under the lower body 11 and laterally to it, and with the shock-absorbing element 17 enclosed between these sheets 16 and the lower insole 18.

The processing and assembly steps of the various component parts of the ski 8 according to the present invention are now described, to make the ski itself.

According to the invention, it is first necessary to obtain the individual component parts of the ski, separated from each other, as will be described below, and subsequently join together the separate component parts thus obtained with their mutual arrangement shown in fig. 2.

The component parts separated from each other are obtained using one or more presses 24 of the traditional type, an example of which is illustrated with reference to figs. 9-11, and using specific molds that are installed in these presses and are shaped with the same shape and dimensions slightly larger than those of each component part to be manufactured.

The various separate component parts of the ski are obtained by molding the relative material using for example the mold 50 shown in figs. 12-17. As can be seen in figs. 9-17, of each press 24, its constructive structure and all its component parts, which are of a per se known type, and the upper punch 51 (see fig. 12-17) of the mold 50 used are not described in detail here. to mold a certain component part of the ski, it is mounted in the upper plate 52 of the press (see fig. 9-11), which is movable vertically, while the lower die 53 (see fig. 12-17) of the same mold is mounted in the lower plate 54 of the press, which is fixed (see fig. 9-11). As can also be seen in figs. 18-23, the example of a mold 55 is shown which is installed in one of the presses 24 and is used to assemble and glue together by molding all the component parts of the ski that have been obtained, with their same mutual arrangement shown in fig. 2. In this case, the specific lower die 56 (also visible in figs. 31 and 32) of this mold can be mounted in the fixed lower plate 54 of the press used, while in the movable upper plate 52 of the press it can be mounted from time to time turns the specific upper punch 57 (see fig. 12-17 and also 31 and 32) of the same mold.

In the mold 55 shown in FIGS. 18-23, both the punch 57 and the matrix 56 of this mold are shaped to assemble and glue at the same time by molding all the component parts of two skis, which are arranged in parallel positions and slightly spaced from each other in the transverse direction of the punch and of the matrix.

The different processing steps are now described for obtaining the upper body 10 and the lower body 11 of each ski, which are carried out using a particular thermoforming and molding mold with the operations described with reference to figs. 24-30, while as already described all the component parts of the ski other than these upper 10 and lower 11 bodies are obtained directly only by molding the relative component material. In particular, these upper 10 and lower 11 bodies are obtained using a particular thermoforming and molding mold 58 (see fig. 26), comprising a movable upper punch 59 and a fixed lower die 60, by means of thermoforming and molding of the rigid laminates 5 of the fig. 1 obtained with the processing steps described above, and consisting of carbon fibers and thermoplastic polymeric materials, preferably consisting of PPS (polyphenylene sulfide). Said punch 59 and die 60 are shaped with different shapes in order to thermoform by molding the upper body 10 and the lower body 11 separately, the profile of which is shown respectively in figs. 29 and 30.

In the following description, the processing steps carried out using the mold 58 shaped to thermoform and mold the upper body 10 are specified, see figs. 24-30, and the same processing steps are also carried out to thermoform and mold the lower body 11, in this case using another mold, shaped with the same shape and dimensions as this lower body.

In fig. 24 it can be seen that in the first processing step the upper punch of the mold 58 is raised with respect to the lower die 60 of the die itself, and does not appear visible in this figure, so that a rigid laminate 5 is positioned on said lower die 60, obtained and constituted as described above, which has been cut in advance with the desired dimensions, using a suitable cutting tool known per se. This rigid laminate 5 can also be placed on a frame (not shown) located at a close distance above the lower die 60.

In fig. 25 it is noted that in this phase the rigid laminate 5 is subjected to heating by means of heating devices, to soften the carbon fiber laminates, and then subject them to molding in order to obtain the finished products with the shape, dimensions and appearance desired aesthetics. As heating devices, quartz infrared lamps 61 are preferably used, mounted in a mobile mechanism (not shown) suitably supported and operated in an alternating horizontal direction above the rigid laminate 5, which in turn is held in position by suitable tensors. (not shown) associated with the mold 58. Such infrared lamps 61 continuously irradiate the laminates of carbon fibers preferably combined with the thermoplastic polymeric material PPS, and they have for example a power of 750 watts for each lamp, and in this phase, 40 to 60 quartz infrared lamps are advantageously but not necessarily used, which are operated for a limited time, for example in the order of 2-3 minutes, so as to make the laminates ductile. carbon fibers, i.e. deformed at about 280 ° - 300 ° C. The duration of the irradiation times of the carbon fiber laminates depends on the thickness of the laminates and on the amount of thermoplastic polymer used. Since carbon has a high electrical and thermal conductivity, it assumes the characteristics of an electric capacitor by amplifying the electromagnetic field that is created. The irradiation of the carbon fiber laminates continues until the carbon rapidly reaches heat saturation in the electromagnetic field thus generated, and this condition is verified. In this condition, this rigid laminate 5 is ready to be thermoformed by molding in the mold 58, and the infrared lamps 61 are moved by the aforementioned mobile mechanism from their position above the rigid plate 5, freeing up the space for the upper punch 59 , which can thus be lowered during the subsequent molding step of the rigid laminate 5 thus heated.

To carry out the molding of the rigid laminate 5 thus heated, each mold 58 that is used is previously heated to temperatures lower than that in which said rigid laminate 5 was heated, and preferably to a temperature between 150 ° and 200 ° C.

In the subsequent processing step shown in fig. 26, in which the molding of the rigid laminate 5 is carried out, the upper punch 59 is lowered and pressed against the rigid laminate 5 with a high pressure, preferably of the order of 25 tons. for a limited period, between about 3-4 minutes. Thanks to the lower heating temperature of the mold, the thermal inertia of the carbon fibers of the related rigid laminates is interrupted and the cooling phase of the body is started from time to time obtained from the molding of the laminates themselves.

This is determined by the fact that the thermoplastic polymer composing the carbon fiber laminate has a glass transition (Tg) of 88/90 ° C, so when the carbon in the mold reaches this temperature, the thermal motions end and the laminates of the body become rigid. At this point, as shown in fig. 27, the mold is opened and the body thus formed is extracted from the mold itself, in the subsequent step shown in fig. 28.

This body is then trimmed, preferably immediately after extraction from the mold 58, as soon as the body itself has cooled, to thus obtain the final finished element.

With these processing steps, it is thus possible to obtain shells with high quality levels and with the possibility of reusing the shells for other uses, thanks to the fact that they consist of carbon fibers combined with thermoplastic material, which can be heated again and thermoformed.

The upper 10 and lower 11 bodies thus formed (see also the relative figs. 29 and 30) are shaped with the desired shapes and dimensions, starting from the rigid laminates described above, thanks to the fact of mathematically calculating the linear expansion of the polymer in advance. thermoplastic used (in this case, the PPS) with respect to the shrinkage of the carbon fibers on a surface such as that of the ski shells. The computer-aided design allowed the Applicant to process virtual geometric models using specific hardware and software to size the molds, such as the molds 58, suitable for the thermoforming of the thermoplastic carbon constituting the rigid laminates 5 to make the ski shells. , and this methodology had never been adopted before, given the different manufacturing methods and the different component materials used up to now to make the skis.

It should also be noted that the heating of the rigid laminates to obtain their thermoforming as described above can also be performed with heating devices other than the infrared lamps 61 described above, using for example electrical resistances, or similar means, suitable for determining the heating temperatures described above, without thereby departing from the scope of protection of the present invention.

By replacing the mold in the press with other types of molds, with punches and dies shaped in different ways, it is thus possible to print bodies with different shapes, sizes and aesthetic aspects, which have autonomous bearing structures based on carbon fibers, and can be applied in other types of skis.

According to the present invention, moreover, for the thermoforming of thermoplastic carbon, in addition to the aforementioned PPS superpolymer, polyamide 6 and polymeric blends formed by a stable mixture of two or more polymers can also be used as thermoplastic matrices. Fully miscible blends are homophasic while partially miscible blends are heterophasic. The usable blends with good characteristics are PA / PP (polyamide and polypropylene); PA / ABS (polyamide and acrylonitrile, butadiene, styrene); PE / PP (polyethylene and polypropylene).

The shells thus constituted are subsequently joined with the remaining component parts of each ski, with the arrangement of the various component parts shown in fig. 31, using the gluing molds shown both in the same fig. 31 and in fig. 32, and with the processing steps shown in figs. 33-38.

However, before joining the different component parts of the ski, at least the external surfaces of the bodies 10 and 11 suitable for being glued to the central body 14 are subjected to a treatment to increase their surface roughness. Treatments of this kind are carried out to increase the roughness and surface roughness, in order to improve the gripping action of the glue used to join the different component parts, and these treatments can be mechanical abrasion treatments such as sandblasting, shot peening. , brushing, etc., or chemical, photochemical, electrochemical treatments, cold plasma flaming, etc. Preferably, the surface roughness of the surfaces of the bodies 10 and 11 is increased by at least two / three times, and it has been found in practice that the increased roughness also leads to an increase in the flexural strength of the ski. To glue the various component parts of the ski, a uniform layer of glue is spread manually or with known automated systems on at least one external surface of each component part of the ski, with the exception of the external surfaces not to be glued on the upper body 10 , of the insole 18 and of the metal sheets 16. A bi-component substance, based on polyurethane or epoxy, or other substances suitable for use, can be used as an adhesive and / or glue substance.

The present ski manufacturing process first of all provides for the arrangement in the mold 55 for assembling and gluing the various component parts of the ski, with the arrangement shown in fig. 2, however overturned with respect to it, and the mutual superposition of all these component parts. In fig. 31 shows the various components of the ski 8, separated from each other and with the same arrangement as fig. 2, however overturned, and with the lower fixed die 56 and the upper punch 57 movable vertically. In this arrangement, however, the reinforcing elements 12 and 13 have not been provided, but they are advantageously used and are glued with the remaining component parts of the ski with the same arrangement of fig. 2. As can be seen from this fig. 31 and also from fig. 32, the lower fixed matrix 56 is shaped as an elongated body 62 with a box-like parallelepiped shape, delimited by a flat front end 63 and a flat rear end 64 and has slightly larger dimensions than those of the various component parts that can be superimposed and glued together. them skiing. The elongated box-like body 62 is hollowed out for almost its entire length with a cavity 65, shaped to receive the various component parts of the ski to be joined together and ending with a front end 66 and a rear end 67, of the same shape and shape. slightly larger than the corresponding front 19 and rear 20 ends of the component parts of the ski shown in fig. 2. In turn, as can be seen again from figs. 31 and 32, the upper movable punch 57, which in Figure 32 is shown upside down, is shaped as an elongated body 68 with a box-like parallelepiped shape, delimited by a flat front end 69 and a flat rear end 70 and hollowed for almost its entire length with a cavity 71, shaped to receive the different component parts of the ski to be joined together and ending with a front end 72 and a rear end 73, of the same shape and slightly larger in size than the corresponding front end 19 and rear 20 of the component parts of the ski shown in FIG. 2.

In figs. 33-38 now shows the processing steps carried out to assemble and glue together the various component parts of the ski, superimposed on each other with the arrangement of fig. 31 and using the component parts of the gluing mold 55. To glue the various component parts of the ski, the fixed lower matrix 56 of the mold 55 has a seat 74 suitable for housing the various component parts of the ski 8 inside it. and the upper movable punch 57 of the mold has a protruding portion 75 adaptable at least partially to insertion in the seat 74 of the die 56 (as shown in Fig. 37).

The seat 74 of matrix 56 provides:

- a lower horizontal flat wall 76 adapted to house the flat upper wall 30 of the upper body 10 of the ski (see fig. 33);

- a first portion of vertical wall 77 provided above the flat horizontal wall 76 and adapted to house the lower body 11, the sheets 16, the insole 18 and the shock-absorbing element 17 provided between the sheets 16;

- a second vertical wall portion 78 connected above said first vertical wall portion 77 and adapted to house and allow the movement of the protruding portion 75 of the upper punch 57 (see fig. 37).

Between the lower flat wall 76 and the vertical wall portion 77 of the seat 74 of the die 56 of the mold there is provided a free space 79 (see also Fig. 38) which does not come into contact with any of the component parts of the ski 8 and in particular does not even come into contact with the terminal edges 80 and 81 of the inclined walls 32 and 31 of the upper body 10.

The purpose of this free space 79 is to allow a better adhesion of the component parts of the ski, because on the one hand it allows the discharge of any excess adhesive substance during the gluing of the various component parts of the ski and on the other it allows to exercise a greater pressure on the component parts of the ski and ensures that the latter are perfectly arranged in a pack during the gluing phase.

To facilitate the positioning of the foils 16, the mold provides a plurality of magnetic elements 82 (see fig. 38) distributed in recessed seats inside the walls that delimit the vertical wall portion 77 of the seat 74 of the lower fixed matrix 56 of the mold. .

According to the invention, the protruding portion 75 of the upper punch 57 of the mold has substantially the same shape as the ski to be assembled and in particular has an outermost surface 83 (see fig. 33), suitable for coming into contact with the ski. insole 18 and the blades 16 of the ski, having exactly the shape of the sliding surface to be obtained for the ski, and of the side walls 84 also having the same shape as the side walls of the ski.

The different processing steps are now described for assembling and gluing together all the component parts of the ski, in the lower matrix 56 of the mold with the arrangement illustrated in fig.

31 and in fig. 34.

In the working phase of fig. 35 a), it is noted that first of all the upper body 10 is inserted into the seat 74 of the lower die 56 in an inverted position, so that the upper wall 30 of the body itself comes into contact with the horizontal wall 76 of the die 56 and that the walls 31 and 32 of this body adhere flush with the walls of the seat 74, with the exception of the fact that the relative terminal edges 81 and 80 of these inclined walls 31 and 32 remain slightly spaced from the opposite walls of the seat 74, due to the presence of the corresponding free space 79.

In the next step of fig. 35 b), the filling body 14 is positioned in the cavity delimited by the upper body 10 and in this condition the external horizontal surface (not shown) of this body protrudes slightly (for example by a few tenths of a millimeter) from the terminal edges 81 and 80 of the upper cover 10.

In the subsequent phase of fig. 36 a), it can be seen that on the external surface of the filling body 14 thus housed the lower body 11 is superimposed in contact, which covers the whole filling body 14, and its lateral edges come into contact with the opposite walls delimiting the seat 74, thus covering the free spaces 79; then, the shock absorbing element 17 is positioned and centered on the upper surface of the lower body 11.

In the subsequent phase of fig. 36 b), it is noted that the insole 18 is superimposed in contact and in a central position on the upper surface of the shock-absorbing element 17, and in the free cavities (not shown) between the lateral edges of the insole 18 and the opposite wall of the seat 74 are positioned the metal sheets 16, the positioning of which is facilitated and made stable by the presence of the magnets 82 (see fig. 38), which keep these metal sheets 16 attracted in this position. Although not shown here, the additional reinforcing elements are also 12 and 13 are joined and glued to the component parts of the ski, with the same upside-down arrangement illustrated in fig. 2. In this condition, all the component parts of the ski are positioned in the seat 74 and ready to be glued together by molding.

In the subsequent phase of fig. 37, the upper punch 57 of the mold is lowered, so that the protruding portion 75 of the same penetrates into the seat 74 and the external surface 83 of this protruding portion 75 comes into contact with the relative external surface of the insole 18, shaped in a corresponding manner, and in this condition the upper punch 57 is pressed against the component parts of the ski with the desired pressure and for the time necessary to cause the mutual bonding of all these component parts. This bonding also takes place, as already specified, with the mold heated to a predetermined temperature, which determines during the molding time the polymerization of the resinous films of the adhesives used, thus making the ski one-piece. In this condition, then, the lower surface 87 of the punch 57 and the upper surface 86 of the die 56, opposed to this lower surface 87, are spaced apart by a portion H, which makes it possible to further adjust the downward stroke of the punch 57 with respect to the matrix 56, if required to exert an optimal pressure on all the component parts of the ski, and to improve the union between the parts themselves by distributing the pressure thus exerted in a more homogeneous way over the entire surface of the ski.

At the end of this molding phase, the component parts of the ski are perfectly glued together and, after the whole assembly has cooled to the required temperature, the mold is opened and the ski thus obtained is extracted from the mold itself, manually or with automated methods. This cooling time is chosen in order to consolidate the structural parameters of the ski, its geometric shape and the relative ribs.

Then, the ski is finished in the traditional way and, after having left it "to rest" for a period of time ranging from a few hours to a few days, the grinding and finishing of the ski is carried out. This rest time is necessary to allow the complete drying of the glue and the adhesion between the component parts produced by the glue itself to occur.

Claims (15)

"PROCESS FOR MANUFACTURING SKIS, AND EQUIPMENT OF VARIOUS KIND FOR SLIDING ON THE SNOW, WITH THERMOFORMABLE MATERIALS WITH CARBON FIBER-BASED CARBON FIBER-BASED CARBON STRUCTURES, AND MOLDS OF THERMOFORMING OF THESE PRODUCTS, AS WELL AS 'SKIS, AND EQUIPMENT FOR SLIDING' OBTAINED " CLAIMS 1. Process for manufacturing skis, and tools of various kinds for sliding on snow, with thermoformable materials having load-bearing structures based on carbon fibers, in which each ski (8) is substantially constituted by a load-bearing structure or body (10) based on carbon fibers, applied in the upper part of the ski (8), by a first additional reinforcement element (12) and by a second additional reinforcement element (13) applied under said load-bearing structure or shell (10) and formed by discontinuous reinforcing fibers of the liquid crystalline polymer type hot spun, preferably by fibers of the "Vectran" type, or by non-woven fabric with fibers oriented randomly to each other, compacted or not compacted together by needling, the ski being furthermore consisting of at least one central body or filling core (14), interposed between said first and second additional reinforcement elements (12, 13) and consisting of natural wood-based materials or from plastic materials, and preferably from closed-cell synthetic expanded synthetic foam, such as closed-cell PVC, the ski being also made up of identical metal sheets (16) arranged parallel and slightly spaced apart in the direction of the width of the ski (8 ), under said second additional reinforcement element (13), by at least one shock-absorbing element (17) and by a lower insole (18), in which said shock-absorbing element (17) is enclosed between said metal sheets (16) and said lower sole (18) and serves to dampen the stresses and vibrations of the ski, and is made of Kevlar, wood or other traditional plastic material or a traditional synthetic fiber, and in which said lower sole (18) is made of a high or very high density polyethylene such as HDPE or UHMWPE, loaded with graphite, characterized by the fact that said load-bearing structure or body (10) is made up of carbon fibers with m intermediate odule of 300 GPa., which are pulled at a temperature above 2500 ° C, up to limit temperatures of 3000 ° C, through the use of a pyrolysis oven or similar equipment, on which the carbon fibers are deposited and pulled by computerized modular tensors, until obtaining a macromolecular alignment along the longitudinal axis of the fibers themselves, with a maximum value of 2/3%, obtaining anisotropic carbon fibers with high rigidity, with stiffness values between 150 GPa and 500 GPa, and preferably of 300 GPa., That the carbon fibers thus pulled are joined together to form carbon fiber rovings, whose skeins are composed of about 12,000 threads per skein, which said threads are woven on looms of the traditional type at room temperature, until different and complex textile configurations of the relative skeins are obtained, which configurations are suitable for being subjected subsequently, after the treatment of the hanks to the subsequent steps of the process, to a thermoforming step by means of thermoforming means known per se, which the different yarns thus obtained are interconnected, by twill-weave weaving with looms known per se at an ambient temperature and for times necessary to obtain a complete interconnection of the yarns themselves, verifiable by checks, and the threads of this weaving are heat-sealed together in order to obtain a bound fabric, and that the interconnections thus made of the different yarns used produce a continuous fabric woven with a weight of 280 gr / sqm. and with a variable thickness preferably between 0.25 and 0.30 mm. ; that the continuous carbon fiber fabrics that are obtained from the loom are deposited on traditional heated presses, and a thermoplastic polymeric material is then sprayed onto the fabrics comprising polymeric powders PPS (polyphenylene sulfide) at a temperature of 25 ° C with relative humidity of the 65%, with a percentage ranging from 30% to 40% by weight of PPS powders and a percentage ranging from 60 to 70% by weight of the continuous carbon fiber fabrics; that at the end of the spraying of the PPS polymeric powders on the different carbon fiber fabrics, which are separated from each other, several layers of carbon fiber fabrics covered in this way are superimposed on each other, in such a way as to obtain a desired quantity of structural laminates formed from these coated carbon fiber fabrics, depending on the type of ski to be obtained, and these layers of coated carbon fiber fabrics are superimposed on each other through the use of translators with tension activators, and in this phase the fibrous material is moved under said press heated with a heating temperature up to 350 ° C, with a temperature tolerance of / - 10 ° C, and with a pressure of 30-35 tons for a period of time ranging from 20 to 30 minutes, and this handling of the fibrous material is carried out by means of the use of pneumatic systems known per se, with a slow unidirectional movement, so as to subject in succession release of all the fibrous material under the same said temperature and pressure conditions; that at the end of this operative phase, the semicrystalline polymeric powders are melted and saturate the weaving meshes of the carbon with a percentage of 30-40% by weight; that subsequently a cooling phase of all the fibrous material is carried out, up to the temperature between 15 ° and 20 ° C, so that at the end of this cooling phase a rigid laminate is formed with continuous fiber thermoplastic characteristics and with orientation spatial or three-dimensional, which laminate has a high elasticity; that said rigid laminate is positioned and thermoformed within at least a first thermoforming and molding medium with a temperature of about 280 ° C-300 ° C, so as to soften and make the rigid laminate ductile, for durations depending on the thickness of the laminates and by the amount of thermoplastic polymer used, a condition in which the carbon, which has a high electrical and thermal conductivity, assumes the characteristics of an electric capacitor, amplifying the electromagnetic field that is created; that the rigid carbon fiber laminate is heated until the carbon reaches heat saturation in the electromagnetic field thus generated; that the rigid laminate thus heated is taken from the position in which it is found and is automatically transferred to at least a second molding means (58), which is heated to temperatures lower than the heating temperature of the rigid laminate, and preferably at a temperature between 150 ° and 200 ° C, to be subsequently pressed with a high pressure, of the order of 25 tons, for a limited period, and is then extracted from said second molding means (58), thus obtaining said supporting structure or body ( 10) with the desired shape, size and aesthetic aspects; the process being further characterized in that said first and second additional reinforcing elements (12, 13), said central body or filling core (14), said metal sheets (16), said shock-absorbing element (17) and said lower insole ( 18) are obtained separately by third molding means using specific molds (50); that before joining together all the component parts of the ski, said load-bearing structure or body (10) is subjected to a surface treatment to increase its roughness and surface roughness, to improve the gripping action of at least one known glue in itself which is subsequently applied in position to join the different component parts, while on the other component parts of the ski is also applied superficially at least one glue substance known per se, for the union with the other component parts of the ski, and this application is not carried out on the external surfaces not to be glued of a part of said body (10), of said sole (18) and of said metal sheets (16); and finally characterized by the fact that all the component parts of the ski are glued together by molding the parts themselves by means of fourth assembly and molding means (55), realizing said supporting structure or body (10) with an upper body (10) and with a lower body (11), which are joined together to form a closed box-like structure (9), inside which said central body or filling core (14) is arranged, and arranging in a superimposed position between them, from above towards the bottom, said upper body (10), said filling body (14), said lower body (11), said shock-absorbing element (17), enclosed between said metal sheets (16), and said lower insole (18). 2. Process for manufacturing skis according to claim 1, characterized in that the most common weaving of the yarns is characterized in equal measure by weft threads (6) and by warp threads (7), intertwined with each other, or also with a prevalence of warp threads (7) of 70% and therefore with weft threads (6) of 30%, intertwined with each other. 3. Process for manufacturing skis according to claim 1, characterized in that the cooling of the fibrous material is carried out in a natural way through the use of a chiller that cools the water passing through said press. 4. Process for manufacturing skis according to claim 1, characterized in that the heating of the rigid carbon fiber laminates (5) is carried out by irradiation through about 40-60 quartz infrared lamps, with a power of 750 watts per each lamp. 5. Process for manufacturing skis according to claim 1, characterized in that the heating of the rigid carbon fiber laminates (5) can also be carried out by means of electric heating resistors. 6. Process for manufacturing skis according to claim 1, characterized in that polyamide 6 and polymeric blends formed by a stable mixture of two or more polymers can also be used as thermoplastic matrices, in which the completely miscible blends are homophasic while those partially miscible are heterophasic. 7. Process for manufacturing skis according to claim 6, characterized in that the usable blends with good characteristics are PA / PP (polyamide and polypropylene); PA / ABS (polyamide and acrylonitrile, butadiene, styrene); PE / PP (polyethylene and polypropylene). 8. Process for manufacturing skis according to claim 1, characterized in that the surface treatment of said load-bearing structure or shell (10) can be carried out by mechanical abrasion treatments such as sandblasting, shot peening, brushing, or by chemical treatments , photochemical, electrochemical, cold plasma flame. 9. Molding means used to make a ski manufactured with the manufacturing process according to claims 1-5 and 8, characterized in that said second molding means comprises at least one thermoforming and molding mold (58) including a movable upper punch ( 59) and a fixed lower die (60), and heating devices (61) of the relative rigid laminates (5), mounted in a movable mechanism of the mold arranged above the relative rigid laminates (5) and operable in an alternating horizontal direction, called punch (59) and die (60) being shaped with different shapes to thermoform by molding said upper (10) and lower (11) shells separately, starting from a relative rigid laminate (5), said movable punch (59) being initially raised to arrange in the mold (58) a relative rigid laminate (5) to be thermoformed, which is heated by means of said heating devices (61) which, at the end of the heating at the temperature and for the desired time of said rigid laminate (5), they are moved by said movable mechanism, freeing the space for said upper punch (59), which can thus be lowered with consequent molding of the rigid laminate (5) thus heated, with subsequent extraction from the mold (58) of each upper (10) and lower (11) body thus formed. 10. Molding means according to claim 9, characterized in that said heating devices (61) comprise about 40-60 quartz infrared lamps, with a power of 750 watts for each lamp. 11. Molding means according to claim 9, characterized in that said heating devices (61) comprise electric heating resistors. 12. Molding means used to make a ski manufactured with the manufacturing process according to claims 1-5 and 8, characterized in that said third molding means comprise a mold (50) including at least one movable upper punch (51) and at least a fixed lower die (53), and shaped to mold the respective component parts of the ski, except said upper (10) and lower (11) shells, and mounted respectively in the upper vertically movable plate (52) and in the lower fixed plate (54 ) of a traditional press (24). 13. Molding means used to make a ski manufactured with the manufacturing process according to claims 1-5 and 8, characterized in that said fourth assembly and molding means (55) comprise a mold (55) installed in a press ( 24) of the traditional type and including a vertically movable upper punch (57) and a fixed lower die (56), said movable upper punch (57) being shaped as an elongated body (68) with a box-like parallelepiped shape, delimited by one end flat front (69) and a flat rear end (70) and hollowed for almost its entire length with a cavity (71), shaped to receive the different component parts of the ski (8) to be joined overlapping each other and ending with a front end (72) and a rear end (73), of the same shape and slightly larger in size than the corresponding front (19) and rear (20) ends of the different component parts of the sci (8), and said lower fixed matrix (56) being shaped as an elongated body (62) with a box-like parallelepiped shape, delimited by a flat front end (63) and a flat rear end (64), and presenting dimensions slightly larger than those of the different component parts of the ski (8) to be joined overlapping each other and said elongated box-like body (62) being hollowed for almost its entire length with a cavity (65), shaped to receive the different component parts of the skis (8) to be joined overlapping each other and ending with a front end (66) and a rear end (67), of the same shape and slightly larger than the corresponding front (19) and rear (20) ends of the different component parts of the ski (8), the various component parts of the ski (8) being housed in the mold (55) by arranging in succession within said cavity (65) of said matrix (56) said upper body (10), said first element ofadditional reinforcement (12), said central filling body (14), said second additional reinforcement element (13), said lower body (11), said shock-absorbing element (17), enclosed by said metal sheets (16), and said lower sole (18), and on the component parts thus arranged by being lowered said upper punch (57), with consequent molding and assembly by gluing all these component parts and forming the finished ski (8). Carbon fiber-based ski (8), obtained with the manufacturing process according to claims 1-8, and with the molding means according to claims 9-13, characterized by the superimposed arrangement and by the joining and adaptation reciprocals of an upper bearing body (10), a first additional reinforcement element (12), a filling body (14), a second additional reinforcement element (13), a lower bearing body (11), a shock-absorbing element ( 17) enclosed by two metal sheets (16) and a lower sole (18). Carbon fiber-based ski (8) according to claim 14, characterized by reinforcing plates (25) of rigid material, housed and fixed in corresponding seats (26) made in said central filling body (14), in the position in which the traditional bindings for ski boots are usually constrained, said plates (25) being able to increase the thickness of the supporting structure of the ski, so as to allow a more secure and reliable connection of the screws of the specified bindings.