WO2017212394A1

WO2017212394A1 - Process for the manufacture of skis, with thermoformable materials having a load bearing structure based on carbon fibers, thermoforming molds for such product, skis obtained through this process.

Info

Publication number: WO2017212394A1
Application number: PCT/IB2017/053308
Authority: WO
Inventors: Marco ASCHERI
Original assignee: Aseo S.R.L.
Priority date: 2016-06-07
Filing date: 2017-06-05
Publication date: 2017-12-14
Also published as: ITUA20164146A1

Abstract

Process for manufacturing of skies, and equipment of various kind for sliding on the snow, with thermoformable materials having load bearing structures based on carbon fibers, and molds for thermoforming such products as well as so obtained skies and equipment for sliding on the snow. There are described the various phases of the manufacturing process for obtaining the different component parts of the ski (8), the materials of which are described, and the upper (10) and lower (11) bodyworks of the same ski, formed by carbon fibers mixed with polymeric powders PPS or other thermoplastic polymeric material, and for overlapping and joining to each other, through glueing, the different component parts with an established arrangement, by using a first thermoforming and molding means and a second molding means (58) for forming the bodyworks (10, 11), third molding means (50) for forming the other component parts of the ski (8), and fourth assembling and molding means (55) for glueing to each other all the component parts of the ski (8) with the established arrangement.

Description

PROCESS FOR THE MANUFACTURE OF SKIS, WITH THERMOFORMABLE

MATERIALS HAVING A LOAD BEARING STRUCTURE BASED ON CARBON FIBERS, THERMOFORMING MOLDS FOR SUCH PRODUCT, SKIS

OBTAINED THROUGH THIS PROCESS.

The invention refers to a process for manufacturing of skies, and equipment of various kind for sliding on the snow, with thermoformable materials having load bearing structures based on carbon fibers, and it also refers to thermoforming molds for such products as well as a ski, and equipment obtained therefor.

For manufacturing skis, and equipment of various kind for different uses, and in particular but not exclusively for ski runs and/ or off -piste skies and for tourism skies, it is known the fact to use at large extent a manufacturing technology of the sandwich type, by using a set of components with materials of traditional type, such as metallic alloys, fiberglass, elastomeric materials and wood multilayer cores, shaped with the form of the respective product to be obtained, which components are overlapped and glued to each other with epoxy resins for making them structural components. These skis and equipment have a good mechanical resistance, however they have a very high weight that doesn't allow an universal application thereof, but it limits their use exclusively for particular application fields.

Another widely used technology for manufacturing said products for sliding on the snow foresees the use of polyurethane, that is injected into the component materials of the same products as structural element. The chemical reaction of the polyol with the isocyanate, composing the polyurethane, determines the gluing of all the component materials of the ski (steel laminas, polymeric plastic laminates of the thermosetting type and carbon fibers), and of the other equipment for sliding on the snow, which materials are overlapped in advance to each other and the said polyurethane is injected among them. This manufacturing technology still having lower manufacturing costs, requires long and difficult working processes, and also it doesn't give to the products such a mechanical resistance as to ensure a long life during the time of these products. As a consequence, the so manufactured products have a limited duration on the time.

The object of the present invention is to realize skies and equipment of various kind with component materials different than the ones used in the above specified manufacturing

technologies, and such as to confer to the skis and equipment better structural characteristics with a greater mechanical resistance, allowing to obtain higher performances and a higher safety and a considerable elasticity during their use

Another important object of the present invention is to realize some skies and equipment with load- bearing structures always based on carbon fibers, which might be combined with materials with thermoplastic matrix, in a way to permit the so obtained assembly to be thermoformed, namely at first to be heated at a high softening temperature and thereafter to be molded by means of proper molds, so as to obtain skies and equipment having the desired forms and dimensions, which have a high mechanical resistance and a high elasticity and, after having been formed and cooled down, they assume a solid rigid state.

These objects are attained, according to the present invention, by means of a process for manufacturing of skies and equipment of various kind for sliding on the snow, which

thermoformable materials have load-bearing structures made of carbon fibers and with a set of working phases which will be described in detail, and with 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 so obtained skies and equipment for sliding on to the snow.

The invention will be better understood from the following description, by way of not-limiting example only, of the present process for manufacturing of skies and equipment for sliding on the snow, as well as of the used thermoforming molds and of a ski or equipment thereby realized, with reference to the attached claims and the following drawings, wherein : - Fig. 1 shows a perspective front view of some stiff laminates, separated to each other, and each one formed by carbon fibers braided to each other and used in the process for manufacturing of skies and equipment according to the present invention ;

- Fig. 2 shows a perspective exploded front view of the different component parts separated to each other and of one ski realized with the process according to the present invention ;

- Fig. 3 shows a schematic perspective front and exploded view of a central item of the ski of Fig. 1, and of the various component parts thereof ;

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

- Figs. 5, 6, 7 and 8 show the transverse cross-sections of the ski of Fig. 4, effected along the lines A-A, B-B, C-C and D-D of the Fig. 4, respectively ;

- Fig. 9 shows a front view of a machine press, arranged for assembling from time to time a forming mold provided for molding one or more component parts of the ski manufactured in accordance to the present invention ;

- Fig. 10 shows a side view of the machine press of Fig. 9 ;

- Fig. 11 shows a plan view of the machine press of Fig. 9 ;

- Fig. 12 shows a front view of the component parts of one of the forming molds, according to the invention ;

- Fig. 13 shows a plan view of the component parts of the mold of Fig. 12 ;

- Fig. 14 shows a perspective front view of the upper punch and of the lower matrix of the forming mold of Fig. 12 ;

- Fig. 15 shows an enlarged view of the component parts of the forming mold of Figs. 12 and 13 ;

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

- Fig. 17 show an enlarged perspective front view of the lower part of the mold of Fig. 14, with a different viewpoint ; - Fig. 18 shows a front view of the component parts of the gluing mold constituting another one of the molds according to the invention ;

- Fig. 19 shows a side view of the component parts of the mold of Fig. 18 ;

- Fig. 20 shows a plan view of the component parts of the mold of Fig. 18 ;

- Fig. 21 shows an exploded perspective front view of the upper punch and the lower matrix of the gluing mold of Fig. 18 ;

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

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

- Figs. 24-30 show schematically various phases of manufacturing of one of the stiff laminates according to Fig. 1, constituting one of the component parts of the ski of Fig. 2 ;

- Fig. 31 shows a schematic perspective front view of a mold for assembling the various component parts of the ski, for forming the ski ;

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

- Figures 33-37 show with respective schematic front view with transversal cross-section, effected in the central part of the ski according to the invention, of the mold of Fig. 31 at different assembling phases thereof ;

- Fig. 38 shows a schematic and enlarged front view of a constructive item of the Fig. 37 .

The present invention refers to a process for manufacturing of skies, and equipment of various kind for sliding on the snow, with thermoformable materials having load bearing structures based on carbon fibers, and it also refers to thermoforming molds for such products as well as a ski, and an equipment obtained therefor.

In particular, as skies to be manufactured there are intended in particular but not exclusively the ski-runs and/or off-piste skies and for tourism skies, and also the skies normally used by generic skiers as well as by skiers for racing skiers.

In the following, it will be described in detail the structure of a ski with its various component parts, and the relative used component materials, as well as the reciprocal arrangement of such component parts, and all the manufacturing phases provided for by the present manufacturing process for assembling such component parts of the skies.

However, before to describe what it has been specified, there will described the essential and innovative component materials that are used for manufacturing the skies, according to the present invention, the structural composition and the technical characteristics of which will be claimed later on, which component materials are used in combination with additional component materials, per se known and used for long time in this field.

The essential component materials that are used according to the present invention are the carbon fibers, which, as it is known, are obtained by the pyrolysis of the acrylic fibers PAN

(poly aery lonitrile), of the which carbon fibers for generic uses are obtained at 1200° C, whereas those ones with a 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.

Such carbon fibers have an extremely low weight, still having a high toughness and notable mechanical properties as a high compression resistance, a very good stiffness and a good behavior to fatigue, in consequence of the particular crystalline structure of the graphite.

The use of such carbon fibers, moreover, confers to the skies extraordinary characteristics, in terms of both the performances and the attainable aesthetical appearances and of the imagine.

Hereinafter, there will be described also the additional essential component materials that are used according to the present invention, together with the carbon fibers, with which they are combined with the manufacturing phases according to the invention, that will be also described in detail. According to the present invention, for manufacturing the skies there are used carbon fibers with the intermediate modulus of 300 GPa,

Before to describe the various processing phases for manufacturing the skies, there are described the different manufacturing phases that are performed onto the carbon fibers, for allowing to obtain a stiff laminate from the assembly of such carbon fibers, and of the materials that will be described, and that are needed for realizing one of the component parts of the skies, and particularly the bodywork of the same skies.

To the aim, in a first manufacturing phase the carbon fibers are drawn at a temperature higher than 2500° C, up to extreme temperatures of 3000° C, and this operation is effected by means of the use of a pyrolysis furnace, on to which the carbon fibers are disposed and drawn by means of computerized modular tensioning elements, until to obtain a macromolecular alignment along the longitudinal axis of the same fibers, with a maximum value of 2/3%.

This manufacturing phase on to the carbon fibers allows to obtain high rigidity anisotropic carbon fibers, with rigidity values comprised between 150 GPa and 500 GPa, and preferably of 300 GPa. Then, the so drawn carbon fibers are joined to each other for forming some rovings of carbon fibers, the skeins of which are composed approximately of 12000 yarns for each skein, so as to be ready to be woven.

Such yarns are then woven on to particulars looms of electronic type, which are manufactured by the Applicant, and aren't described in the present description, and such a weaving is performed at the room temperature, until to obtain some different and complex textile configurations of the relative skeins, which configurations are suitable to be subsequently submitted, after the treatment of the skeins to the phases of the process that will be described, to one thermoforming phase.

The so obtained different yarns are interconnected to each other, by means of twill-weave weaving with proper looms at a room temperature and for the times needed for obtaining a complete interconnection of the same yarns, that can be verified by means of checking on to loom displays.. The most common weaving of the yarns is distinguished by weft yarns and by warp yarns, which are interconnected to each other in a regular manner, in an equal extent of warp yarns and weft yarns, or also with a majority of 70% of warp yarns, and therefore with 30% of weft yarns.

The yarns of this weaving are thermic welded to each other, by permitting to obtain a bound web, which has a good capability to cover with drapery. These weavings may be performed in different ways, for obtaining different visible effects depending on the customers' requests, and anyway they always allow to submit the so obtained carbon fibers fabrics to the manufacturing phases that will be described. The so effected interconnections of the different used yarns produce a wefted continuous web with a weight of 280 gr/m2 and with a thickness variable preferably between 0,25 and 0,30 mm. A high level of interconnections among the yarns of the fabric may facilitate a better adaptation to the shape of the mold of the press machines that are used during this manufacturing phase, so that some types of these fabrics may adapt them perfectly also to the relative

thermoforming phase that is performed, together with the material that will be described, and may originate better aesthetic appearances and mechanical characteristics.

The continuous carbon fiber fabrics that are obtained by the loom are disposed on to particular steel surface planes of such press machines, and on to the fabrics there is then sprayed a thermoplastic polymeric material at the temperature of 25 °C with a relative humidity of 65%, comprising preferably some polymeric powders PPS (polyphenylene sulfide), which are constituted by a linear chain aromatic crystalline thermoplastic polymer, formed by benzene rings connected to sulfur atoms. The polyphenylene sulfide is used for prolonged uses at 280° C, it withstands to the chemical agents, and is insoluble and is considered a super polymer.

This thermoplastic polymeric material is fire retardant with high resilience, and is mainly used in the aeronautic field, and these polymeric powders PPS are contained into steel tanks of the lamination plant, and according to the present invention these two materials are used with a percentage comprised from 30% to 40% by weight of PPS powders and a percentage comprised from 60 to 70% by weight of the continuous carbon fiber fabrics. At the end of spraying the PPS polymeric powders on to the different carbon fiber fabrics, that are separated to each other, more layers of the so covered carbon fibers fabrics are overlapped to each other, in such a way as to obtain a desired quantity of structural laminates formed by these covered carbon fiber fabrics, depending on the type of product to be obtained, and these layers of covered carbon fiber fabrics are overlapped to each other by means of the use of translator means with stress activators. During this operative phase, the surface planes supporting the fibrous material are moved below a heated press of traditional type (not shown) with a heating temperature up to 350° C, with a tolerance of temperature of +/- 10° C, and with a pressure of 30-35 tons for a time period comprised between 20-30 minutes, and such a movement of the surface planes is effected by means of the use of pneumatic systems with a slow unidirectional movement, in order to submit in sequence all the fibrous material at the above described same temperature and pressure conditions.

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

Subsequently, there is effected a phase of cooling of the entire fibrous material, up to a temperature comprised between 15° C and 20° C, and this cooling is effected in a natural way by means of the use of a chiller that cools the water passing into the steel surface planes, and in such a way that at the end of this cooling phase there is formed a stiff laminate with thermoplastic characteristics with continuous fiber and with a spatial namely tridimensional orientation, which laminate lends itself for being thermoformed for obtaining the desired products and has a high elasticity, and moreover such laminate becomes stiff when each thermoformed product is subsequently cooled down.

The thickness of the so formed stiff laminate will be a function of the number of fabrics overlapped on to the working surface plane.

Fig. 1 schematically shows with enlarged scale some stiff laminates 5, separated to each other, and each one formed by a set of carbon fibers constituted by respective weft yarns 6 of carbon fibers and by warp yarns 7 of carbon fibers, braided to each other with the above described looms, with the configuration shown in the same Fig. 1.

The so obtained carbon fibers laminate is therefore ready for being thermoformed with the working phases and under the conditions that will be shortly described, for obtaining the skies and the equipment for sliding on to the snow with the desired shapes, aesthetic appearances and dimensions. Such skies and equipment may also be molded again by means of thermoforming, for obtaining other skies and equipment with different aesthetic appearances, shapes and dimensions, by leaving integral the structure of the continuous carbon fiber, without the emission of remaining polluting gases, in that the thermoforming process, that will be shortly described, occurs without chemical reactions and polluting drains.

The thermoforming of the so obtained stiff laminates of carbon fibers will be after described, with particular respect to the Figures 24-30.

Referring now to the Fig. 2, there are shown different component parts of the ski 8 according to the present invention, comprising the following separated component parts, that are then joined to each other as it will be described :

- a closed load bearing box-like shaped structure 9, applied into the upper part of the ski and constituted by a bodywork or upper load bearing element 10 and by an additional bodywork or lower load bearing element 11, separated and spaced away to each other in the vertical direction ;

- a first and a second additional reinforcing element 12 and 13 and at a least a central body or filling core 14, which are all associated with the above said closed load bearing box-like shaped structure 9 ;

- a set of lower closing elements, which are applied below said closed load bearing box-like shaped structure 9 and are marked with the reference numeral 15 and are formed by both at least two metallic laminas 16, identical and arranged parallel and slightly spaced away to each other in the wide direction of the ski, and by at least a shock absorber element 17 and by a lower base 18. Fig. 4 shows a plan view of the ski 8 according to the present invention, with all its component parts joined and overlapped to each other as it will be described, from which it is noted that in the example here described of the present ski 8, it results to be shaped both with a first enlarged end portion 19 and slightly curved and raised, constituting the front part of the ski, and by a second flat end portion 20 slightly raised, constituting the rear part of the ski, and by a lengthened central portion 21, joined with such front 19 and rear 20 end portions and shaped with side edges 22 and 23, symmetrical to each other and with a shape slightly concave for the entire length of the same central portion, from the one to the other one of such front 19 and rear 20 end portions. Naturally, the ski may be made also with shapes and dimension which are different than the ones here shown by way of example, provided that it could be always constituted by the same above described component parts and manufactured with the working phases that will be described, thus without departing from the scope of the present invention.

The upper bodywork 10 and the lower bodywork 11 of the above said load bearing structure 9 are each constituted by a stiff laminate with thermoplastic characteristic with continuous fibers, formed as previously described, namely by carbon fibers and PPS polymeric powders, which stiff laminate is thermoformed by arranging the same one into one or more correspondent molds of the traditional type of one thermoforming plant, wherein each stiff laminate is obtained with the operative phases that will be subsequently described, with particular reference to the Figures 24-30.

Such upper 10 and lower 11 bodyworks have the same shape and length and are able to be overlapped and connected to each other as it will be described, and are also shaped with the same front 19 and rear 20 end portions of the ski 8 shown in fig. 4, respectively.

Such a thermoforming plant comprises one or more presses 24 of the traditional type, an example of which is illustrated with reference to the Figures 9-11, whereas Figs. 12-23 show by way of example different types of used molds, with the relative component parts of the same molds, which will be hereinafter described and are assembled on to one or more presses 24, for joining to each other the different component parts of the ski 8, with the reciprocal arrangements and with the working phases provided by the present process, that will be described later on.

In turn, said first and second additional reinforcing elements 12 and 13 are shaped with the same shape and length of the upper 10 and lower 11 bodyworks and with their front 19 and rear 20 end portions like those of the correspondent end portions of the same bodyworks, and such reinforcing elements 12 and 13 are interposed between said bodyworks 10 and 11, in such positions that the first reinforcing element 12 be applied into contact below the lower surface of the upper bodywork 10, and the second reinforcing element 13 be applied into contact over the upper surface of the lower bodywork 11, and that between said first and second reinforcing element 12 and 13 the above said central filling body 14 be interposed and into contact therewith.

The first and the second additional reinforcing elements 12 and 13 are each constituted by at least a layer (not shown) of discontinuous reinforcing fibers of the per se known type, and randomly oriented for the entire extent of the relative reinforcing element.

In the present example of ski, as discontinuous fibers there are to be intended 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 layer of fibers of each one of the additional reinforcing elements 12 and 13 is constituted by fibers of the melt spun liquid crystal polymer (LCP fiber), preferably fibers marketed with the trade mark "Vectran".

According to another embodiment, each additional reinforcing element is a not woven web with fibers randomly oriented to each other.

According to an additional embodiment, the discontinuous fibers randomly oriented of each additional reinforcing element are compacted by means of needle punch.

According to an additional embodiment, each additional reinforcing element provides at least a layer of discontinuous and randomly oriented fibers, which layer has a thickness comprised between 0, 1 mm and 0,5 mm, and preferably comprised between 0,2 and 0,25 mm. According to an additional embodiment, each additional reinforcing element provides a thickness comprised between 0, 1 mm and 3 mm, and preferably between 0,2 and 1 mm.

According to still another embodiment, each additional reinforcing element provides at least a layer of discontinuous and randomly oriented fibers, which has a weight for surface comprised between 80 and 400 g/m².

According to still another embodiment, the thickness of each additional reinforcing element isn't uniform along the entire longitudinal axis K (see Fig. 4) of the ski. For example, each additional reinforcing element may have a greater thickness, for example a thickness comprised between two or six times the minimum thickness of the same additional element.

Such a greater thickness for example may be provided in the additional reinforcing element 12 in correspondence of a first portion PI provided in correspondence of the front end portion 19 of the ski, in which said first portion be extended for example from such a front end portion 19 toward the center of the ski, for a segment having a length comprised between 20 and 70 cm, and preferably comprised between 30 and 50 cm.

Furthermore, such a greater thickness may be also provided in correspondence of a second portion P2 of the ski, provided in correspondence of a central line J (see Fig. 4) of the ski, which second portion be extended upstream and downstream of the line J, for example for a segment having a length comprised between 10 and 50 cm, preferably comprised between 15 and 25 cm, in a way that the total length of the second portion P2 be comprised between 20 and 100 cm, and preferably between 30 and 50 cm. Such a greater thickness may be also provided in correspondence of a third portion P3 of the ski, provided in correspondence of the rear end portion 20 of the same ski, wherein such a first portion be extended for example from such rear portion 20 toward the center of the ski, for a segment having a length comprised between 10 and 70 cm, and preferably comprised between 20 and 50 cm. For example, in the first portion PI and between the lower surface of the upper bodywork 10 and the upper surface of the filling body 14 there may be provided from two to six layers and preferably four layers of discontinuous and randomly oriented reinforcing fibers, and still in the first central portion PI and between the lower surface of the upper bodywork 10 and the upper surface of the filling element 14 there may be provided from two to four layers and preferably two layers of such reinforcing fibers, whereas in the remaining portions of the ski it may be provided a layer of such fibers. Preferably, one layer of such fibers is also provided in the other areas of the filling body 14, in a way that this latter be completely covered by such layer/layers of discontinuous and randomly oriented reinforcing fibers. According to another embodiment, each additional reinforcing element is provided between both at least a portion of the internal surface of the upper bodywork 10 and the upper surface of the central filling body 14 and between at least a portion of the upper surface of the lower bodywork 11 and a lower surface of the central filling body 14.

According to an additional embodiment, each additional reinforcing element covers totally the central filling body 14.

According to still another embodiment, each additional reinforcing element is secured to, by means of a gluing substance, to at least a portion of the internal surface of the upper bodywork 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 bodywork 11 and to a lower surface of the filling body 14. It has been surprisingly checked experimentally that the presence of the additional reinforcing element, comprising the discontinuous and randomly oriented fibers, and particularly the fibers of the "Vectran" type, allows to reduce in a remarkable way the vibrations of the ski and to increase in a considerable way the ultimate tensile strength of the ski, as well as to improve the dimensional stability of the upper 10 and lower 11 bodyworks realized as above described.

It is also to point out that the presence of each additional reinforcing element may also not be provided, since it is not essential for manufacturing and assembling the ski.

Referring again to the Fig. 2, it is noted that the above said central filling body 14 of the ski 8 is interposed, as already described, between the above said additional reinforcing elements 12 and 13 and is constituted by natural materials based on the wood or by plastic materials, and preferably by synthetic foamed foam with closed cell, with a density comprised between 50 and 90 Kg/m³, as for example PVC with closed cell, such filling body being shaped with the same shape and dimensions slightly lower than the ones of the bodyworks 10 and 11 and the additional reinforcing elements 12 and 13, and also the front 19 and rear 20 end portions thereof are shaped like the correspondent end portions of the other already described component parts.

Preferably, the ski 8 foresees at least a reinforcing plate 25, and advantageously two reinforcing plates 25 od stiff material, adapted to improve the thickness of the load bearing structure 9 of the ski in the ski portions in which there are usually secured the traditional bindings (not shown) for the ski boots, in a way to allow a more safe and reliable connection of the screws of the bindings referred to. The reinforcing plates 25 have preferably a thin flat shape and each of them is housed and fixed into a correspondent seat 26 provided for a determined depth into the central filing body 14, in a way that in their housing position the plates 25 are flushing with the upper surface 27 of the same central body.

Referring again to the Fig. 2, there are synthetically described the lower closing elements of the ski, that are applied below said load bearing structure 9 and comprise as already specified the two metallic laminas 16, the shock absorber element 17 and the lower base 18.

Such metallic laminas 16, preferably made of steel, are inserted into side cuts (not shown) equal to each other, provided along the two concave side edges 22 and 23 of the ski 8, and are extended from the front contact line 28 of the relative side edges of the ski up to the rear contact line 29 of the same edges, thereby delimiting along the ski the relative areas Gl, G2 and G3, shaped with different shapes and dimensions.

In turn, the shock absorber element 17 is enclosed between said metallic laminas 16 and the lower base 18 and serves to dampen the stresses and vibrations of the ski, and is constituted for example by Kevlar, wood or other plastic material of traditional type, or by a synthetic fiber suitable for this aim, also of the traditional type. Such a shock absorber element 17 has the same shape and length of said component parts of the ski forming the load bearing box-like shaped structure 9 and also the front 19 and rear 20 end portions thereof are shaped like the ones of said component parts of the load bearing box-like shaped structure 9.

Finally, the lower base 18 is preferably made of a high or very high density polyethylene, for example of HDPE or UHMWPE type, preferably filled with graphite, and has also the same shape and length of said component parts of the ski forming the load bearing box-like shaped structure 9, and also its front 19 and rear 20 end portions are shaped like the ones of said component parts of the load bearing box-like shaped structure 9.

Referring now to the Fig. 3, there are shown in detail the above described reciprocal arrangements of the different component parts of the ski, of which there are shown the relative central portions only, and from this Figure it is noted that the upper bodywork 10 has an upper wall 30, that in the example has a flat shape, and some short side walls 31 and 32 inclined outward in directions opposed to each other, each one for example with an inclination angle comprised between 92° and 120° with respect to the upper wall, and such inclined walls 31 and 32 delimit to each other a cavity 33 for housing the underlying first and second reinforcing elements 12 and 13 and the filling central body 14, in the positions that will be described. In turn, also the first upper reinforcing element 12 has an upper wall 34, that in the example has a flat shape, and some short side walls 35 and 36 inclined outward in directions opposed to each other, which delimit to each other a cavity 37 which is adaptable on to the underlying central filling body 14.

Such a central filling body 14 is shaped thin with an upper flat wall 38 and, in the shown example, also with the seat 26 into which the correspondent reinforcing plate 25 is inserted flushing, and it is also shaped with inclined side walls 39 and 40 joined to a lower flat wall 41 of the same filling body, and the so conformed body 14 is adapted by inserting it into the cavity 37 of the overlapped first upper reinforcing element 12.

In turn, the second lower reinforcing element 13 is shaped thin and with parallelepiped shape, with an upper flat wall 42 and a lower flat wall 43, parallel to this latter. In this way, the central filling body 14 may be overlapped onto the second lower reinforcing element 13 by arranging the lower flat wall 41 of the filling body 14 into contact onto the upper flat wall 42 of the second reinforcing element 13.

For enclosing the filing body 14 into the area comprised between the first and the second reinforcing elements 12 and 13, such a body is realized with a height greater than the one of such an area, so that when the material of the body 14 is introduced into the above said area, such a material is compressed by gluing itself on to the internal walls of the reinforcing elements 12 and 13, thereby ensuring a better adhesion to these internal walls.

In turn, the lower bodywork 11 is shaped thin and with parallelepiped shape, with an upper flat wall 44 and lower flat wall 45. In this manner, the second reinforcing element 13 may be overlapped onto the lower bodywork 11, by arranging the lower flat wall 43 of such reinforcing element 13 into contact with the underlying upper flat wall 44 of the lower bodywork 11. In turn, the metallic laminas 16 are shaped of rectilinear shape, for being able to be inserted as already described into the side cuts of the two concave side edges 22 and 23 of the ski 8, whereas finally the shock absorber element 17 and the lower base 18 are both shaped with parallelepiped shape with the respective upper surfaces 46, 47 and lower surfaces 48, 49 that are flat, and wherein the shock absorber element 17 is positioned as above described, whereas the lower base 18 is applied and fixed in to lower position of the ski.

Referring now to the Figs. 5-8, there are shown all the component parts of the ski 8 assembled to each other, with transversal cross-sections provided through the lines A-A, B-B, C-C, D-D of Fig.4, respectively, and all these cutaway components parts are constituted by the closed load bearing box- like shaped structure 9, arranged onto the upper part of the ski and formed by the upper bodywork 10 and the lower bodywork 11 joined to each other, by leaning advantageously the inclined walls 31 and 32 of the upper bodywork 10 (see Fig. 3) on to the upper flat surface 44 of the lower bodywork

11 and by securing rigidly these bodyworks by means of a gluing substance, as it will be subsequently described in detail, and in this manner into the chamber defined between the upper bodywork 10 and the lower bodywork 11 there are enclosed hermetically from the top downward the upper reinforcing element 12, the central filling body 14 and the lower reinforcing element 13. Under this condition, as it is visible in Fig. 6, the width LI of the lower bodywork 11 is preferably greater than the width L 2 among the joining points of the inclined walls 31 and 32 of the upper bodywork 10 with the lower bodywork 11. As it is visible from these Figures 5-8, furthermore, the thickness of the closed load bearing structure 9 is variable in the different longitudinal positions of the ski foreseen in correspondence of the above said transversal cross section lines, whereas the upper bodywork 10 has the same width, and the upper flat surface 30 of the upper bodywork 10 has the same width in the Figs. 5, 6 and 8 and a smaller width in the Fig. 7, in which it is joined with two inclined upper surfaces 50 and 51 symmetrical to each other, and in turn the lower bodywork 11 has also the same width for the entire length of the ski.

Such a closed load bearing box-like shaped structure 9 is manufactured by means of thermoforming of the upper 10 and lower 11 bodyworks into specific molds, whereas the component parts enclosed by such a load bearing structure are atfirst manufactured by means of molding into correspondent molds and then they are glued in the interior of the load bearing structure 9 by specific molds, with the manufacturing phases that will be hereinafter described.

In turn, also all the lower closing elements of the ski are at first manufactured by means of molding into correspondent molds, and then they are arranged overlapped to each other and glued to each other and under the load bearing structure 9, by means of a specific molds and with the

manufacturing phases that will be described, with the same arrangement shown in the Fig. 2, namely with the metallic laminas 16 applied under to the lower bodywork 11 and laterally thereto, and with the shock absorber element 17 enclosed among such laminas 16 and the lower base 18. There are now described the manufacturing and assembling phases of the different component parts of the ski 8 according to the present invention, for realizing the same ski.

According to the invention, first of all it is necessary to obtain the single component parts of the ski, separated to each other, as it will be described later on, and subsequently to join to each other the so obtained separated component parts with their reciprocal arrangement shown in the Fig. 2.

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

The different component parts separated to each other of the ski are obtained by means of molding of the relative material by using for example a mold 50 represented in the Figs. 12-17. As visible in the Figs. 9-17, for each press 24 there are not described here in detail the constructive structure and all the component parts thereof, that are of the per se known type, and the upper punch 51 (see Figs. 12-17) of the mold 50 used for molding a determined component part of the ski, is assembled into the upper plate 52 of the press (see Figs. 9-11), that is movable in the vertical direction, whereas the lower matrix 53 (see Figs. 12-17) of the same mold is assembled onto the lower plate 54 of the press, that is of the stationary type (see Figs. 9-11). As visible moreover in the Figs. 18-23, shown therein is the example of a mold 55 that is installed in to one of the presses 24 and is used for assembling and gluing to each other by means of molding all the component parts of the ski that have been obtained, with their same reciprocal arrangement shown in the Fig. 2.

In this case, the specific lower matrix 56 (visible also in Figs. 31 and 32) of this mold may be assembled into the stationary lower plate 54 of the used press, whereas the specific upper punch 57 (see Figs. 12-17 and also 31 and 32) of the same mold may be assembled from time to time into the upper movable plate 52 of the press. In the mold represented in Figs. 18-23, both the punch 57 and the matrix 56 of this mold are shaped for assembling and gluing contemporarily by means of molding all the component parts of two skies, that are arranged in position parallel and slightly spaced away to each other in the transversal direction of the punch and the matrix.

There are now described the different manufacturing phases for obtaining the upper 10 and the lower 11 bodyworks of each ski, which are effected by using a particular thermoforming and molding mold with the operations described with reference to the Figs. 24-30, whereas as already described all the component parts of the ski which are different than such upper 10 and lower 11 bodyworks are obtained directly by molding of the relative component material, only. In particular, such upper 10 and lower 11 bodyworks are obtained by using a particular thermoforming and molding mold 58 (see Fig. 26), comprising an upper movable punch 59 and a lower stationary matrix 60, by means of thermoforming and molding of the stiff laminates 5 of the Fig. 1 obtained with the manufacturing phases previously described, and constituted by carbon fibers and by thermoplastic polymeric materials, preferably constituted by PPS (polyphenylene sulfide). Such punch 59 and matrix 60 are shaped with different shapes for thermoforming by molding separately the upper bodywork 10 and the lower bodywork 11, the profile of which is represented in Figs. 29 and 30, respectively.

In the following description, there are specified the manufacturing phases effected by using the mold 58 shaped for thermoforming and molding the upper bodywork 10, see Figs. 24-30, and the same manufacturing phases are also effected for thermoforming and molding the lower bodywork 11, in such a case by using another mold, shaped with the same shape and dimensions of this lower bodywork.

In the Fig. 24 it is noted that in the first manufacturing phase the upper punch of the mold 58 is lifted with respect to the lower matrix 60 of the same mold, and doesn't appear visible in this Figure, so that a stiff laminate 5 is positioned on to said lower matrix 60, which laminate is obtained and constituted as previously described, which has been cut in advance with the desired dimensions, by using a suitable per se known cutting tool. Such a stiff laminate 5 may be also leant on a loom (not shown) situated near on to the lower matrix 60.

In the Fig. 25 it is noted that in this phase the stiff laminate 5 is submitted to the heat through heating devices, for softening the carbon fibers laminates, and then to submit the same ones to the molding for obtaining the finished products with the desired shape, dimensions and aesthetic appearances As heating devices there are preferably used some quartz infrared lamps 61, assembled in to a movable mechanism (not shown) opportunely supported and actuated in the alternate horizontal direction above the stiff laminate 5, that in turn is held in position by means of suitable tensioning means (not shown) associated with the mold 58. Such infrared lamps 61 provide for irradiating continuously the carbon fibers laminates combined preferably with the thermoplastic polymeric material PPS, and they have for example a power of 750 watt for each lamp, and in this phase there are used advantageously, but not necessarily, from 40 to 60 quartz infrared lamps, which are operated for a limited time, for example in the order of 2-3 minutes, in such a way to make ductile the carbon fibers laminates, namely deformed to about 280° - 300° C. The durations of the irradiating times of the carbon fibers laminates depends on the thickness of the laminates and the quantity of the employed thermoplastic polymer. Since the carbon has a high electrical and thermal conductivity, it takes the characteristics of an electric capacitor by amplifying the electromagnetic field being created.

The irradiation of the carbon fibers laminates prosecutes up to the carbon reaches quickly the heat saturation into the so generated electromagnetic field, and this condition is checked. Under this condition, such a stiff laminate 5 is ready for being thermoformed by molding into the mold 58, and the infrared lamps 61 are moved by means of the above said movable mechanism from their position overlapped to the stiff laminate 5, by making free the area for the upper punch 59, that may so be lowered during the subsequent molding phase of the so heated stiff laminate 5. For performing the molding of the so heated stiff laminate 5, each used mold 58 is heated in advance to temperatures lower than the one to which such stiff laminate 5 has been heated, and preferably at a temperature comprised between 150° and 200° C.

In the subsequent manufacturing phase shown in the Fig. 26, in which there is performed the molding of the stiff laminate 5, the upper punch 59 is lowered and pressed on to the stiff laminate 5 with a high pressure, preferably in the order of 25 Tons for a limited time, comprised between about 3-4 minutes. Thanks to the lower heating temperature of the mold, the thermic inertia of the carbon fibers of the relative stiff laminates is interrupted and it is started the cooling phase of the bodywork from time to time obtained by molding the same laminates.

This is determined thanks to the fact that the thermoplastic polymer composing the carbon fibers laminate has a glass transition (Tg) of 88/90° C, so that when the carbon in the mold reaches this temperature, the thermic motions end and the laminates of the bodywork laminates become stiff. At this point, as visible in the Fig. 27, the mold is opened and the so formed bodywork is extracted from the same mold, in the subsequent phase shown in the Fig. 28.

Such a bodywork is then trimmed, preferably immediately after the extraction from the mold 58, as soon as the same bodywork has been cooled, for obtaining so the definitive finished element. With these manufacturing phases, it is so possible to obtain some bodyworks with high qualitative levels and with the possibility to use again the same bodyworks for other uses, thanks to the fact that they are constituted by carbon fibers coupled with thermoplastic material, that may be again heated and thermoformed.

The so formed upper 10 and lower 11 bodyworks (see also the relative Figs. 29 and 30) are shaped with the desired shapes and dimensions, starting from the above described stiff laminates, thanks to the fact to calculate mathematically and in advance the linear dilatation of the used thermoplastic polymer (in this case, the PPS) with respect to the shrinkage of the carbon fibers onto a surface like that of the skies bodyworks. The design, aided by computer, has allowed the Applicant to work out some virtual geometrical models through specific hardware and software for dimensioning the molds, like the molds 58, adapted to the thermo forming of the thermoplastic carbon constituting the stiff laminates 5 for realizing the skies bodyworks, and such a methodology had not been yet used previously, owing to the different manner of manufacturing of the skies and the different component materials used hitherto for manufacturing the skies.

Furthermore, it is to point out that the heating of the stiff laminates for obtaining their

thermoforming as above described, may be performed also with heating devices different from the above described infrared lamps 61, by using for example some electrical resistances, or similar means, adapted to determine the above described heating temperatures, thus without departing from the protection field of the present invention.

By replacing the mold in the press with other types of molds, with punches and matrixes configured in different manners, it is so possible to mold some bodyworks with different shapes, dimensions and aesthetic appearances, which have autonomous load bearing structures based on carbon fibers, and may be applied to other types of skies.

According to the present invention, furthermore, for thermoforming the thermoplastic carbon, in addition to the above said super polymer PPS, it is possible to use as thermoplastic matrixes also polyamide 6 and polymeric blends formed by a stable mixture of two or more polymers. The completely mixable blends are homophasic whereas the ones partially mixable 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 so constituted bodyworks are subsequently joined to the remaining component parts of each ski, with the arrangement of the different component parts shown in the Fig. 31, by using some glueing molds shown both in the same Fig. 31 and in the Fig. 32, and with the manufacturing phases shown in the Fig. 33-38.

However, before to join the different component parts of the skis, at least the external surfaces of the bodyworks 10 and 11, which are adapted to be glued with the central body 14, are submitted to a treatment for increasing their surface roughness. These kinds of treatments are effected for increasing the surface roughness, in order to improve the gripping action of the glue used for joining the different component parts, and such treatments may be mechanical abrasive treatments such as for example the sandblasting, the peen forming, the brushing, etc., or by means of chemical, photo-chemical, electrochemical treatments or by cold plasma flame -hardening, etc.

Preferably, the surface roughness of the surfaces of the bodyworks 10 and 11 is increased of at least of two/three times, and it has been remarked in the practice that the increasing of the roughness also involves an increasing of the bending resistance of the ski. For glueing the various component parts of the ski, an uniform layer of glue is applied manually or with automatic systems of the per se known type onto at least an external surface of each component part of the ski, except the external surfaces not to be glued of the upper bodywork 10, the base 18 and the metallic laminas 16.

As adhesive and/or glueing substance, a bi-component substance may be used, based on to the polyurethane or epoxy resin, or other substances suitable for the use.

The present manufacturing process of the ski provides first of all the arrangement of the various component parts of the ski into the assembling and glueing mold 55, with the arrangement shown in the Fig. 2, but turned upside down with respect thereto, and the reciprocal overlapping of all these component parts. Fig. 31 shows the various components of the ski 8, separated to each other and with the same arrangement of the Fig. 2, but turned upside down, and with the lower stationary matrix 56 and the upper punch 57 movable in the vertical direction. In this arrangement, however, there have not yet provided the reinforcing elements 12 and 13, but the same ones are

advantageously used and are glued with the remaining component parts of the ski with the same arrangement of the Fig. 2. As visible from such Fig. 31 and also from the Fig. 32, the lower stationary matrix 56 is shaped like a lengthened body 62 of a box-like parallelepiped shape, delimited by a front flat end portion 63 and by a rear flat end portion 64 and has dimensions slightly greater than the ones of the various component parts that may be overlapped and glued to each other of the ski. The lengthened box-liked shaped body 62 is hollowed for almost the entire length thereof with a cavity 65, shaped for receiving the different component parts of the ski to be joined to each other and terminating with a front end portion 66 and a rear end portion 67, having the same shape and dimensions slightly greater than the corresponding front end portion 19 and rear end portion 20 of the component parts of the ski shown in the Fig. 2. In turn, as still visible from the Figs. 31 and 32, the upper movable punch 57, that in fig. 32 is shown turned upside down, is shaped like a lengthened body 68 of a box-like parallelepiped shape, delimited by a front flat end portion 69 and by a rear flat end portion 70 and is hollowed for almost the entire length thereof with a cavity 71, shaped for receiving the different component parts of the ski to be joined to each other and terminating with a front end portion 72 and a rear end portion 73, having the same shape and dimensions slightly greater than the corresponding front end portion 1 and rear end portion 20 of the component parts of the ski shown in the Fig. 2.

Figs. 33-38 show now the different manufacturing phases performed for assembling and gluing to each other the various component parts of the ski, overlapped to each other with the arrangement of the Fig. 31 and by using the component parts of the gluing mold 55.

For performing the gluing of the various component parts of the ski, the lower stationary matrix 56 of the mold 55 foresees a seat 74 adapted to house in its interior the different component parts of the ski 8 and the upper movable punch 57 of the mold foresees a protruded portion 75 which is adaptable at least partially by insertion into the seat 74 of the matrix 56 (as shown in the Fig. 37). The seat 74 of the matrix 56 provides for :

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

- a first portion of vertical wall 77 provided above the flat horizontal wall 76 and adapted to house the lower bodywork 11, the laminas 16, the base 18 and the shock absorber element 17 provided among the laminas 16 ;

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

A free space 79 is provided between the lower flat wall 76 and the portion of vertical wall 77 of the seat 74 of the matrix 56 of the mold (see also the Fig. 38), which space does not come into contact with no one of the component parts of the ski 8 and in particular it does not come into contact not even with the ending edges 80 and 81 of the inclined walls 32 and 31 of the upper bodywork 10. The scope of such free space 79 is to allow a better adhesion of the component parts of the ski, in that on the one hand it allows the drainage of any exceeding adhesive substance during the gluing of the various component parts of the ski and on the other hand it allows to exert a greater pressure onto the component parts of the ski and guarantees that these latter be arranged perfectly packed during the gluing phase.

For facilitating the positioning of the laminas 16, the mold foresees a plurality of magnetic elements 82 (see the Fig. 38) distributed into some seats hollowed in the interior of the walls delimiting the portion of vertical wall 77 of the seat 74 of the lower stationary matrix 56 of the mold.

According to the invention, the protruded portion 75 of the upper punch 75 of the mold has substantially the same shape of the ski to be assembled and provides in particular a surface 83 thereof (see the Fig. 33) more external, adapted to come into contact with the base 18 and the laminas 16 of the ski, having exactly the shape of the sliding surface to be obtained for the ski, and the side walls 84 having the same shape of the side walls of the ski too.

There are now described the different manufacturing phases for assembling and gluing to each other all the component parts of the ski, into the lower matrix 56 of the mold with an arrangement shown in the Fig. 31 and in the Fig. 34.

In the manufacturing phase of Fig. 35 a), first of all it is noted that the upper bodywork 10 is inserted into the seat 74 of the lower matrix 56 in a position turned upside down, in such a way that the upper wall 30 of the same bodywork comes into contact with the horizontal wall 76 of the matrix 56 and that the inclined walls 31 and 32 of such a bodywork are flushing adhering with the walls of the seat 74, except that the relative ending edges 81 and 80 of such inclined walls 31 and 32 remain slightly spaced away from the opposite walls of the seat 74, owing to the presence of the correspondent free space 79.

In the subsequent phase of the Fig. 35b), the filling body 14 is placed into the cavity delimited by the upper bodywork 10 and under this condition the external horizontal surface (not shown) of such body is slightly projected (for example of few tenths of millimeters) from the ending edges 81 and 80 of the upper bodywork 10.

In the subsequent phase of the Fig. 36a), it is noted that onto the external surface of the so housed filling body 14 the lower bodywork 11 is overlapped into contact thereon, which covers the entire filling body 14, and its side edges come into contact with the opposite walls delimiting the seat 74, thereby covering the free spaces 79 ; thereafter, the shock absorber element 17 is placed and centered onto the upper surface of the lower bodywork 11.

In the subsequent phase of the Fig. 36b), it is noted that the central base 18 is overlapped centrally into contact onto the upper surface of the shock absorber element 17, and the metallic laminas 16 are placed into the free cavities (not shown) between the side edges of the base 18 and the opposite wall of the seat 74, which positioning is facilitated and made stable by the presence of the magnets 82 (see the Fig. 38), that keep attracted in this position such metallic laminas 16. Even if here it is not represented, also the additional reinforcing elements 12 and 13 are joined and glued to the component parts of the ski, with the same arrangement, turned upside down, illustrated in the Fig. 2. Under this condition, all the component parts of the ski are arranged into the seat 74 and ready for being glued to each other by means of molding.

In the subsequent phase of the Fig. 37, the upper punch 57 of the mold is lowered, so that the protruded portion 75 thereof enters the seat 74 and the external surface 83 of such protruded portion 75 comes into contact to the relative external surface of the base 18, shaped in a correspondent manner, and under this condition the upper punch 57 is pressed against the component parts of the ski with the desired pressure and for the time necessary for determining the reciprocal glueing of all these component parts. This glueing also happens, as already specified, with the mold heated at a pre-established temperature, that during the molding time provides for the polymerization of the resin films of the used adhesives, thereby making the ski a single -piece ski. Then, under this condition, the lower surface 87 of the punch 57 and the upper surface 86 of the matrix 56, opposite to such a lower surface 87, are spaced away to each other of a segment H, which fact makes it possible to adjust further the run downward of the punch 57 with respect to the matrix 56, when it is required for exerting an optimal pressure onto all the component parts of the ski, and for improving the joining between the same ones by distributing in a more homogenous manner the so exerted pressure onto the entire surface of the ski.

At the end of this molding phase, the component parts of the ski are perfectly glued to each other and, after that the entire assembly has been cooled at the required temperature, the mold is opened and the so obtained ski is extracted from the same mold, manually or with automatic methods. Such cooling time is selected in a way to strengthen the structural parameters of the ski, its geometrical shape and the relative camber.

Thereafter, the ski is finished in a traditional way and, after letting it to "rest" for a time comprised from some hours to some days, it is effected the grinding and the finishing of the ski. Such a rest time is necessary for allowing that the complete drying of the adhesive substance and the adhesion between the component parts produced by the same adhesive substance has been accomplished.

Claims

1. Process for manufacturing of skies, and equipment of various kind for sliding on the snow, with thermoformable materials having load bearing structures based on carbon fibers, wherein each ski (8) is substantially constituted by a load bearing structure or bodywork (10) based on the carbon fibers, applied on to the upper part of the ski (8), by a first additional reinforcing element (12) and a second additional reinforcing element (13) applied below said load bearing structure or bodywork (10) and formed by discontinuous reinforcing fibers of the hot spun crystalline liquid polymeric type, preferably by fibers of the "Vectran" type, or by not woven web with fibers randomized oriented to each other, which are compacted or not compacted to each other by means of needle punching, the ski being also constituted by at least a central body or filling core (14), interposed between said first and second additional reinforcing element (12, 13) and constituted by natural materials based on to wood or by plastic materials, and preferably by synthetic foamed foam with closed cell, such as PVC with closed cell, the ski being moreover constituted by metallic laminas (16) identical and arranged parallel and slightly spaced away to each other in the wide direction of the ski (8), below said second additional reinforcing element (13), by at least a shock absorber element (17) and by a lower base (18), wherein said shock absorber element (17) is enclosed between said metallic laminas (16) and said lower base (18) and serves for dampen the stresses and vibrations of the ski, and is constituted by Kevlar, wood or other plastic material of traditional type, or by a synthetic fiber of traditional type, and wherein said lower base (18) is made of a high or very high density polyethylene such as HDPE or UHMWPE, filled with graphite, characterized in that such load bearing structure or bodywork (10) is constituted by carbon fibers with intermediate modulus of 300GPa, which are drawn at a temperature higher than 2500° C, up to extreme temperature of 3000°C , by means of the use of at least a pyrolysis furnace or similar apparatus, on to which the carbon fibers are disposed and drawn preferably by means of computerized modular tensioning elements, until to obtain a macromolecular alignment along the longitudinal axis of the same fibers, with a maximum value of 2/3%, by obtaining high rigidity anisotropic carbon fibers, with rigidity values comprised between 150 GPa and 500 GPa, and preferably of 300 GPA, that the so drawn carbon fibers are joined to each other for forming some rovings of carbon fibers, the skeins of which are composed approximately of 12000 yarns for each skein, that said yarns are woven on to particulars looms of traditional type at the room temperature, until to obtain some different and complex textile configurations of the relative skeins, which configurations are suitable to be submitted, after the treatment of the skeins to the subsequent phases of the process, to one thermoforming phase, by means of thermoforming means of per se known type, that the different so obtained yarns are interconnected to each other, by means of twill- weave weaving with per se known looms at a room temperature and for the times needed for obtaining a complete

interconnection of the same yarns, that can be verified by means of checking, and the yarns of this weaving are thermic welded to each other in a manner to obtain a bound web, and that the so effected interconnections of the different used yarns produce a woven continuous web with a weight of 280 gr/qm and with a thickness variable preferably between 0,25 and 0,30 mm, that the continuous carbon fiber fabrics that are obtained by the loom are disposed on to traditional heated presses, and on to the fabrics it is then sprayed a thermoplastic polymeric material comprising some polymeric powders PPS (polyphenylene sulfide) at the temperature of 25° C with a relative humidity of 65%, with a percentage comprised from 30% to 40% by weight of PPS powders and a percentage comprised from 60 to 70% by weight of the continuous carbon fiber fabrics, that at the end of spraying the polymeric powders PPS on to the different carbon fiber fabrics, that are separated to each other, more layers of the so covered carbon fibers are overlapped to each other, in such a way as to obtain a desired quantity of structural laminates formed by these covered carbon fiber fabrics, depending on the type of ski to be obtained, and these layers of covered carbon fiber fabrics are overlapped to each other by means of the use of translator means with stress activators, and in this phase the fibrous material is moved below said heated press with a heating temperature up to 350° C, with a tolerance of temperature of +/- 10° C, and with a pressure of 30-35 tons for 20- 30 minutes, and such movement of the fibrous material is effected by means of the use of per se known pneumatic systems with a unidirectional slow movement, in order to submit in sequence all the fibrous material at the same temperature and pressure conditions, that at the end of this operative phase the semi-crystalline polymeric powders are melt and saturate the woven loops of the carbon, with a percentage of 30-40% by weight; that subsequently there is effected a phase of cooling of the entire fibrous material, up to a temperature comprised between 15° C and 20° C, and in such a way that at the end of this cooling phase there is formed a stiff laminate with

thermoplastic characteristics with continuous fiber and with a spatial namely tridimensional orientation, which laminate has a high elasticity ; that said stiff laminate is positioned and thermic formed into at least a first thermic forming and molding means with a temperature of about 280° C- 300° C, in a manner to soften and make ductile the same stiff laminate, for durations depending on the thickness of the laminates and the quantity of the employed thermoplastic polymer, under which condition the carbon, that has a high electrical and thermal conductivity, takes the characteristics of electric condenser by amplifying the electromagnetic field being created, that the heating of the carbon fiber stiff laminate proceeds as long as the carbon reaches the heat saturation into the so generated electromagnetic field, that the so heated carbon fiber stiff laminate is picked up from the position in which it is located and is transferred automatically toward at least a second molding means (58), that is heated at temperatures lower than the one for heating the stiff laminate, and preferably at a temperature comprised between 150° and 200° C, for being subsequently pressed with a high pressure, in the order of 25 tons for a limited period, then it is extracted from said second molding means (58), thereby obtaining said load bearing structure or bodywork (10) with the desired form, dimensions and aesthetical appearances ; the process being also

characterized in that said first and second additional reinforcing elements (12, 13), said central body or filling core (14), said metallic laminas (16), said shock absorber element (17) and said lower base (18) are obtained separately by means of third molding means utilizing specific molds (50) ; that before joining to each other all the ski component parts said load bearing structure or bodywork (10) is submitted to a surface treatment for increasing the surface roughness, for improving the gripping of at least a per se known adhesive substance which is subsequently applied in position for joining the different component parts, while on to the other component parts of the ski it is also applied on to the surface thereof at least a per se known adhesive substance, for being joined with the other component parts of the ski, and such application isn't effected on to the outer surfaces not to be glued of a part of said bodywork (10), of said base (18) and of said metallic laminas (16) ; and characterized in that all the ski component parts are adhered to each other by molding the same parts by means of fourth assembling and molding means (55), by making said load bearing structure or bodywork (19) with an upper bodywork (10) and a lower bodywork (11), which are joined to each other for forming a closed box-like shaped structure (9), in the interior of which said central body or filling core (14) is arranged, and by arranging in an overlapped position, from the top downward, said upper bodywork (10), said filling body (14), said lower bodywork (11), said shock absorber element (17), enclosed between said metallic laminas (16), and said lower base (18).

2. Process according to claim 1, characterized in that the most common weaving of the yarns is distinguished in the same extent by weft yarns (6) and by warp yarns (7), which are braided to each other, or also with a majority of 70% of warp yarns (7) and therefore with 30% of weft yarns, which are braided to each other.

3. Process according to claim 1, characterized in that the fibrous material is cooled in a natural manner by employing a chiller which refrigerates the water passing through said press.

4. Process according to claim 1, characterized in that the heating of the carbon fiber stiff laminates (5) is effected by means of radiation by means of about 40-60 quartz infrared lamps, with a power of 750 watt for each lamp.

5. Process according to claim 1, characterized in that the heating of the carbon fiber stiff laminates (5) may be effected also by means of electrical heating resistances.

6. Process according to claim 1, characterized in that as thermoplastic matrixes there may be used also polyamide 6 and polymeric blends formed by one stable mixture of two or more polymers, in which the totally mixable blends are homophasic, whereas the partially mixable ones are heterophasic.

7. Process according to claim 6, characterized in that the blends able to be used with good characteristics are PA/PP (polyamide and polypropylene) ; PA/ABS (polyamide and acrylonitrile, butadiene, styrene) ; PE/PP (polyethylene and polypropylene).

8. Process according to claim 1, characterized in that the surface treatment of said load bearing structure or bodywork (10) may be effected by means of mechanical abrasive treatments such as the sandblasting, the peen forming, the brushing, or by means of chemical, photo-chemical, electrochemical treatments or by cold plasma flame -hardening.

9. Molding means utilized for realizing a ski manufactured with the manufacturing process according to the claims 1-5 and 8, characterized in that said second molding means comprises at least a thermoforming and molding mold (58) including an upper movable punch (59) and a lower stationary matrix (60), and heating devices (61) of the relative stiff laminates (5), mounted on to a mold movable mechanism arranged above the relative stiff laminated (5), and which can be actuated in the alternate horizontal direction, said punch (59) and matrix (60) being shaped with different shapes for thermoforming by molding separately said upper bodywork (10) and lower bodywork (11), starting from a relative stiff laminate (5), said movable punch (59) being at the beginning raised for arranging into the mold (58) a relative stiff laminate (5) to be thermoformed, which is heated by means of said heating elements (61) which, at the end of heating at the desired temperature and time of said stiff laminate (5), are displaced by said movable mechanism by making free the space for said upper punch (59), which may be therefore lowered with consequent molding of the so heated stiff laminate (5), with subsequent extraction from the mold (58) of each so formed upper bodywork (10) and lower bodywork (11).

10. Molding means according to claim 9, characterized in that said heating elements (61) comprise about 40-60 quartz infrared lamps, with a power of 750 watt for each lamp.

11. Molding means according to claim 9, characterized in that said heating elements (61) comprise some electric heating resistances.

12. Molding means used for realizing 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 a movable upper punch (51) and at least a stationary lower matrix (53), and shaped for molding the respective ski component parts, except said upper bodywork (10) and lower bodywork (11), and mounted respectively in the vertically movable upper plate (52) and the stationary lower plate (54) of a press (24) of traditional type.

13. Molding means utilized for realizing a ski manufactured with the manufacturing process according to claims 1-5 and 8, characterized in that said fourth assembling and molding means (55) comprise a mold (55) installed in to a press (24) of traditional type and including a vertically movable upper punch (57) and a stationary lower matrix (56), said movable upper punch (57) being shaped as an extended body (68) having box-like parallelepiped shape, delimited by a flat front end portion (69) and by a flat rear end portion (70) and hollowed for almost the entire length thereof with a cavity (71), shaped for receiving the different component parts of the ski (8) to be joined overlapped to each other and terminating with a front end portion (72) and a rear end portion (73), having the same shape and dimensions slightly greater than the corresponding front end portion (19) and rear end portion (20) of the different component parts of the ski (8), and said stationary lower matrix (56) being shaped as an extended body (62) having box-like parallelepiped shape, delimited by a flat front end portion (63) and by a flat rear end portion (64), and having dimensions slightly greater than those ones of the different component parts of the ski (8) to be joined overlapped to each other, and said extended box-like body (62) being hollowed for almost the entire length thereof with a cavity (65), shaped for receiving the different component parts of the ski (8) to be joined overlapped to each other and terminating with a front end portion (66) and a rear end portion (67), having the same shape and dimensions slightly greater than the corresponding front end portion (19) and rear end portion (20) of the different component parts of the ski (8), the different component parts of the ski (8) being housed in to the mold (55) by arranging in succession into said cavity (65) of said matrix (56) said upper bodywork (10), said first additional reinforcing element (12), said filling central body (14), said second additional reinforcing element (13), said lower bodywork (11), said shock absorber element (17), enclosed by said metallic laminas (16), and said lower base (18), and on to the so arranged component parts being lowered said upper punch (57), with consequent molding and assembling by means of glueing of all these component parts and formation of the finished ski (8).

14. Ski (8) based on carbon fibers, obtained with the manufacturing process according to claims 1-8 and with the molding means according to claims 9-13, characterized by the overlapped

arrangement and by the reciprocal joining and adaptation of an upper load bearing bodywork (10), a first additional reinforcing element (12), a filling body (14), a second additional reinforcing element (13), a lower load bearing bodywork (11), a shock absorber element (17) enclosed by two metallic laminas (16) and a lower base (18).

15. Ski (8) based on carbon fibers, according to claim 14, characterized by reinforcing plates (25) of rigid material, housed on to and fixed into corresponding seats (26) provided in said filling central body (14), in the position in which there are usually linked the traditional fastening elements for the ski-boots, said plates (25) being adapted to increase the thickness of the ski load bearing structure, in a manner to allow a more safe and reliable connection of the screws of the above specified fastening elements.