Method and apparatus for manufacturing a ski

Abstract

The object of the application is a method and apparatus for manufacturing a ski. Glue is applied at least to an upper surface and sides of a ski body (2) by means of a glue applying device (3), and the glue is allowed to dry at least partially. At least one surface film is attached to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure in a film forming device (4) such that the film conforms to the upper surface and the sides of the body. A base material is attached to a lower surface of the ski body.

Description

FIELD

[0001] The object of the application is a method defined in claim 1 and an apparatus defined in claim 10 for manufacturing a ski.BACKGROUND

[0002] Previously known are various methods and devices for manufacturing skis. It is known to manufacture a ski body, i.e. core, and provide surface and base materials as desired in connection with the ski body.PURPOSE

[0003] The purpose of the invention is to disclose a new type of method and apparatus for manufacturing a ski. Additionally, the purpose of the invention is to provide an efficient and simple way to manufacture skis. Additionally, the purpose of the invention is to provide an easily modifiable process for manufacturing skis. Additionally, the purpose of the invention is to provide a process in which skis may be easily manufactured with a desired shape and look. Additionally, the purpose of the invention is to provide a process in which a surface film that gives the ski its graphic appearance may be easily attached to the ski and, if needed, removed from the ski without damaging the ski body.SUMMARY

[0004] The method and apparatus according to the invention are characterized by what is presented in the claims.

[0005] In a method for manufacturing a ski a ski body is formed, glue is applied at least to an upper surface and sides of the ski body, and the glue is allowed to dry at least partially. At least one surface film is attached to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and a base material is attached to a lower surface of the ski body.

[0006] An apparatus comprises at least one glue applying device for applying glue at least to an upper surface and sides of a ski body, at least one film forming device for attaching at least one surface film to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and at least one gluing device for attaching a base material to a lower surface of the ski body.DETAILED DESCRIPTION

[0007] In a method for manufacturing a ski a ski body is formed, glue is applied at least to an upper surface and sides of the ski body, and the glue is allowed to dry at least partially, at least one surface film is attached to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and a base material is attached to a lower surface of the ski body by gluing, and the glue used for attaching the base material is applied by means of at least one slot nozzle of a glue dispenser.

[0008] An apparatus includes at least one glue applying device for applying glue at least to an upper surface and sides of a ski body, at least one film forming device, e.g. surface film device, for attaching at least one surface film to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and at least one gluing device for attaching a base material to a lower surface of the ski body, and the gluing device includes at least one glue dispenser and at least one slot nozzle for applying the glue to one surface of the base material.

[0009] In this context, ski refers to any ski, ski blank or corresponding type of sports or recreational equipment as well as to a runner of a device or equipment moving on snow or the like. The ski comprises a ski body. Surface materials as desired may be provided to upper and lower surfaces of the ski body. The ski body may be a layered structure comprising more than one layer.

[0010] In one embodiment, the method comprises at least the steps of a. forming a ski body, comprising a core layer and one or more reinforcement layers attached to the core layer and comprising ski tip and / or tail reinforcements, b. shaping the formed ski body, e.g. by milling / grinding, and / or shaping the ski tail and tip, and optionally rounding the sides of the ski body, c. applying glue at least to an upper surface and sides of the ski body, and allowing the glue to dry at least partially, d. attaching at least one surface film to the upper surface of the ski body by means of a negative pressure or positive pressure operated press and heat such that the film conforms to the upper surface and the sides of the body, e. applying glue to one surface of a base material by means of a glue dispenser, gluing the base material to a lower surface of the ski body, and directing the ski body together with the base material through pressure rolls to form a pressed product.

[0011] In one embodiment, in step a) the ski body is formed by attaching the reinforcement layer by gluing to at least one surface of the core layer. The gluing may be done by any suitable glue, e.g. by means of an epoxy glue or a polyurethane glue. In one embodiment, the gluing is done by means of an epoxy glue. In one embodiment, the gluing is performed by hot pressing, preferably without a mould. In one embodiment, the gluing is performed by hot pressing between two metal surfaces to form a unitary ski body.

[0012] In one embodiment, the apparatus includes at least one hot pressing device for forming the ski body, wherein the ski body comprises a core layer and one or more reinforcement layers attached to the core layer and comprises ski tip and / or tail reinforcements. Preferably, the ski body is formed in the hot pressing device without a mould. In one embodiment, the apparatus includes at least one hot pressing device for forming the ski body, wherein the hop pressing device comprises at least two metal surfaces between which a unitary ski body is formed by hot pressing.

[0013] In one embodiment, in step a) at least one surface reinforcement laminate is attached to an upper surface of the core layer, and / or at least one base reinforcement laminate is attached to a lower surface of the core layer.

[0014] Any glue suitable for the intended use may be used as the glue that is applied to the upper surface and the sides of the ski body. It is advantageous to use a glue that provides sufficient adhesion of the surface film to the ski body while also allowing the surface film to be removed after attaching the film.

[0015] In one embodiment, the glue that is applied to the upper surface and the sides of the ski body is a dispersion glue, for gluing the surface film to the ski body. In one embodiment, the glue that is applied to the upper surface and the sides of the ski body is a thermally activatable dispersion glue. Any dispersion glue suitable for the intended use, e.g. a polyurethane dispersion glue or other suitable dispersion glue, may be used as the dispersion glue.

[0016] The glue may be applied by any suitable device, such as glue applying device, to the upper surface and the sides of the ski body. In one embodiment, the glue is applied by means of roller application to the upper surface and the sides of the ski body. In one embodiment, the glue applying device comprises at least one roller applicator.

[0017] In one embodiment, the film forming device comprises at least one negative pressure or positive pressure operated press. In one embodiment, the film forming device comprises a negative pressure operated press. In one embodiment, the film forming device comprises a positive pressure operated press. Preferably, heat is utilized during the attachment and / or formation of the surface film. The glue applied to the surface of the ski body may be activated by means of heat, facilitating the attachment of the surface film. In one embodiment, heat stored in the ski body and / or in the glue is utilized. In one embodiment, the film forming device comprises a heat source, a heating device or a heat generating element, preferably to provide additional heat. In one embodiment, the attachment of the surface film is done at a temperature in the range of 60 - 90 °C, and in one embodiment in the range of 62 - 80 °C, to activate the glue.

[0018] In this context, film forming device refers to any film forming and / or film attaching device. In one embodiment, the surface film is formed and attached to the surface of the ski body by means of the film forming device. In one embodiment, the surface film, preferably a finished surface film, is attached by means of the film forming device. In one embodiment, the film forming device is a film attaching device by means of which the surface film is attached to the surface of the ski body. In one embodiment, the film forming device is a surface film device that both forms and attaches the surface film, or that alternatively attaches the surface film.

[0019] The surface film may be patterned in a desired manner, and / or it may have any graphic look or colours as desired. Preferably, the graphic appearance of the ski is provided by the surface film.

[0020] In one embodiment, after attaching the surface film, the ski body comprising the surface film is cooled. In one embodiment, after attaching the surface film, the ski body is cooled by turning off the heating. In one embodiment, after attaching the surface film, the ski body is cooled by turning off the heating but maintaining negative pressure, or alternatively positive pressure.

[0021] In one embodiment, after attaching the surface film, the surface film may, if desired or necessary, be removed from the ski body without damaging the ski body. In one embodiment, the surface film is removable from the ski body after attaching the film. In one embodiment, a new surface film is attached to the upper surface of the ski body after removing the previous surface film. Thus, the surface film may be replaced without damaging the ski body.

[0022] In one embodiment, the surface film attached to the ski body is finished by cutting excess film material off before attaching the base material. In one embodiment, the apparatus includes at least one finishing device for finishing the surface film by cutting. In one embodiment, the finishing device comprises at least one cutting device for cutting the film material, specifically the film material that extends beyond the sides of the ski. Any finishing device suitable for the intended use may be used. Alternatively, the finishing may be done manually between the manufacturing steps.

[0023] The base material may be attached by gluing to the lower surface of the ski body. In one embodiment, the glue used for attaching the base material is applied by means of at least one slot nozzle or slot nozzles of a glue dispenser to the surface of the base material. Any glue suitable for the intended use may be used as the glue. In one embodiment, a hot melt glue, e.g. a polyurethane hot melt glue, is used as the glue. In one embodiment, the gluing device comprises a glue dispenser for dispensing the glue to the surface of the base material. In one embodiment, the gluing device includes at least one slot nozzle for applying the glue to one surface of the base material. In one embodiment, the gluing device includes at least one glue dispenser and at least one slot nozzle for applying the glue to one surface of the base material. In one embodiment, the gluing device includes more than one slot nozzle. In one embodiment, the gluing of the base material is done at room temperature.

[0024] In one embodiment, the apparatus includes one or more pressure rolls through which the ski body together with the base material is directed to travel to form a pressed product.

[0025] The ski body may be shaped to a desired shape. The shaping may be done for example by milling, grinding or other suitable manner. In one embodiment, the ski tail and / or tip is shaped. In one embodiment, the shaping is done before glue application for attaching the surface film and / or before the glue applying device. In one embodiment, the shaping is done by means of a shaping device. In one embodiment, the shaping is done by a separate device. In one embodiment, the apparatus includes at least one shaping device for shaping the formed ski body, e.g. by milling / grinding.

[0026] The method and apparatus according to the invention may be used in the manufacture of any type of ski. The method and apparatus may be modified easily according to the intended use or application. The method and apparatus may be used for example in the manufacture of cross country skis, touring skis, other skis or corresponding products.

[0027] The ski manufacturing method and apparatus according to the invention provide significant advantages compared to the prior art. By means of the invention, skis as desired may be formed quickly and easily. Due to the invention, the manufacture of skis may be adjusted easily and the skis or ski types that are manufactured may be easily modified. Thus, also smaller batches may be efficiently manufactured. Due to the invention, skis are provided a desired look, such as graphic appearance, easily and suitably for each ski type. Additionally, the surface film is easily removable and / or replaceable, and thus for example possible defects in quality of the surface film or its attachment may be corrected easily and quickly by removing the film without damaging the ski body. Thus, wastage may be minimized in the manufacture of skis.LIST OF FIGURES

[0028] Fig. 1 illustrates one process application for manufacturing a ski according to the invention.EXAMPLES

[0029] The invention will now be described by way of detailed examples of embodiments with reference to the accompanying figure.

[0030] In a process for manufacturing a ski according to Fig. 1 a ski body (2) is first formed in a forming device (1). Glue is applied to an upper surface and sides of the ski body (2) by means of a glue applying device (3), and the glue is allowed to dry at least partially. A dispersion glue, such as a thermally activatable dispersion glue, may be used as the glue. A surface film or more than one surface film is attached to the surface of the ski body to which the glue was applied, by means of heat and negative pressure, or alternatively heat and positive pressure, in a film forming device (4) such that the film conforms to the upper surface and the sides of the body. In attaching the surface film, a negative pressure, or alternatively positive pressure, operated press may be used. Preferably, the ski body coated with the surface film is cooled. In addition, it is possible to remove and / or replace the surface film if an error occurs in attaching the surface film, for example before or after the cooling. Optionally, the surface film may be finished by cutting excess film material off before attaching a base material. The base material is attached to a lower surface of the ski body by means of a gluing device (5). Glue is applied to one surface of the base material by means of a glue dispenser, for example by means of a slot nozzle or slot nozzles of the glue dispenser. A hot melt glue may be used as the glue. The base material is glued to the lower surface of the ski body. A finished ski body (6) together with the base material is directed through pressure rolls to form a pressed product.

[0031] According to the example, a ski body (2) is formed, comprising a core layer and one or more reinforcement layers attached to the core layer and comprising ski tip and / or tail reinforcements, in the forming device (1). The different layers are attached by gluing, e.g. by means of an epoxy glue or a polyurethane glue.

[0032] According to one example, the formed ski body (2) is shaped, e.g. by milling / grinding, and / or the ski tail and tip are shaped, and if necessary, the sides of the ski body are rounded before applying the glue by means of the glue applying device (3) and attaching the surface film.Example 1

[0033] In this example a ski is formed by the apparatus according to Fig. 1.

[0034] A ski body (2), comprising a core layer and several reinforcement layers attached to the core layer, is formed in a first ski body forming step by means of a forming device (1). Additionally, the ski body comprises ski tip and / or tail reinforcements. The reinforcement layers and the core layer are joined by gluing by means of an epoxy glue. The layers are glued between two steel sheets under hot pressing with the epoxy glue to form a single piece, without a separate mould.

[0035] The ski body may be shaped, if desired, e.g. by milling and / or grinding, and further the ski tail and / or tip may be shaped. If necessary, the sides of the ski body may be rounded.

[0036] The ski blank now looks like a ski, but it has no base material or surface film.

[0037] A dispersion glue, e.g. a thermally activatable dispersion glue, is applied to an upper surface and sides of the ski body by means of a glue applying device (3), and the glue is allowed to dry at least partially. The application of the glue may be done e.g. about one day before the next work stage or alternatively the same day. However, the glue is allowed to dry before the next stage.

[0038] A surface film or, alternatively, several surface films are attached to an upper surface and sides of the ski body by means of a negative pressure operated press and heat in a film forming device (4) such that the film conforms to the upper surface and the sides of the body. The surface film that comprises the graphic appearance of the ski is wrapped around the upper surface of the ski blank under the effect of suction and heat. At the same time, the glue is activated as it is heated, for example at a temperature below 70°C, and adheres to the surface film. The heat source is turned off, but the suction is left on until the pieces have cooled down to near room temperature. This stage results in a ski having the surface film attached to it but with no base material. It is possible to remove the surface film after attaching, if an error has occurred in the attachment or the surface film has a defect, and thus the undamaged ski body may be reused and a new surface film may be attached to it by means of the attachment step described above. Excess material, i.e. skirt, of the surface film may be cut off, i.e. the ski blank having the surface film may be finished before attaching the base material.

[0039] Attachment of the base material is done by means of a continuously operated device that includes a gluing device (5) and pressure rolls. Glue is applied to one surface of the base material by means of a glue dispenser in the gluing device (5), and the base material is glued to a lower surface of the ski body. A polyurethane hot melt glue, e.g. unfilled monomer reduced PUR hot melt glue, is used as the glue. The application is conducted with a slot nozzle of the glue dispenser to the base material in a precise manner. After applying the glue, the base material and the ski blank that was prepared in the previous work stages meet and the base material is glued onto the lower surface of the ski body in connection with the gluing device. The ski body together with the base material is directed through pressure rolls, in this example through three pressure rolls, to form a pressed ski product. Finally, the sides of the base of the ski and / or the ski base may be finished, if desired.Example 2

[0040] In this example a ski is formed according to Example 1, wherein the ski body comprises the following layers: upper surface laminate, optionally one or more surface reinforcement laminates, core part having plastic tip and tail reinforcements at both ends, base reinforcement laminate, and base surface laminate.

[0041] The ski is formed from the above described ski body by attaching the surface film and the base material.

[0042] The method and apparatus for manufacturing a ski according to the invention are applicable in a variety of embodiments for use in the manufacture of a wide range of skis from different raw materials. The method and apparatus according to the invention are applicable in a variety of embodiments for use in a wide range of ski manufacture applications.

[0043] The invention is not limited to the above examples only, but many modifications are possible within the scope of the inventive idea defined by the claims.

Claims

1. A method for manufacturing a ski, characterized in that the method comprises the steps - forming a ski body, - applying glue at least to an upper surface and sides of the ski body, and allowing the glue to dry at least partially, and attaching at least one surface film to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and - attaching a base material to a lower surface of the ski body by gluing, and applying the glue used for attaching the base material by means of at least one slot nozzle of a glue dispenser.

2. The method according to claim 1, characterized in that the method comprises the steps a. forming a ski body, comprising a core layer and one or more reinforcement layers attached to the core layer and comprising ski tip and / or tail reinforcements, b. shaping the formed ski body and / or shaping the ski tail and tip, and optionally rounding the sides of the ski body, c. applying glue at least to an upper surface and sides of the ski body, and allowing the glue to dry at least partially, d. attaching at least one surface film to the upper surface of the ski body by means of a negative pressure or positive pressure operated press and heat such that the film conforms to the upper surface and the sides of the body, and e. applying glue to one surface of a base material by means of a glue dispenser, gluing the base material to a lower surface of the ski body, and directing the ski body together with the base material through pressure rolls to form a pressed product.

3. The method according to claim 2, char- acterized in that in step a) the ski body is formed by attaching the reinforcement layer by gluing to at least one surface of the core layer.

4. The method according to claim 3, char- acterized in that the gluing is performed by hot pressing between two metal surfaces to form a unitary ski body.

5. The method according to any of claims 2 - 4, characterized in that in step a) at least one surface reinforcement laminate is attached to an upper surface of the core layer, and / or at least one base reinforcement laminate is attached to a lower surface of the core layer.

6. The method according to any of claims 1 - 5, characterized in that the glue that is applied to the upper surface and the sides of the ski body is a thermally activatable dispersion glue.

7. The method according to any of claims 1 - 6, characterized in that after attaching the surface film, the ski body is cooled.

8. The method according to any of claims 1 - 7, characterized in that the surface film attached to the ski body is finished by cutting excess film material off before attaching the base material.

9. An apparatus for manufacturing a ski, characterized in that the apparatus includes - at least one glue applying device (3) for applying glue at least to an upper surface and sides of a ski body (2), - at least one film forming device (4) for attaching at least one surface film to the upper surface of the ski body by means of heat and negative pressure or heat and positive pressure such that the film conforms to the upper surface and the sides of the body, and - at least one gluing device (5) for attaching a base material to a lower surface of the ski body, and the gluing device (5) includes at least one glue dispenser and at least one slot nozzle for applying the glue to one surface of the base material.

10. The apparatus according to claim 9, characterized in that the film forming device (4) comprises at least one negative pressure or positive pressure operated press.

11. The apparatus according to claim 9 or 10, characterized in that the apparatus includes at least one finishing device for finishing the surface film by cutting.

12. The apparatus according to any of claims 9 - 11, characterized in that the apparatus includes one or more pressure rolls through which the ski body together with the base material is directed to travel to form a pressed product.

13. The apparatus according to any of claims 9 - 12, characterized in that the apparatus includes at least one hot pressing device for forming the ski body (2), wherein the ski body comprises a core layer and one or more reinforcement layers attached to the core layer and comprises ski tip and / or tail reinforcements, and the hot pressing device comprises at least two metal surfaces between which a unitary ski body is formed by hot pressing.

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