Heated Roller Structuring for Polyethylene Ski Surfaces

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Solution Overview

Problem

Current methods for processing polyethylene ski surfaces, such as grinding, struggle to achieve consistent and defined macro, micro, and nanostructures, leading to variations in sliding properties and performance, especially in high-performance skis where small differences can result in significant time gaps during downhill runs.

Innovation Solution

A method involving heating the ski surface to allow plastic deformation and using a rotary-driven roller with controlled relative speed and contact pressure to apply macro, micro, and nanostructures, allowing for uniform and adaptable surface structuring, including the use of a roller with defined micro and macro structures to achieve optimal sliding properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional grinding methods (belt grinding or stone grinding) are used to process ski surfaces, then the sliding surface can be processed, but it is not possible to achieve a defined and consistent macro, micro, and nanostructure, leading to variations in sliding properties and performance

Engineering Contradiction:

Improvesurface structure consistencyVSAvoidsliding property uniformity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The ski surface is pre-heated to a temperature permitting plastic deformation before the rolling process. This preliminary thermal treatment enables the subsequent rolling operation to successfully imprint defined macro, micro, and nanostructures that would otherwise be impossible to achieve on cold, rigid polyethylene surfaces with traditional grinding methods

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the temperature parameter of the ski surface from ambient to a state permitting plastic deformation. This parameter change fundamentally alters the material properties of the polyethylene, making it sufficiently pliable to receive and retain precisely defined surface structures from the rolling tool, thereby achieving consistent macro, micro, and nanostructuring

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the roller is pressed onto the sliding surface with high contact pressure to achieve defined structures, then the structuring quality improves, but the risk of roller surface sticking due to adhesion of soft plastic increases

Engineering Contradiction:

Improvesurface structure definitionVSAvoidroller surface sticking

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The roller is cooled continuously or periodically during the rolling process to prevent the softened plastic from adhering to the roller surface. This thermal management approach allows the application of sufficient contact pressure to achieve well-defined surface structures while periodically removing heat to prevent sticky adhesion

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Temperature acts as an intermediary parameter that is carefully controlled during the rolling process. The ski surface is heated to enable plastic deformation for good structure transfer, while the roller itself is kept cooler to prevent sticking, creating an optimal temperature gradient between the workpiece and the tool

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the entire sliding surface width is processed at once using a roller with width corresponding to the sliding surface width, then processing efficiency improves, but the requirement for roller precision and uniformity increases

Engineering Contradiction:

Improveprocessing speedVSAvoidroller surface uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The roller surface is segmented into different functional zones along its width, with each zone having specific macro, micro, or nanostructures optimized for different parts of the ski surface. This segmentation allows the entire ski width to be processed simultaneously while each zone contributes its specific structuring function, maintaining high productivity without requiring the entire roller surface to be perfectly uniform

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method enables precise control over the sliding surface structures, enhancing sliding properties and reducing wear, allowing for consistent performance across different snow conditions and extending the life of ski surfaces by ensuring uniform and reproducible processing.

Implementation Method 1

the sliding surface is heated to a temperature permitting plastic deformation

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the roller is cooled

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentEP2462998B1Method and device for treatment of a plastic sliding surface, in particular of a polyethylene sliding surface, of sliding devices like skis

Publication Date: 2017.10.25 STROI JOHANN

AI summary

The method involves heating the sliding surface to a temperature enabling plastic deformation and processing the heated sliding surface with a rotatably driven roller (3,4). The surface of the roller has a relative speed to the sliding surface. The relative speed is varied over the length of the sliding surface. Independent claims are also included for the following: (1) a device for processing a plastic-particularly polyethylene sliding surface of sliding units such as skis; and (2) a sliding surface with a nanostructuring.