CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S. C. §119 from U.S. Provisional Patent Application Number 63/320,093, entitled "Injection Molded Ski," filed on March 15, 2022, the subject matter of which is expressly incorporated herein by reference.

TECHNICAL FIELD

[0002] The present invention relates generally to sporting equipment, and more specifically, to snow skis.

BACKGROUND INFORMATION

[0003] Skiing is a popular snow sport shared by many. Skis typically include two narrow strips of semi-rigid material worn underneath a user’s feet. The user glides over snow via the skis. Typical skis are formed from multiple layers of fiberglass and other materials. Most skis are manufactured via a layup manufacturing process.

SUMMARY

[0004] An injection-molded ski includes a ski body and two ski edges attached to edge surfaces of the ski body. The ski body is formed from a uniform material and has top, bottom, and edge surfaces and a binding mounting platform. The binding mounting platform is formed on the top surface and receives a boot binding. The ski edges comprise an edge portion and securing features, such as hooks, loops, contours, or shapes. In one embodiment, a ski is injection-molded using a molding material, such as glass-reinforced nylon or a combination of one or more suitable materials. The body of the novel ski is formed from a homogenous mixture or combination. The injection-molded ski does not have multiple coplanar layers of different materials as in conventional skis. A novel mold facilitates injection of molding material around and/or between the securing features thereby locking the edges in place when the molding material cools.

[0005] The novel injection-molded ski has improved durability, flexibility, strength, and performance characteristics as compared to conventional skis. The novel injection-molded ski has reduced manufacturing complexity as compared to conventional ski manufacturing techniques. Conventional skis are formed by layering multiple layers of different materials in a layup process. The novel injection-molded ski tends to have reduced susceptibility to failure due to moisture or wear. When outer walls of a conventional ski are breached, the conventional ski is particularly susceptible to damage caused by entry of moisture between layers of the ski.

[0006] In various exemplary embodiments, methods and apparatuses are provided for a snow ski that comprises a uniform material. In an embodiment, a ski is injection-molded using glass-reinforced nylon, although other suitable materials can be utilized. To obtain precise ski characteristics, the ski is designed to have a balance of flexibility and strength in response to various loading scenarios. As a result, the disclosed ski provides an optimum balance of engineered strength and aesthetic design.

[0007] In one embodiment, an injection-molded ski is provided that includes uniform material forming a ski body having top, bottom, and edge surfaces and a binding mounting platform formed on the top surface to receive a boot binding. The apparatus also includes two ski edges attached to the edge surface along the left and right sides of the ski body, respectively.

[0008] In another embodiment, a method is provided that comprises securing ski edges in a first half of a mold so that the ski edges are secured against at least one surface of the first half of the mold. The method also comprises securing a second half of the mold to the first half of the mold to form a cavity, and injecting material into the cavity to form a ski body so that at least a portion of the ski edges are molded within the ski body. [0009] In other embodiments, the novel techniques are employed to manufacture at scale any body having an exposed structure of a different material. A body is formed from a first material. A structure is formed from a second material. The structure has securing features. At least part of the structure is exposed along an exterior of the body. The structure is secured to the body by molding or depositing the first material between or around the securing features of the structure. In embodiments that involve inj ection molding, one or more molds are constructed such that the structure is flush against at least one surface of one mold. When the molding material is deposited into the mold, the structure is fixed in place to ensure at least part of the structure remains exposed to an exterior. In embodiments that involve additive manufacturing, the first material is deposited around securing features of the structure.

[0010] The foregoing is a summary and thus contains, by necessity, simplifications, generalizations, and omissions of detail; consequently, it is appreciated that the summary is illustrative only. Still other methods, and structures and details are set forth in the detailed description below. This summary does not purport to define the invention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings, where like numerals indicate like components, illustrate embodiments of the invention.

[0012] FIG. 1 shows a perspective view of a ski constructed in accordance with one embodiment.

[0013] FIG 2 shows top and bottom views of the ski shown in FIG. 1.

[0014] FIG. 3 shows a left side view of the ski shown in FIG. 1.

[0015] FIG. 4 shows the top view of the ski shown in FIG. I and includes cross-section indicators A and B.

[0016] FIGS. 5A-B show cross-sectional views of the ski shown in FIG. 4 taken at the cross-section indicators A and B.

[0017] FIG. 5C shows a front view of the ski and a rear view of the ski. [0018] FIG. 6 shows an exemplary injection molding machine suitable for use to form an injection-molded ski in accordance with various embodiments.

[0019] FIG. 7 shows an exemplary method for forming a mold to produce an injection-molded ski in accordance with various embodiments.

[0020] FIG 8 shows an exemplary method for forming an injection-molded ski in accordance with various embodiments.

[0021] FIG. 9 shows a side view of an injection-molded ski with a ski binding.

[0022] FIG. 10 shows a perspective view of an injection-molded ski with the ski binding.

[0023] FIG. 11 shows an embodiment of a first half of a mold configured to produce an injection-molded ski.

[0024] FIG. 12 shows an embodiment of a second half of a mold configured to produce an injection-molded ski.

[0025] FIG. 13 shows another embodiment of a second half of a mold configured to produce an injection-molded ski.

[0026] FIG. 14 shows an expanded view of a portion of the second half of a mold configured to produce an injection-molded ski.

[0027] FIGS. 15A-F show detailed views of a ski molding process.

[0028] FIGS. 16A-B show cross-sectional views of a ski and a mold during the molding process.

[0029] FIGS. 17A-B show exemplary ski edges.

DETAILED DESCRIPTION

[0030] In various embodiments, a novel ski is disclosed. In one embodiment, the novel ski is provided with improved durability, flexibility, strength, and performance characteristics. Additionally, the novel ski reduces manufacturing complexity as compared to known ski manufacturing techniques and tends to reduce mean time between failure.

[0031] FIG. 1 shows a perspective view of a ski 100 constructed in accordance with one embodiment. In this embodiment, the ski 100 is injection-molded using a material, such as heated glass-reinforced nylon. In this embodiment, the material is a uniform and homogenous composition of two or more different materials combined together.

[0032] In various embodiments, the material used for injection-molding comprises a fiber reinforced thermoplastic (e.g., polypropylene or polyethylene) or nylon. The reinforcing fiber in one embodiment is glass fiber. The material is formed by melting one or a combination of suitable materials with the reinforcing fiber to form a mixture that can be heated and injected into a mold. In one embodiment, the material comprises a polymer matrix of one or more of a high quality polypropylene, polyethylene, nylon, or other suitable material reinforced with glass fiber or other suitable reinforcing material. In one embodiment, the combined material comprises 20% to 40% by weight of glass fiber reinforcing material. The ability to combine materials makes the ski 100 suitable for varying performances.

[0033] The ski 100 comprises a ski body having a front end 102, a tail end 104, and an integrated binding platform 106. In an embodiment, a ski binding attaches to the binding platform 106 to secure a ski boot of a user.

[0034] The front end 102 and the tail end 104 provide unique curves that rise early to avoid catching on snow when skiing. The rise of the tail end 104 allows for safer backwards skiing. This is especially important for short skis as more pressure is applied on the tips than on the tips of a standard-length ski.

[0035] In an embodiment, the binding platform 106 is designed to have holes (or openings) that accept posts, bolts, screws, or other fasteners to secure a boot binding to the binding platform.

[0036] The ski 100 also comprises a right-side ski edge 108 A and a left-side ski edge 108B that are molded into the ski body on each side. The ski edges 108A-B comprise metal, plastic, or other hard material that provides a sharp edge that facilitates turning while skiing. The ski 100 also includes text, graphics, or other markings forming a logo 110 that is molded into the ski body.

[0037] In various embodiments, the ski 100 provides a variety of advantages over conventional fiberglass- laminated skis. The uniform material provides damping and the profile of the ski is tapered in the range of 14 (one-fourth) inch to 7s (five-eighths) inch to provide strength and flex for comfortable skiing and turning. For example, the ski’s profile has a ridge in the middle and tapers down to the ski’s edges. The ski’s profile also tapers to the ends of the ski from the middle of the ski. Thus, the ski’s profile tapers in two dimensions to provide favorable damping characteristics for skiing with more control and less ski chatter (or vibration). The ski is also very durable since in one embodiment the ski comprises glass-filled nylon, which is a very hard material and forms a ski that will not suffer from delamination or water seepage like conventionally laminated skis. [0038] FIG. 2 shows top 200 and bottom 220 views of the ski 100 shown in FIG. 1. The top view 200 shows the binding platform 106, which has a platform length 204 of approximately 31.5 centimeters (cm) and a platform width 206 of approximately 5 cm. In an embodiment, the ski 100 has an overall length 202 in a range of 20 to 200 cm, but in one embodiment, the overall length 202 is approximately 85 cm.

[0039] In one embodiment, the ski 100 fits into the category of "short skis" or "mini skis" that are skis under 115 cm. In another embodiment, the ski length can be proportional or set based on the ski width or binding width. In one embodiment, the length is less than ten times the width at the middle of the ski (middle width 210). In another embodiment, the length is less than nine times the width at the middle of the ski (middle width 210). By providing a ski having a length and width in accordance with the above dimensions and having a uniform material, the ski has desirable stability, strength, flexibility, and performance characteristics that yield significant improvements compared to conventional skis as described throughout the present disclosure.

[0040] The bottom view 220 illustrates the location of the ski edges 108A-B and each ski edge has a length 214 in a range of 40 to 70 cm, and in one embodiment, the length is approximately 63.5 cm. Horizontal tapering of the ski results in a front width 208 of approximately 11 cm, a middle width 210 of approximately 10 cm, and a tail width 212 of approximately 10.5 cm. It should be noted that the above dimensions are exemplary and that the ski dimensions can be larger or smaller, and the horizontal tapering can be adjusted to achieve desired performance characteristics. In various embodiments, the widths of the front, middle, and tails sections are within a range of 5-25 cm and a thickness within a range of 0.5 cm to 3 cm. [0041] FIG. 3 shows a left side view 300 of the ski 100 shown in FIG. 1. The side view 300 illustrates that the ski 100 comprises vertical tapering from the center to the ends with a front thickness 302 of approximately 1 cm, a tail thickness 304 of approximately 1 cm, and a center thickness 306 that includes the binding platform of approximately 1.5 cm. It should be noted that the above dimensions are exemplary and that the ski dimensions can be larger or smaller. For example, in various embodiments, the ski thickness at any point on the ski is in a range of 0.5 to 4 cm. The side view 300 also shows the location of the left ski edge 118A. In an embodiment, the ski 100 comprises a % (three-fourths) degree to !4 (one-half) degree slope from the binding platform 106 to the tip of the ski front end 102 to provide an even flex pattern.

[0042] FIG. 4 shows the top view 200 of the ski 100 shown in FIG. 1 and includes cross-section indicators A and B. FIG. 4 also illustrates that the ski 100 includes a vertical taper from center line 402 to the outer edges (indicated at 404), which provides increased strength.

[0043] FIGS. 5A-B show cross-sectional views of the ski 100 shown in FIG. 4 taken at the cross-section indicators A and B. The cross-sectional view shown in FIG. 5A illustrates features 502 of the platform 106. The cross-sectional view shown in FIG. 5B illustrates the vertical taper 504 of the ski 100 at location B.

[0044] FIG. 5C shows a front view of the ski 100 and a rear view of the ski 100. In one embodiment, the front end of the ski includes a tab 506 that helps guide the ski 100 through snow.

[0045] FIG. 6 shows an exemplary injection molding machine 600 suitable for use to form an injection-molded ski in accordance with one embodiment. The machine 600 comprises an injection portion 602 and a clamping portion 604.

[0046] The injection portion 602 comprises a motor drive 606, hopper 608, reciprocating screw 610, barrel 612, heater 614, and nozzle 616. The clamping portion 604 comprises a moveable platen 618, mold 620, cavity 622, and platen motor 624.

[0047] During operation, the mold 620 is secured in the clamping section 604 by the platen motor 624 moving the platen 618 to press or secure the mold 620 to the cavity 622. Material 626 is placed in the hopper 608 and the screw motor drive 606 turns the reciprocating screw 610 to move the material 626 dispensed from the hopper 608 toward the nozzle 616. While the reciprocating screw 610 is moving, the material 626 is heated to liquid form by the heater 614.

[0048] As the heated liquid moves toward the nozzle 616, it is compressed so that it flows through the nozzle 616 and into cavity 622. The heated liquid then flows from the cavity 622 into the mold 620. Once the mold 620 is filled with the heated liquid, the mold 620 is removed from the molding machine 600 and allowed to cool. After a selected cooling time interval, the mold 620 is opened and the injection-molded part is extracted.

[0049] FIG. 7 shows an exemplary method 700 for forming a mold to produce an injection-molded ski in accordance with various embodiments. For example, the method 700 is suitable for use to form two halves of a mold as shown in FIGS. 11-14.

[0050] At block 702, two halves of a mold are formed so that together, the mold will form a cavity to produce a ski having selected shape and size characteristics. For example, the cavity will produce a ski having the dimensions and features of the ski 100. [0051] At block 704, the first half of the mold is formed to accept pins to secure and align metal edges of the ski within the cavity.

[0052] At block 706, the first half of the mold is formed to have a port that allows material to be injected into the cavity.

[0053] At block 708, the second half of the mold is formed to accept pins to further secure and align metal edges within the cavity.

[0054] At block 710, the second half of the mold is formed to produce a binding platform on the top of the ski.

[0055] Thus, the method 700 operates to form a mold that can be used to injection-mold a ski.

[0056] FIG. 8 shows an exemplary method 800 for forming an injection-molded ski in accordance with various embodiments. For example, method 800 is suitable for use with the mold formed by method 700 to produce an injection-molded ski, such as the ski 100, in accordance with the embodiments.

[0057] At block 802, a first half of a mold is secured in an injection-molding machine. [0058] At block 804, ski edges are secured in the first half of the mold. For example, the ski edges 108A-B are made of metal, hard plastic, or other suitable material. The ski edges are secured to the first half of the mold by pins, clips, press-fit, or other attachment mechanisms. During the molding process, the ski edges are molded within the ski body (e g., such as by over-molding or insert molding) when heated liquid material surrounds portions of the ski edges to secure these portions within the ski body when the heated liquid material cools.

[0059] At block 806, a molding material is formed and heated for use during the molding process. In one embodiment, the molding material comprises glass-reinforced nylon pellets and pigment pellets to form a pellet mixture that is heated to form a liquid. For example, in one embodiment, the pigment pellets have a desired color, such as yellow, so that the molded ski takes on a desired appearance.

[0060] At block 808, a securing mechanism, such as pins, clips, press-fit, or other attachment mechanism, is inserted into the second half of the mold. For example, pins are inserted in the second half of the mold to further align and secure the ski edges within the cavity.

[0061] At block 810, the first half of the mold is secured to the second half of the mold so that both halves secure the ski edges within the mold.

[0062] At block 812, the heated material is injected into the cavity of the mold and around the ski edges, which will secure the ski edges to the ski body. In one embodiment, the material, such as glass-reinforced nylon, is heated to 400 degrees Fahrenheit for the injection process.

[0063] At block 814, the mold is cooled for a selected time duration.

[0064] At block 816, the mold is opened, and the ski is ejected from the mold.

[0065] At block 818, the ski is trimmed to remove artifacts of the molding process. [0066] Thus, the method 800 operates to utilize a mold to form an injection-molded ski. [0067] FIG. 9 shows a side view of an injection-molded ski with a ski binding 904 attached to the binding mounting platform 106 and a ski boot 902 attached to the ski by the ski binding 904. [0068] FIG. 10 shows a perspective view of an injection-molded ski with the ski binding 904 attached to the binding mounting platform 106 and a ski boot 902 attached to the ski by the ski binding 904.

[0069] FIG. 11 shows an embodiment of a first half of a mold configured to produce an injection-molded ski. For example, the mold comprises two halves that are secured together for use during the inj ection process, and then split apart or opened to ej ect the molded ski. As illustrated in FIG. 11, the mold half shown (top half cold side) includes features to form the binding platform 106 and a logo 110. Also shown in FIG. 11 are top pin 1102 and pin holes 1104 that are used to align and secure the ski edges within the mold.

[0070] FIG. 12 shows an embodiment of a second half of a mold configured to produce an injection-molded ski. The mold half shown (bottom half hot side) includes an injection port 1202 that allows liquid to be injected into the mold. Also shown are ski edges that are aligned and secured within the mold by bottom pins 1204.

[0071] FIG. 13 shows another embodiment of a second half of a mold configured to produce an injection-molded ski. The mold half shown (bottom half hot side) includes an injection port 1202 that allows liquid to be injected into the mold. Also shown are the pins 1204 that align and secure the ski edges.

[0072] FIG. 14 shows an expanded view of a portion of the second half of a mold configured to produce an injection-molded ski. The mold half shows a detailed view of the pins 1204 that align and secure the ski edges.

[0073] FIG. 15A shows a detailed view of a ski molding process. As indicated at 1502, a first half of a mold is open and includes bottom pins and an injection port 1 10. The bottom pins will be used to align and secure ski edges, and the injection port will be used to inject liquid material into the mold.

[0074] FIG. 15B shows a subsequent operation in the ski molding process. As indicated at 1504, ski edges are aligned to be placed into the first half of the mold. When the ski edges are inserted into the mold, the ski edges will be secured against at least one of a side surface of the mold and a bottom surface of the mold. This will prevent liquid material that is injected into the mold from getting between the ski edges and the side and/or bottom surfaces of the mold.

[0075] FIG. 15C shows a subsequent operation in the ski molding process. As indicated at 1506, the ski edges are inserted into the mold and aligned and secured by the bottom pins.

[0076] FIG. 15D shows a subsequent operation in the ski molding process. As indicated at 1508, a second half of the mold that includes top pins is aligned and brought into contact with the first half of the mold thereby forming a cavity. When the mold is closed, the top pins will further operate to align and secure the ski edges.

[0077] FIG. 15E shows a subsequent operation in the ski molding process. As indicated at 1512, the two halves of the mold are brought together to form a cavity and material (e.g., hot, liquid material) is injected into the mold through the injection port to fill the cavity.

[0078] FIG. 15F shows a subsequent operation in the ski molding process. As indicated at 1514, the cavity is filled with the injected material and will be cooled before opening to remove the molded ski.

[0079] It should be noted that the operations shown in FIGS. 15A-F are exemplary and can be modified or otherwise reconfigured in accordance with the embodiments.

[0080] FIG. 16A shows a cross-sectional view 1600 of a ski during the molding process. For example, the cross section C-C of a mold filled with material is shown.

[0081] FIG. 16B also shows a detailed cross-sectional view 1602 that illustrates the arrangement of the bottom pin, top pin, ski edge, and liquid material injected into the mold.

[0082] In another embodiment, the ski is formed using three-dimensional (3D) printing or other additive manufacturing techniques. In such 3D printing or additive manufacturing processes, a ski body is formed by depositing a material in a selected pattern layer by layer. In one embodiment, a 3D printer is configured to print the ski body using a first material and ski edges using a second material. For example, the first material is a polymer matrix of one or more of a high quality polypropylene, polyethylene, nylon, material reinforced with glass fiber, or other suitable reinforcing material, and the second material is one or any combination of metal, plastic, composite material, or any other suitable edge material. In another embodiment, a modified configuration of the mold is used and the ski edges are installed as the printing process progresses.

[0083] In still another embodiment, the ski is molded as described above, however, the mold is configured to produce areas of the ski, such as the binding platform 106, that can be modified after the molding process to accept a variety of boot bindings. For example, in one embodiment, the binding platform 106 is molded as a rectangular block on top of the ski that can be cut, shaped, or drilled, either manually or using a computerized tool such as a computer numerical control (CNC) milling machine (negative manufacturing), to form a desired binding platform that accepts a particular ski binding. In one embodiment, any portion or portions of the ski can be molded to provide regions that can be subsequently processed, such as by milling, to complete or customize the ski. In one embodiment, the entire ski can be molded as described above into a rough shape, such as a rectangular block, that can be subsequently processed, such as by milling, to complete or customize the ski.

[0084] FIG. 17A shows exemplary ski edges. In one embodiment, the ski edges comprise an edge portion 1702 and securing features 1704. The securing features 1704 comprises any suitable contours or shapes such that during the molding process, the molding material flows around and/or between the shapes or contours to lock the edges in place when the molding material cools. Thus, the securing features 1704 will secure the ski edges to the ski body during the molding process as the injected material surrounds the securing feature and hardens. The edge portion 1702 will be exposed outside the ski body, thus allowing the sharpness of the edge portion 1702 to facilitate turning while skiing.

[0085] In one embodiment, the ski edges are made from metal material, such as hardened steel. In another embodiment, the ski edges are made from any suitable composite or synthetic material. In still another embodiment, the ski edges comprise a molded component comprising one or any combination of metal, plastic, composite material, or any other suitable material polymer matrix of one or more of a high quality polypropylene, polyethylene, nylon, or other suitable material reinforced with glass fiber or other suitable reinforcing material. The molded ski edge component is then installed in the ski mold and over-molded into the ski body during the injection molding process described above.

[0086] In one embodiment, the ski edges are not attached to the ski body during the molding process but are attached to the ski body using one or any combination of glue, screws, rivets, fasteners, or other attachment means. For example, the ski body is molded to have recessed regions at the locations of the ski edges. After the molding process is completed, ski edges are attached to the recessed regions on the ski body. For example, the ski edges can be glued or attached by mechanical fasteners. Thus, a variety of ski edges can be designed to fit into the recessed regions allowing the ski edges to be reconfigured as needed. Also, the ski edges can be removed and replaced in case of damage or to accommodate a change in ski performance.

[0087] FIG. 17B shows a detailed view of an exemplary ski edge. In one embodiment, the detailed view shows the edge portion 1702 and securing features 1704.

[0088] Although certain specific embodiments are described above for instructional purposes, the teachings of this patent document have general applicability and are not limited to the specific embodiments described above. It is appreciated that the above injection molding techniques are usable to manufacture long skis, snowboards, and other types of equipment. It is also appreciated that the novel manufacturing techniques are applicable to generate any structure of a first material, such as molding material, in which the structure has an exposed second material, such as metal, wood, bamboo, or other material different from the first material Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.