U.S. patent number 3,902,732 [Application Number 05/332,362] was granted by the patent office on 1975-09-02 for advanced composition ski.
Invention is credited to Albert A. Fosha, Jr., Harry K. Mathewson.
United States Patent |
3,902,732 |
Fosha, Jr. , et al. |
September 2, 1975 |
Advanced composition ski
Abstract
A lightweight ski and method of making same wherein the
structural reinforcement for the ski has unidirectional graphite
fibers in a resin matrix. Fibers extend longitudinally and at
45.degree. from longitudinal.
Inventors: |
Fosha, Jr.; Albert A.
(Bellevue, WA), Mathewson; Harry K. (Sedmond, WA) |
Family
ID: |
23297894 |
Appl.
No.: |
05/332,362 |
Filed: |
February 14, 1973 |
Current U.S.
Class: |
280/610; 156/172;
273/DIG.23; 428/116; 428/408; 428/902 |
Current CPC
Class: |
A63C
5/126 (20130101); A63C 5/12 (20130101); Y10T
428/30 (20150115); Y10S 273/23 (20130101); Y10S
428/902 (20130101); Y10T 428/24149 (20150115) |
Current International
Class: |
A63C
5/12 (20060101); A63c 005/00 (); A63c 005/12 () |
Field of
Search: |
;280/11.13L,11.13S,11.13F ;156/172,185 ;161/68 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Schonberg; David
Assistant Examiner: Mitchell; David M.
Attorney, Agent or Firm: Case; Morris A.
Claims
We claim:
1. An integrated ski comprising:
a. a core selected from materials consisting essentially of foamed
plastic, wood and honeycomb;
b. a reinforcement layer above the core and a reinforcement layer
below the core of unidirectional longitudinally extending graphite
fibers imbedded in resin, each layer comprising: a center section
extending throughout about the center 15 percent of length of the
core of four plies, each about 0.004 inch to 0.006 inch thick of 65
volume percent graphite fibers and an elastic modulus of about
23,000,000 p.s.i., and one additional ply for the center section
layer above the core, a second section extending outwardly in both
directions from the center section, each part extending throughout
about 33 percent of length of the core of four plies, each about
0.004 inch to 0.006 inch thick of 65 volume percent and an elastic
modulus of about 18,000,000 p.s.i., and a third section of two
parts with one part extending from the forward second section to
the tip of the core and the second part extending from the aft part
of the second section to the tail of the core with the parts of the
third section each comprising three plies each about 0.004 inch to
0.006 inch thick of 60 volume percent of graphite and an elastic
modulus of about 10,000,000 p.s.i.
c. a pair of reinforcing layers of unidirectional graphite fibers
imbedded in resin, one of which encircles the core with graphite
fibers extending at 45.degree. from longitudinal in one direction
and the other encircles the core with its graphite fibers extending
at 45.degree. from longitudinal in the other direction, each layer
in the pair comprises a center section extending throughout the
center about 40 percent of length of the core of a single ply about
0.004 inch to 0.006 inch thick with a volume percent of graphite of
about 30 percent and an elastic modulus of about 10,000,000 p.s.i.,
and a second section of two parts one of which extends from the
center section to the nose of the core and the other extends from
the center section to the tail of the core with each layer of the
pair comprising a single ply about 0.004 inch to 0.006 inch thick
with a volume percent of graphite of about 60 percent and an
elastic modulus of about 23,000,000 p.s.i.
d. an outer bottom, top and sides of material consisting
essentially of acrylonitrile -- butadiene -- styrene or high
density polyethylene; and
e. a metal edge reinforcement at each junction between the bottom
and a side.
2. An integrated ski as in claim 1, further comprising a metal
layer between the top outer material and the core in the center
section of the core.
Description
BACKGROUND OF THE INVENTION
Recent art in making snow ski's have been to make ski's from a box
structure for the sides, top and bottom which encases a core
covered with a reinforcement of fiber glass all of which is
laminated into a finished ski. The torsional and flexural
characteristics of these ski's may be varied by changing the
thickness pattern or by adding or subtracting material or by both.
Providing ski's of varying thickness requires expensive tooling and
adding materials increase the weight of the ski, while removing
materials degrade the strength. Presently available standard size
ski's (205 cm in length) have a minimum weight in excess of eight
pounds per pair.
It was discovered that a ski may be obtained which weighs less than
six pounds per pair and may have tailor-made flexural and torsional
characteristics with a barely noticeable variation in thickness
and/or weight.
BRIEF SUMMARY OF THE INVENTION
Unidirectional graphite fibers in a resix matrix are applied in a
layer above and a layer below a core of a ski. The fibers are
oriented such that they extend longitudinally along the core. It
has been found that this combination of unidirectional graphite
fibers in resin when incorporated into a ski with covering top,
bottom and sides will provide proper reinforcement. In preferred
embodiments the layer above and below the core will each have a
thickness of from about 0.008 inch to 0.040 inch with a graphite
volume percent of about 50 to 70 and a modulus of elasticity of
about 10,000,000 p.s.i. to about 41,000,000 p.s.i. In yet other
embodiments the thickness varies from about 0.016 inch to 0.032
inch and the modulus to from about 10,000,000 p.s.i. to 25,000,0000
p.s.i.
The greatest load bearing requirements on the ski, under the foot
of the skier, is at approximately the lengthwise midpoint of the
ski's. In practicing this invention the flexural characteristics
may be varied from midpoint to the tip and from midpoint to the
tail with stepwise layers of reinforcement with at least one layer
extending the length of the ski, a second and shorter layer
extending fore and aft from the lengthwise center of the ski and
other yet shorter layers extending from the midpoint. The flexural
characteristics may also be varied stepwise by the use of graphite
fibers with different modulus of elasticity.
Unidirectional graphite fibers in a resin matrix spirally encompass
the core of the ski with a layer of fibers extending at 45.degree.
from longitudinal in one direction and a second layer of fibers
extending at 45.degree. from longitudinal in the other direction,
to control torsional characteristics. In one preferred embodiment
each layer varies in thickness from about 0.004 inch to about 0.008
inch with a graphite volume percent of about 10 to 70 and the
modulus of elasticity of from about 10,000,000 p.s.i. to 41,000,000
p.s.i. The torsional characteristics may be varied by stepwise
layers or by varying the elastic modulus.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a ski.
FIG. 2 is a fragmented perspective view of the ski of FIG. 1,
partially cut away to show the details of fiber orientation.
FIG. 3 is a cross section of the ski of FIG. 1 taken along the
lines 3--3 in the direction of the arrows.
FIG. 4 is a lengthwise cross section of the ski of FIG. 1 showing
only the core with an exaggerated thickness of layers of
reinforcement having longitudinally extending fibers.
FIG. 5 is a sectional end view of core material located in a mold
and sandwiched between reinforcing layers having longitudinally
extending fibers.
FIG. 6 is a cross section as in FIG. 3 showing the assembled
components of the ski in a mold.
FIG. 7 shows a sectional end view of a core with reinforcement
layers in a mold.
DETAILED DESCRIPTION
This ski has as its reinforcement members unidirectional graphite
fibers embedded in a resin. The graphite fibers or filaments are
typically produced by using a rayon or pitch fiber, cross linking
the polymer and finally converting to a graphite filament form of
carbon at a temperature of about 1,000.degree.C. High modulus and
high strength characteristics of the filaments are developed in the
filaments by stretching at temperatures of about 2,000.degree.C.
The tensile modulus of elasticity of the graphite fibers may be
varied from about 27,000,000 p.s.i. to about 58,000,000 p.s.i. One
may choose the fibers to place in a resin matrix to obtain the
preferred tensile modulus of elasticity for use in ski's of from
about 10,000,000 p.s.i. to about 41,000,000 p.s.i. for the cured
matrix.
Bundles or tows of several thousand graphite filaments are encased
in a resin matrix and flattened into tapes or broadgoods. The
uncured thickness of these tapes may be from about 0.004 inch to
0.008 inch and the volume percent of graphite may be varied from
about 10 to 70 percent. Several plies of these tapes may be placed
one upon another without materially effecting the overall thickness
of a ski. The fibers may be embedded in a matrix of epoxy,
phenolic, and polyester resins to name a few of the resins that may
be used with epoxy preferred. However, other resins may be used,
and this is not intended to be limiting.
The arrangements of reinforcing unidirectional graphite fibers in a
resin matrix is best shown in FIGS. 2 and 3. An integrated ski 10
has core 12. This core may be of honeycomb, wood, or foamed
plastic, such as but not limited to foamed polyurethane. A layer 14
of longitudinally extending graphite fibers in resin is placed
above the core and a second layer 16 is placed below the core.
A pair 18 of reinforcing layers shown in FIG. 3 are positioned at
90.degree. to each oher and are made up of a layer 20 and layer 22
best shown in FIG. 2. Layer 20 has unidirectional graphite fibers
encircling the core 12 with the fibers extending at 45 degrees from
longitudinal in one direction and fibers of layer 22 extending at
45 degrees in the other direction.
The core 12 with reinforcing layers 14, 16, 20 and 22 are alll
encased or boxed in top section 24, side section 26 and 26a and
bottom or runner section 28. These encasing sections may preferably
be made of acrylonitrile -- butadiene -- styrene (A.B.S.) or high
density polyethylene known as P-Tex. The P-Tex is preferred as the
bottom section to act as the running surface. These materials are
in semi-rigid slabs and are formed to shape. The ski has L-shaped
metal edge reinforcement runners 30 and 30a. If desired a metal or
fiberglass reinforcement 32 may be used in the top center of the
ski to accept fasteners from the binding. An optional decorative
top sheet 34 may be used. A phenol formaldehyde or melamine
formaldehyde resin is preferred for the decorative sheet as they
are both abrasion resistant and color fast.
In one embodiment, see FIG. 4, the longitudinally extending
reinforcing tape is arranged with additional layers 36 and 38 above
the core and additional layers 40 and 42 below the core. These
additional layers are centered on the lengthwise midpoint of the
core and extend for varying lengths.
In yet another embodiment additional pairs of layers of 45.degree.
from longitudinal reinforcing tape extend stepwise varying lengths
from the midpoint of the core.
Desired flexural and torsional strengths and flexibility patterns
may be obtained by varying the structural strength of the fibers
used at different points along the ski. In one preferred embodiment
the longitudinally extending fibers in the reinforcing layer are
made up by varying the number of plies, the modulus of elasticity
and the volume percent of graphite at different lengths along the
core. An overlap of about one-quarter inch is required for splicing
between materials of different properties in the same ply. A center
section layer, second section layer, extending outwardly from the
center section in both directions and tip and tail sections
extending outwardly from the second sections are used to obtain
varying flexural characteristics. In one preferred embodiment the
center section of about 15 percent of the length of the core has
five plies of reinforcing tape above the core and four plies below
the core with each ply of about 0.004 inch to 0.006 inch thick of a
matrix with 65 percent graphite volume and an elastic modulus of
about 23,000,000 p.s.i.; the second section of two parts with one
part extending about 33 percent of the length of the core towards
the tip, and the other extending about 33 percent of the length of
the core towards the tail has four plies above and four plies below
the core with each ply of about 0.004 inch to 0.006 inch thickness
of reinforcing tape of 65 volume percent of graphite and an elastic
modulus of about 18,000,000 p.s.i.; and a pair of end sections with
each extending from a second section toward the tip or the tail of
about 9 percent of the length of the core and having three plies
above and three plies below the core with each ply about 0.004 inch
to 0.006 inch thick of a reinforcing tape of 60 volume percent
graphite and an elastic modulus of about 10,000,000 p.s.i. This
preferred embodiment also uses a ply of reinforcing tape with
graphite fibers extending at 45.degree. in one direction from
longitudinal and a second similar ply at 45.degree. from
longitudinal in the other direction. Each center section ply is
about 0.004 inch to 0.006 inch thick and has a modulus of
elasticity of about 10,000,000 p.s.i. and a graphite volume percent
of 30 percent in the center about 40 percent of length. Each ply in
the sections extending from the center section to the tip and from
the center section to the tail have a thickness of about 0.004 inch
to 0.006 inch, a graphite volume percent of about 65 and a modulus
of elasticity of about 25,000,000 p.s.i.
The ski may be prepared by first preparing a core with cured
reinforcing layers which is then placed inside the outer box-like
members to form a ski assembly inside a mold and the assembly
heated under pressure to obtain an integrated ski. The ski may also
be prepared by making up the ski assembly in the final mold.
In FIG. 5 a reinforcing tape 44 of longitudinally extending
graphite fibers in as resin is placed in the recess of a formed
mold 46. Core material 48 and then another layer of reinforcing
tape 50 of longitudinally extending graphite fibers in resin is
placed on top and mold part 52 inserted into the recessed lower
mold. The core with reinforcing layers is cured at about
250.degree.- 350.degree.F at about 15-75p.s.i. The cured core with
reinforcement is then cut to an undersize shape of a ski to become
the reinforcement for a ski.
Alternatively reinforcement tapes 44 and 50 may each be placed in a
formed mold or tool and cured at about 250.degree.-350.degree.F
under pressures of about 15-75p.s.i. These tapes would then be
coated with a suitable adhesive and bonded to core material 48
under temperatures and pressures as outlined above. If desired the
shaped reinforced core now shown in FIG. 7 as core 12 with lower
reinforcement 16 and upper reinforcement 14, may be encircled with
a pair of 45.degree. from longitudinal transverse reinforcing tape
shown as 18 and either placed in the recessed mold 54 to be cured
or placed directly in a ski assembly for final integration into a
ski.
To form an integrated ski, see FIGS. 3 and 6, a bottom running
surface member 28 is placed in a recessed mold 56, next metal edge
members 30 and 30a are placed in the mold then side members 26 and
26a. The inside of these surfaces are coated with a suitable
adhesive and the core with longitudinal and if desired transverse
at 45 degree reinforcing fibers in resin placed inside the side and
bottom box-type structure. The core with reinforcement may be
prepared and precured or may be laid up inside the box structure. A
top layer 24 with the side adjacent the structure coated with a
suitable adhesive is placed on top to form a ski assembly which may
be cured in the mold at about 250.degree. to 350.degree.F with a
pressure of about 15 to 75 p.s.i. If desired the top center section
of the ski may have metal or fiberglass sheet 32 placed in the
assembly prior to curing. Optionally one may place decorative sheet
34 above the top member 24 before curing the assembly.
* * * * *