Water skis having a reinforced, foamed-in-place, plastic hull bonded to an aluminum deck

Claim 2

The process of manufacturing water skis which comprises the steps of: (a) positioning small diameter steel rods, at least some of which extend substantially the length of the ski, within the cavity of a mold with plastic jigs which cause the rods to be spaced above the lower surface of the ski, said jigs becoming a part of the water ski; (b) injecting a polyurethane foam into the mold against a prepositioned aluminum deck; (c) allowing the polyurethane foam to harden in the mold while simultaneously bonding to the aluminum deck; and (d) removing from the mold a water ski blank which has a reinforced plastic hull bonded to said aluminum deck.

Claim 3

Processes of claim 1 in which at least one of said jigs is provided with restraining tabs to prevent significant movement of the reinforcing rods during injection and foaming of the plastic.

Claim 4

Processes of claim 1 or 2 in which: (a) the aluminum deck is larger than the mold cavity, the aluminum deck serving to close the mold; and (b) after the water ski blank has been removed from the mold, the excess aluminum is trimmed to the desired water ski shape.

Claim 5

Processes of claim 3 in which the aluminum deck is generally rectangular in shape prior to said trimming.

Claim 6

The process of manufacturing water skis which consists essentially of: (a) positioning from 3-7 small diameter spring steel rods within the cavity of a mold; said rods having been cleaned; said rods extending lengthwise in said mold and being held in a pre-determined relationship with a series of transverse plastic jigs which support the rods at a pre-determined height above the floor of the mold cavity; (b) closing the mold with a rectangular sheet of aluminum, the lower surface of which has been surface activated with a dichromate/sulfuric acid bath and primed with an epoxy/phenolic primer; (c) injecting polyurethane foam-producing ingredients into said mold to thereby form a foamed in place plastic hull which is bonded to the aluminum sheet; (d) removing the aluminum/foamed plastic composite from the mold; and (e) trimming the aluminum to the desired water ski shape.

Claim 7

The process of manufacturing water skis which consists essentially of: (a) positioning from 3-7 small diameter spring steel rods within the cavity of a mold; said rods having been cleaned; said rods extending lengthwise in said mold and being held in a pre-determined relationship with a series of transverse plastic jigs which support the rods at a pre-determined height above the floor of the mold cavity; (b) closing the mold with a rectangular sheet of aluminum, the lower surface of which has been surface activated with a dichromate/sulfuric acid bath and primed with an epoxy/phenolic primer; (c) injecting polyurethane foam-producing ingredients into said mold to thereby form a foamed in place plastic hull which is bonded to the aluminum sheet; (d) removing the aluminum/foamed plastic composite from the mold; and (e) trimming the aluminum to the desired water ski shape.

Claim 8

Processes of claim 5 in which at least one of said plastic jigs has tabs which extend laterally out over the edge of the mold cavity to permit the jig to be clamped in place between the aluminum sheet and the mold.