Ski

Claim 2

A ski produced by a process comprising the steps of: injecting constituents of a hardenable foam; expanding and hardening the hardenable foam, between at least a first element and a second element, said first element being formed by a process comprising the steps of: providing a solid polymer base film having good adhesion properties with the hardenable foam during the ultimate injection step; providing said first element in the form of a substrate having an internal surface formed by a reinforcement, said reinforcement comprising a member selected from the group consisting of: (1) a textile reinforcement sheet pre-impregnated with a member selected from the group consisting of: thermosetting resin and thermoplastic resin; and (2) a metallic reinforcement; positioning said solid film on said internal surface of said first element to cover said reinforcement; hot forming under pressure said solid film and said first element, after said step of positioning said solid film on said internal surface of said first element, to make said film adhere to said first element; and whereby during said injection step said solid film constitutes a screen between the hardenable foam and the reinforcement and, after injection and hardening said foam adheres perfectly to said film.

Claim 3

A ski according to claim 1, wherein: said textile reinforcement sheet is pre-impregnated with a moist thermosetting resin or partially cross-linked thermosetting resin selected from the group consisting of polyesters, epoxides and polyurethanes.

Claim 4

A ski according to claim 2, wherein: said textile reinforcement sheet has a base of woven or non-woven fibers made of glass, carbon or KEVLAR.

Claim 5

A ski according to claim 1, wherein: said textile reinforcement sheet is pre-impregnated with a thermoplastic resin selected from the group consisting of polyamides, polycarbonates and polyether imides.

Claim 6

A ski according to claim 1, wherein: said textile reinforcement sheet comprises a metallic component, said metallic component selected from the group consisting of steel, aluminum alloy and amorphous metal.

Claim 7

A ski according to claim 4, wherein: said textile reinforcement sheet comprises a base selected from the group consisting of woven and non-woven fibers, said fibers being selected from the group consisting of glass and carbon.

Claim 8

A ski according to claim 1, wherein: said process further comprises, before the step of hot forming under pressure, the steps of (1) providing a second solid polymer base film having good adhesion properties with the hardenable foam during the ultimate injection step; (2) providing said second element in the form of a substrate having an internal surface formed by a second reinforcement, said second reinforcement comprising a member selected from the group consisting of (A) a textile reinforcement sheet pre-impregnated with a member selected from the group consisting of thermosetting resin and thermoplastic resin, and (B) a metallic reinforcement; and (3) positioning said solid film on said internal surface of said second element to cover said second reinforcement.

Claim 9

A ski according to claim 1, wherein: said solid film is made of polyurethane.

Claim 10

A ski according to claim 1, wherein: said solid film is made of acrylonitrile butadiene styrene.

Claim 11

A ski according to claim 1, wherein: said solid film is made of a copolyamide.

Claim 12

A ski according to claim 1, wherein: said solid film is multi-layered.

Claim 13

A ski according to claim 1, wherein: said solid film has a thickness between approximately 0.1 and 1.0 millimeters.

Claim 14

A ski according to claim 1, wherein: said second element comprises a lower ski element, said first element comprises an upper ski element; said step of hot forming under pressure further comprises the step of placing said second element in said mold, whereby said first element and said second element form a closed enclosure whose internal surfaces are formed by internal surfaces of the first element and second element; and said step of injecting comprises injecting said hardenable foam into said closed enclosure.

Claim 15

A ski manufactured by a process comprising the steps of: providing a solid polymer film having good adhesion properties with a hardenable foam; providing a first element in the form of a substrate having an internal surface formed by a reinforcement, said reinforcement comprising a textile reinforcement sheet pre-impregnated with a thermosetting resin; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting said hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 16

A ski manufactured by a process comprising the steps of: providing a solid polymer film having good adhesion properties with a hardenable foam; providing a first element in the form of a substrate having an internal surface formed by a reinforcement, said reinforcement comprising a textile reinforcement sheet pre-impregnated with a thermosetting resin; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting said hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 17

A ski according to claim 14, wherein: said process further comprises the steps of: providing a second element, said second element comprising a lower ski element, said first element comprising an upper ski element; said step of placing said film and said first element in a mold further comprises the step of placing said second element in said mold, whereby said first element and said second element form a closed enclosure whose internal surfaces are formed by internal surfaces of said first element and said second element; and said step of injecting comprises injecting said hardenable foam into said closed enclosure.

Claim 18

A ski manufactured by a process comprising the steps of: providing a solid polymer film having good adhesion properties with a hardenable foam; providing a first element in the form of a substrate having an internal surface formed by a reinforcement, said reinforcement comprising a metallic reinforcement; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting said hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 19

A ski manufactured by a process comprising the steps of: providing a solid polymer film having good adhesion properties with a hardenable foam; providing a first element in the form of a substrate having an internal surface formed by a reinforcement, said reinforcement comprising a metallic reinforcement; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting said hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 20

A ski according to claim 16, wherein: said process further comprises the step of providing a second element, said second element comprising a lower ski element, said first ski element comprising an upper ski element; said step of placing said film and said first element in a mold further comprises the step of placing said second element in said mold, whereby said first element and said second element form a closed enclosure whose internal surfaces are formed by internal surfaces of said first element and said second element; and said step of injecting comprises injecting said hardenable foam into said closed enclosure.

Claim 21

A ski having a composite structure comprising: a first element; a second element; an injected core positioned between said first element and said second element for affixing together said first element and said second element; a solid polymer film having good adhesion properties positioned between said injected core and at least one of said first element and said second element; at least one reinforcement component located between (1) said one of said first element and said second element and (2) said polymer film, said at least one reinforcement component being in contact with said polymer film; wherein said ski is produced by a process comprising the steps of: providing said first element in the form of a substrate having an internal surface formed by said reinforcement, said reinforcement comprising a textile reinforcement sheet preimpregnated with a thermosetting resin; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting a hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 22

A ski having a composite structure comprising: a first element; a second element; an injected core positioned between said first element and said second element for affixing together said first element and said second element; a solid polymer film having good adhesion properties positioned between said injected core and at least one of said first element and said second element; at least one reinforcement component located between (1) said one of said first element and said second element and (2) said polymer film, said at least one reinforcement component being in contact with said polymer film; wherein said ski is produced by a process comprising the steps of: providing said first element in the form of a substrate having an internal surface formed by said reinforcement, said reinforcement comprising a textile reinforcement sheet preimpregnated with a thermosetting resin; positioning said solid polymer film on said internal surface of said first element to cover said reinforcement; placing said film and said first element in a mold; closing said mold and hot forming under pressure said film and said first element to make said film adhere to said first element; and injecting a hardenable foam into said mold, whereby said solid film screens the hardenable foam from the reinforcement and said foam, after injection and hardening, adheres securely to said solid film.

Claim 23

A ski according to claim 18, further comprising: a second polymer film positioned between and adhered to said core and said other of said first element and said second element, said second polymer film being in contact with said core.

Claim 24

A ski according to claim 18, wherein: said at least one reinforcement component is metallic; and said solid film can be formed by an electrostatic powdering process.

Claim 25

A ski according to claim 18, wherein: said polymer film comprises a solid polymer film.