Thermoplastic composite ski and method of manufacture

A method of manufacturing a runner having a base and a core covered with a shell, the shell including an outer layer, the method comprising the steps of:

• (a) providing a thermoplastic composite layer comprised of fibers disposed within a thermoplastic resin;
• (b) joining the thermoplastic composite layer to the outer layer;
• (c) heating the shell, including the outer layer and the thermoplastic composite layer;
• (d) molding the shell, including the outer layer and the thermoplastic composite layer, into a cap to cover the top and sides of the ski, wherein said step of molding the shell is accomplished by pressing the shell into a cap configuration with forming dies, the dies absorbing at least a portion of the heat from said step of heating the shell;
• (e) providing a torsion box disposed around the core;
• (f) providing a base having a bottom surface, a top surface, and lateral sides, the lateral sides having edges extending along at least a portion of the length of the base;
• (g) inserting the core and the torsion box between the base and the shell;
• and
• (h) joining the shell to the base and the core.

A method of manufacturing a runner having a base and a core covered with a shell, the shell including an outer layer, the method comprising the steps of:

• (a) providing a thermoplastic composite layer comprised of fibers disposed within a thermoplastic resin;
• (b) joining the thermoplastic composite layer to the outer layer;
• (c) heating the shell, including the outer layer and the thermoplastic composite layer wherein said step of molding the shell is accomplished by pressing the shell into a cap configuration with forming dies, the dies absorbing at least a portion of the heat from said step of heating the shell;
• (d) molding the shell after heating, including the outer layer and the thermoplastic composite layer, into a cap to cover the top and sides of the ski;
• (e) providing a base having a bottom surface, a top surface, and lateral sides, the lateral sides having edges extending along at least a portion of the length of the base;
• (f) inserting a core between the base and the shell;
• and
• (g) joining the base and the shell together around the core, wherein said steps of inserting a core and joining the base and the shell comprise the steps of positioning the base adjacent the shell, after being molded, into a jig, the thermoplastic composite layer of the shell facing the base, the shell and the base forming the outer shape of the ski and having a void between the base and the shell;
• and injecting foam between the base and the shell into the void, the foam joining the base to the shell.

A method of manufacturing a runner having a base and a core covered with a shell, the shell including an outer layer, the method comprising the steps of:

• (a) providing a thermoplastic composite layer comprised of fibers disposed within a thermoplastic resin;
• (b) joining the thermoplastic composite layer to the outer layer;
• (c) heating the shell, including the outer layer and the thermoplastic composite layer, wherein said step of molding the shell is accomplished by pressing the shell into a cap configuration with forming dies, the dies absorbing at least a portion of the heat from said step of heating the shell;
• (d) molding the shell after heating, including the outer layer and the thermoplastic composite layer, into a cap to cover the top and sides of the ski;
• (e) providing a base having a bottom surface, a top surface, and lateral sides, the lateral sides having edges extending along at least a portion of the length of the base;
• (f) inserting a core between the base and the shell;
• and
• (g) joining the base and the shell together around the core, wherein the thermoplastic composite includes fibers woven together and extending within the thermoplastic resin in a plurality of directions.

A method of manufacturing a runner having a base and a core covered with a shell, the shell including an outer layer, the method comprising the steps of:

• (a) providing a thermoplastic composite layer comprised of fibers disposed within a thermoplastic resin;
• (b) joining the thermoplastic composite layer to the outer layer to increase the thermal stability of the shell;
• (c) joining a structural layer to the core on at least the top of the core;
• and
• (d) joining the thermoplastic composite layer and outer layer to the structural layer and the core after the structural layer is disposed on the core and after the thermoplastic composite layer and outer layer are joined together, wherein the theromoplastic composite and outer layers cover the top and sides of the runner.