3D Composite Molding for Homogeneous Fiber Distribution

Solution Overview

Problem

Existing rotation molding methods fail to achieve homogeneous blending and specific distribution of components in three-dimensional composite articles due to differing sizes, shapes, and densities, leading to separation and agglomeration of materials.

Innovation Solution

A method involving a rotatable casting mold where two materials, at least one being a polymer, are filled and processed with adapted parameters such as rotation speed, heating/cooling times, and axis angles to ensure homogeneous distribution of the second material within the composite object.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rotation molding is used to manufacture three-dimensional composite objects, then large hollow parts with complex geometries can be produced, but homogeneous blending and specific distribution of components cannot be achieved due to differing sizes, shapes, and densities of materials

Engineering Contradiction:

Improvehomogeneous distribution of materialsVSAvoidseparation and agglomeration of materials

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-mixing the thermoplastic foundation powder with the second material (such as fibers or granules) before placing the mixture into the mold. This pre-mixing ensures that materials with differing sizes, shapes, and densities are already homogeneously distributed before the molding process begins, preventing separation and agglomeration during rotation molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by creating a homogeneous mixture of thermoplastic foundation powder and a second material (fibers, granules, or other additives) before molding. This composite approach allows the final product to achieve both the geometric complexity of rotation molding and the homogeneous distribution of multiple materials with different properties.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If multiple materials with different properties are mixed in the mold, then composite functionality can be achieved, but material separation and agglomeration occur due to differing densities and shapes

Engineering Contradiction:

Improvecomposite material functionalityVSAvoidmaterial distribution uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-mixing the thermoplastic foundation powder with the second material (such as fibers or granules) before placing the mixture into the mold. This pre-mixing ensures that materials with differing sizes, shapes, and densities are already homogeneously distributed before the molding process begins, preventing separation and agglomeration during rotation molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by creating a homogeneous mixture of thermoplastic foundation powder and a second material (fibers, granules, or other additives) before molding. This composite approach allows the final product to achieve both the geometric complexity of rotation molding and the homogeneous distribution of multiple materials with different properties.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Achieves a homogeneous and defined blending of materials, resulting in a stable and functional three-dimensional composite object with enhanced properties.

Implementation Method 1

heated beyond the melt temperature of the thermoplastic material being processed

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

thermoplastic foundation powder starts to melt subsequently in the mold

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The melt solidifies by cooling of the still rotating die

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentEP4650139A1Method for manufacturing a three-dimensional composite object

Publication Date: 2025.11.19 ADIDAS AG

Figure 1A~1D
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AI summary

The present invention concerns a method for manufacturing a three-dimensional composite object (21a, 21b, 21c), especially a sports article, comprising the steps: (a.) providing a rotatable casting mold (11); (b.) filling of a first material (14) into the casting mold (11); (c.) filling of a second material (15) into the casting mold (11), wherein the second material comprises fibers, wherein the fibers are coated with the first material and, wherein at least one of the materials (14, 15) is a polymer material; (d.) moving of the casting mold (11); and (e.) adapting of at least one process parameter during the performance of one or more of the preceding steps, so that a homogeneous distribution of the second material (15) in the manufactured composite object (21a, 21b, 21c) is achieved.