Integral Balance Trainer Dome Base Rotational Molding
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Solution Overview
Problem
Conventional balance trainers have fragile joint portions due to separate manufacturing of the dome and base, leading to easy breakage and reduced strength.
Innovation Solution
A balance trainer with a dome and base formed integrally through a mold assembly and rotational molding process, where the dome and base are melt-connected during manufacturing, creating a single, robust piece with varying hardness levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dome and base are manufactured separately and fixed together via connecting means, then the manufacturing process is simpler for each component, but the joint portions become fragile and easy to break
Solution Approach 1:
The patent merges the dome and base into a single integrated structure formed by one piece through rotational molding. The dome portion and base portion are connected via a connecting portion that is formed integrally with both parts, eliminating separate connecting means and fragile joints. This merging resolves the contradiction by achieving both manufacturing simplicity (single-mold process) and structural strength (integral connection without weak joints).
2Adaptability or versatility
If the dome and base are made as separate components, then each component can be optimized independently, but the overall structure becomes more complex and heavier
Solution Approach 1:
The patent combines multiple components (dome, base, and connecting means) into a single integrated structure formed by one piece. This merging reduces structural complexity by eliminating the need for separate components and assembly operations, while maintaining the functional adaptability of the balance trainer through the integral design that allows selective mounting of resistance bands.
3Ease of operation
If separate connecting means are used to join the dome and base, then assembly is straightforward, but additional components increase manufacturing cost and weight
Solution Approach 1:
The patent integrates the connecting portion directly into the molded structure, forming it simultaneously with the dome and base in a single rotational molding process. This eliminates the need for separate connecting components and assembly steps, reducing both the number of parts and manufacturing complexity while maintaining ease of assembly through the integral design.
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
The integral design enhances the strength of the balance trainer, allowing it to support over 2000 kg and simplifies manufacturing, reducing weight and cost while enabling the use of resistance bands without additional fixing components.
Implementation Method 1
The connecting edge is melt-connected to the outer edge of the dome
Implementation Method 2
rotational molding, which includes the following acts in sequence: putting the mold assembly into a rotary furnace and rolling and heating the mold assembly
Data Source
AI summary
A balance trainer having a dome and a base formed integrally is provided. Also, a mold assembly for manufacturing the balance trainer that has a dome mold, a girdle, and a cover is provided. The girdle is sleeved on the dome mold and the cover is fixed on the girdle and thereby a cavity is formed in the mold assembly. Furthermore, a manufacturing process of the balance trainer is also provided. The process has the following steps: preparing ingredients of the dome and the base; feeding the ingredients of the dome into the dome mold; fixing a membrane on the dome mold via the girdle; feeding the ingredients of the base; sealing the ingredients via the cover; and then rotational molding. With the process and the mold, the rotational molding step can mold two materials at the same time, so the product can have two parts with different hardness.