Composite Bat Barrel Porous Separation Layer
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Solution Overview
Problem
Existing composite bat manufacturing techniques face challenges in achieving uniform resin distribution and structural uniformity, particularly when producing multi-wall bats, which require expensive tooling and can result in incomplete resin distribution and increased production complexity.
Innovation Solution
Incorporating a porous separation layer coated with a release agent between structural composite layers in the RTM process, allowing for relative motion and frictional dissipation of energy, enabling the use of traditional single-wall tooling to produce multi-wall bats with uniform resin distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If polymer sheets are used to separate composite layers, then layer separation is achieved, but resin distribution becomes incomplete and uneven
Solution Approach 1:
The patent employs a porous polymer sheet as the separation layer between composite layers. The porous structure allows resin to penetrate through the sheet during the RTM process, enabling uniform resin distribution on both sides while maintaining the separation function. This resolves the contradiction by combining layer separation capability with resin distribution uniformity through the porous material's unique properties.
2Shape
If multiple concentric walls or layers are molded separately and assembled, then multi-wall bat structure is achieved, but tooling costs and production complexity increase
Solution Approach 1:
The patent segments the bat barrel wall into multiple distinct layers separated by porous polymer sheets, allowing each layer to be molded separately using standard single-wall tooling. The segmentation is achieved through the physical separation provided by the porous sheets, which enable independent molding of each wall section while maintaining the multi-wall structure. This resolves the contradiction by enabling multi-wall production without requiring complex multi-wall tooling.
Solution Approach 2:
The patent makes standard single-wall RTM tooling universal by introducing porous separation layers that allow the same tooling to produce multi-wall bats. The porous sheets enable the tooling to serve dual purposes: separating layers during molding while also allowing resin flow. This universality eliminates the need for expensive dedicated multi-wall tooling, resolving the contradiction between achieving multi-wall structure and reducing production complexity.
3Stability of the object's composition
If polymer sheets are used to separate composite layers, then layer separation is achieved, but resin flows along one side to a greater extent than the other
Solution Approach 1:
The porous polymer sheet provides uniform resin distribution by allowing resin to penetrate through the porous structure from both sides. The porous material's capillary action and open cell structure ensure that resin flows evenly to both faces of the separation layer, eliminating the imbalance where resin would otherwise flow along one side to a greater extent. This resolves the contradiction between maintaining layer separation and achieving even resin distribution.
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
This approach allows for the efficient production of multi-wall bats with improved feel and impact absorption, reducing tooling costs and production complexity while maintaining structural integrity.
Implementation Method 1
The separation layer is at least partially coated with a release agent that prevents, or substantially prevents, adherence of the separation layer to at least one of the first or second structural regions
Implementation Method 2
a porous separation layer coated with a release agent between structural composite layers
Implementation Method 3
allowing for relative motion and frictional dissipation of energy
Data Source
AI summary
A composite ball bat or other sporting-good implement includes a handle and a barrel attached to or integral with the handle. The barrel has a wall including a first structural region and a second structural region between which a porous separation layer is positioned. The separation layer is at least partially coated with a release agent that prevents, or substantially prevents, adherence of the separation layer to at least one of the first or second structural regions.