Composite Ice Skate Frame Manufacturing via Tapered Molding
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Solution Overview
Problem
Traditional ice skate support frames made from steel, aluminum, and titanium are difficult and expensive to manufacture while maintaining mechanical strength, and they are heavy, which hinders the development of lightweight ice skates for figure skating.
Innovation Solution
A composite material, such as carbon fibre reinforced epoxy, is used to form a unitary support frame with a tapered elongate body and platform, reducing weight by up to 50% and enhancing structural strength, while allowing for easy blade runner attachment and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel, aluminum, or titanium materials are used for the support frame, then the frame maintains sufficient mechanical strength, but the weight of the ice skate increases and manufacturing becomes difficult and expensive
Solution Approach 1:
The patent applies composite materials (specifically carbon fibre reinforced plastic) to manufacture the support frame. This composite material provides equivalent stiffness and strength to traditional steel structures while significantly reducing the weight. The composite construction allows the frame to achieve the required mechanical properties without the heavy metal alternatives, directly resolving the contradiction between strength and weight.
2Strength
If traditional steel components are used and welded together, then the frame achieves required structural strength, but the number of manufacturing steps increases and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate steel components into a single integrated composite structure. The support frame is manufactured as one piece using composite material molding processes, eliminating the need for separate welding operations and multiple component assembly steps. This integration maintains structural strength while significantly reducing manufacturing complexity and the number of production steps.
3Weight of moving object
If the frame body width is reduced to decrease material usage and weight, then the weight of the support frame decreases, but the junction region may not have sufficient strength to handle stresses
Solution Approach 1:
The patent applies local quality by varying the cross-sectional width of the frame body along its length. The frame body has a maximum width at the junction region where it connects to the platform, providing enhanced strength and stress distribution where needed. The width tapers to a minimum at distal regions where less material is required, reducing overall weight. This localized variation in dimensions optimizes both strength and weight by placing material only where structurally necessary.
Data Source
AI summary
A method of manufacturing a frame for an ice skate boot, the method including:a) moulding a substantially T-shaped body having a first plate and a second plate extending substantially perpendicularly from the first plate;b) milling the first plate to form a platform intended to be uppermost on the frame, in use, for supporting an ice skate boot, the platform having a first support for supporting a forward portion of an ice skate boot and a second support, separate from the first support, for supporting a rearward portion of an ice skate boot;c) milling the second plate to form an elongate body defining an elongate length of the frame, the elongate body having first and second arms extending from the elongate body, where distal ends of the first and second arms are connected to the first and second supports, respectively; andd) forming a mounting arrangement on the elongate body for mounting a blade runner to the elongate body,wherein step a) includes the step of integrally forming the first and second plates from a composite material.