Hot Molding Composite Paddle with Elastic Core
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Solution Overview
Problem
The existing methods for producing composite objects like padel paddles are laborious, require rigorous gluing and finishing, and face challenges in achieving balance and accuracy, leading to high labor costs and management complexities due to inaccurate centering and structural issues.
Innovation Solution
A hot molding method involving a mold with flexible sheets impregnated with a curing agent, a yielding and elastic core, and an interposed flexible layer to create a monolithic structure without gluing, allowing for efficient production with a single molding cycle and aesthetic surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If gluing methods are used to assemble composite objects, then structural integrity can be achieved, but production time and labor cost increase significantly
Solution Approach 1:
The patent merges multiple separate components (outer shell and inner core) into a single monolithic structure through hot molding. The flexible sheets impregnated with curing agent are molded around the core material, creating an integrated composite object without requiring separate gluing operations. This combining of components during the molding process eliminates the need for subsequent assembly operations, thereby reducing production time while maintaining structural integrity.
Solution Approach 2:
The patent utilizes parameter changes in the curing agent during the molding process. The curing agent transitions from a liquid or semi-liquid state to a solidified state through chemical reaction triggered by heat and pressure during molding. This parameter change allows the flexible sheets to bond with the core material and each other, creating structural integrity without requiring mechanical gluing operations after the fact.
2Stability of the object's composition
If traditional assembly methods with gluing are used, then composite structures can be formed, but manufacturing complexity and labor requirements increase
Solution Approach 1:
The patent segments the manufacturing process into a single integrated hot molding operation rather than multiple separate steps (molding outer shell, adding core, gluing, reinforcing). By organizing the process segments into one cohesive operation where all components are prepared and assembled simultaneously in the mold, the patent reduces manufacturing complexity while still achieving stable composite structure formation.
Solution Approach 2:
The flexible sheets impregnated with curing agent serve as an intermediary between the outer shell and inner core components. These sheets facilitate the bonding and integration of different materials during the molding process, enabling composite structure formation without requiring complex assembly fixtures, adhesives, or multiple processing steps. The curing agent-filled sheets act as a mediating substance that simplifies the overall manufacturing process.
3Strength
If rigid structures are added to support glue and reinforce assemblies, then structural strength improves, but weight and production complexity increase
Solution Approach 1:
The patent employs composite materials in the form of flexible sheets impregnated with curing agent. These composite sheets provide both structural support and reinforcement functions simultaneously, eliminating the need for separate rigid support structures. The composite nature of the sheets allows them to flex during molding and then set into a rigid state, providing the necessary structural strength while minimizing weight compared to traditional rigid reinforcement components.
4Manufacturing precision
If multiple production steps are used for gluing and finishing, then quality control is improved, but production efficiency decreases
Solution Approach 1:
The patent applies preliminary action by preparing all components (outer shell, inner core, and flexible sheets with curing agent) before the actual molding operation. The flexible sheets are pre-impregnated with curing agent, and all components are positioned in the mold before closing. This preliminary preparation ensures that when the mold closes and heating begins, everything is already in its final position, allowing for high-quality control in a single operation rather than requiring multiple sequential steps for adjustment and refinement.
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 method enables fast, economical, and balanced production with reduced weight, eliminating the need for gluing and ensuring structural integrity and aesthetic quality by compensating for geometric interference through elastic compaction and yielding during the molding process.
Implementation Method 1
heating the mold to solidify said sheets and layers
Implementation Method 2
a core made of yielding, elastic material is essential, because so the core material is already able to generate a mechanical thrust when it is cold, before the baking in the mold
Implementation Method 3
The interposition of said flexible layer between the core and a said sheet promotes the sheet compaction
Data Source
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AI summary
A method is described for producing by hot molding a composite object formed of an outer shell and a core made of yielding, elastic material. To improve compactness of the object and its aesthetics, there are the steps of - covering opposite sides of a mold cavity respectively with a first and second flexible sheets of material impregnated with curing agent, - putting a core made of yielding, elastic material in the mold so that it is in contact with the first and second sheets; - arranging a flexible layer of material impregnated with curing agent between at least one of said sheets and the core, so that the thickness of the flexible layer will interpose between the core and the at least one sheet forming a step between the core and the at least one sheet when the mold is closed, - closing the mold so that said core externally is wrapped and covered (e.g. completely) by the two sheets, - heating the mold to solidify said sheets and layer, said step being compensated in the molded object by a corresponding depression in the core volume.