Hybrid Baseball Bat with Carbon Fiber Core and Vibration Dampening
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Solution Overview
Problem
Existing hybrid baseball bats face challenges in achieving a consistent large 'Sweet Spot' while maintaining strength and weight control, due to issues with internal core design, material distribution, and certification compliance.
Innovation Solution
The development of a novel hybrid fusion wood/composite bat design featuring a continuous internal support, maximized handle to barrel bonding surface, and vibration dampening characteristics, achieved through advanced manufacturing methods such as centrifugal force and bladder molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pre-formed cylindrical carbon filter sleeve is used in hybrid bat construction, then manufacturing is simplified, but strength is reduced due to concentrated stress points and delamination risk
Solution Approach 1:
The internal support is divided into multiple discrete carbon fiber rods arranged in a specific pattern (e.g., triangular, rectangular) rather than a single cylindrical sleeve. This segmentation distributes stress across multiple points and prevents concentrated stress points, thereby improving structural strength while maintaining manufacturability through modular assembly
Solution Approach 2:
Instead of using a single large cylindrical sleeve that provides excessive material in non-critical areas, the invention uses multiple smaller carbon fiber rods strategically positioned to provide support only where needed. This partial action approach reduces unnecessary material while maintaining strength at critical stress points
2Ease of manufacture
If a uniform diameter cylindrical hole is drilled for the carbon sleeve, then manufacturing is easier, but the Sweet Spot area is reduced due to non-profiled barrel wall thickness
Solution Approach 1:
The hole profile varies along the length of the barrel, with larger diameter sections in areas requiring more support and smaller diameter sections where the Sweet Spot needs to be maximized. This local variation in hole diameter allows optimization of both structural support and hitting surface area, creating thicker walls in non-Sweet Spot areas while maintaining adequate support
3Strength
If additional support is added to the core to ensure maximum strength, then strength is improved, but weight increases and the internal chamber area is minimized
Solution Approach 1:
The invention uses high-strength carbon fiber rods that provide maximum structural support with minimal weight. These composite materials have superior strength-to-weight ratios compared to traditional solid wood or metal supports, allowing the bat to achieve enhanced core strength while maintaining lightweight construction and maximizing the internal chamber area for sound resonance
4Strength
If a two-piece construction with laminated wood pieces and carbon inserts is used, then strength is improved, but weight control becomes more difficult due to extraneous materials
Solution Approach 1:
The invention removes extraneous materials such as metal connectors, excessive adhesives, and unnecessary intermediate layers from the construction process. By using a one-piece wood billet with internally embedded carbon fiber rods, the design eliminates redundant components that add weight without contributing to structural strength, thereby achieving precise weight control while maintaining strength
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 design enhances bat strength, weight control, and performance, meeting BBCOR and USABat certification standards while providing a rich sound similar to traditional wood bats at an affordable price.
Implementation Method 1
advanced manufacturing methods such as centrifugal force and bladder molding
Implementation Method 2
vibration dampening characteristics
Data Source
AI summary
Disclosure herein are various forms of hybrid baseball bats comprising a wood shell having a radial wall and an outer radial surface profile defining a baseball bat. The wood shell having a central core with a central surface thereon extending from a distal end of the bat to the proximal end of the bat. The central surface being profiled with a taper that in some embodiments extends entirely through to the proximal end. A fibrous construct is housed in the central core and infiltrated with an epoxy resin for strength, shape adherence and bonding to the central surface. Disclosed are various manufacturing techniques for manufacturing hybrid bats including resin epoxy infiltration from removable or permanent core forced volume displacement means and/or high-pressure two-part epoxy injection means.