Laminate Blank Customization via Rubber Node Bonding
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Solution Overview
Problem
Existing laminate blanks used for manufacturing components like grips lack customization for user preferences in terms of aesthetics, comfort, and stiffness, and often require additional bonding layers or adhesives for layer integration during the manufacturing process.
Innovation Solution
A laminate blank composed of interlaid ergonomic-comfort rubber layers and rigidifying-support prepreg layers, which can be customized in thickness, color, and pattern, and bonded without additional adhesives through the formation of nodes by extending rubber portions into voids between prepreg fibers during a press cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional bonding layers or adhesives are used for layer integration, then bonding strength is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The rubber layers themselves serve as the bonding mechanism by forming nodes that extend into prepreg fiber voids. The material inherently provides both structural function and bonding function, eliminating the need for separate bonding layers or adhesives. This self-service approach reduces manufacturing complexity while maintaining bonding strength.
Solution Approach 2:
The bonding function is merged with the structural rubber layers. Instead of having separate bonding layers and structural layers, the rubber layers perform both functions simultaneously through node formation, simplifying the overall laminate structure and manufacturing process.
2Adaptability or versatility
If laminate blanks are customized for aesthetics, comfort, and stiffness, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The laminate is divided into discrete rubber layers and prepreg layers that can be independently selected and stacked. This segmentation allows customization of each layer's thickness, material properties, and arrangement to achieve desired aesthetics, comfort, and stiffness characteristics without complicating the overall manufacturing process.
Solution Approach 2:
Different rubber layers can have different material properties, thicknesses, and positions within the laminate stack. This local quality variation enables customization of specific regions to meet aesthetic, comfort, and stiffness requirements while maintaining a consistent manufacturing approach throughout.
3Strength
If rubber layers are extended into prepreg fiber voids to form nodes, then bonding is improved, but manufacturing precision requirements increase
Solution Approach 1:
The node formation process is self-regulating during the press cycle. The rubber material naturally flows into and fills the voids between prepreg fibers under heat and pressure, then solidifies to form strong bonds. This self-service mechanism reduces the need for precise manual positioning or complex control systems, thereby lowering manufacturing precision requirements while maintaining bonding integrity.
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 laminate blank provides customizable grips with enhanced bonding and structural integrity, allowing for varied stiffness and ergonomic design without the need for additional bonding layers, while maintaining durability and comfort.
Implementation Method 1
bonded without additional adhesives through the formation of nodes by extending rubber portions into voids between prepreg fibers during a press cycle
Data Source
AI summary
A laminate blank includes at least one rigidifying layer and at least one comfort layer. The rigidifying layer includes a reinforcement preform and a resin. The layers are pressed to form the laminate blank.