Modular Ski Press Mold Assembly for Fast Model Changeovers
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Solution Overview
Problem
Current ski manufacturing processes are inefficient for small batch sizes due to long setup times and high mold costs, and they suffer from thermal stress and material defects, especially when producing multiple ski models.
Innovation Solution
A modular mold assembly system for ski presses that allows for easy insertion and removal of ski molds, enabling pre- and post-tempering outside the press, and separate heating and cooling cycles, reducing setup times and mold costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid molds are used for ski manufacturing, then manufacturing precision and bonding quality are improved, but setup time and mold costs increase when changing models
Solution Approach 1:
The mold system is divided into separate components: a removable ski mold that can be quickly exchanged and a permanent press structure. This segmentation allows the expensive, precision-critical mold to be separated from the press, enabling quick changes between different ski models without affecting the press setup.
Solution Approach 2:
The ski mold is prepared and pre-assembled with the ski components outside the press before insertion. This preliminary preparation allows for quick model changes by simply removing and replacing the pre-assembled mold unit, significantly reducing setup time while maintaining manufacturing precision.
2Strength
If high pressure is applied during pressing, then bonding strength is improved, but thermal stress and material defects increase
Solution Approach 1:
The press allows for controlled adjustment of pressure parameters during the bonding process. By gradually increasing pressure and maintaining optimal temperature ranges, the system achieves strong bonding while minimizing thermal stress and material defects through precise parameter control.
Solution Approach 2:
The heating elements remain in contact with the ski components throughout the entire pressing process, providing continuous and uniform heating. This continuous thermal action ensures even temperature distribution, preventing thermal shocks and material defects while maintaining bonding quality.
3Temperature
If heating elements are integrated into the press structure, then temperature control is improved, but device complexity increases
Solution Approach 1:
The heating elements are segmented and positioned as separate components within the press structure, specifically in the upper and lower pressing surfaces. This segmentation allows for independent control and maintenance of heating elements while maintaining effective temperature control during the bonding process.
Solution Approach 2:
The press structure is designed to accommodate multiple functions: mechanical pressing, thermal heating, and temperature control. By integrating heating elements into the pressing surfaces, the same structural components serve multiple purposes, reducing overall device complexity while improving temperature control capability.
4Productivity
If multiple mold sets are used for different ski models, then productivity is improved, but mold costs increase
Solution Approach 1:
The mold system is segmented into removable ski molds that can be quickly exchanged between different models. This allows a single press to handle multiple ski models by simply changing the mold, eliminating the need for multiple expensive mold sets and reducing overall mold costs while maintaining high productivity.
Solution Approach 2:
The mold system transitions from static, permanent molds to dynamic, interchangeable molds. The removable ski mold design enables flexible reconfiguration for different ski models, allowing the press to adapt to varying production requirements without requiring multiple dedicated mold sets, thus reducing mold costs while maintaining productivity.
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
Enables efficient, serial production of skis in batch sizes of one with minimal setup times and reduced mold costs, while minimizing thermal stress and material defects.
Implementation Method 1
The bonding process is typically carried out using a combined method of pressure and temperature
Implementation Method 2
Pressure is applied to this unit, consisting of the mold or base/lid and the ski materials sandwiched between them
Implementation Method 3
In the vacuum process, the assembled ski is hermetically sealed with a bag or film, and a vacuum pump is used to create a vacuum
Data Source
Figure 1~2
AI summary
The invention relates to a mold set to be inserted in a ski press (2), comprising a lower structure having a base plate (4), a lower contour (5) and a lower heating element (7), and an upper structure having a cover plate (16), an upper contour (15) and an upper heating element, so that a ski mold can be inserted between the lower structure and the upper structure.