Molded Thermoplastic Force-Transfer Joint for Sports Equipment
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Solution Overview
Problem
Existing sports equipment manufacturing processes are inefficient and costly, and the use of thermoplastics is not efficient, and the connection of the component parts is not efficient, and the production of a piece of sports equipment is costly, and the production of a piece of sports equipment is costly.
Innovation Solution
The method for producing a piece of sports equipment comprises an elongate hollow semi-finished product and a planar element, wherein the elongate hollow semi-finished product is connected to the planar element at a first longitudinal end, and the planar element is molded onto the elongate semi-finished product using injection molding, creating a strong and cost-effective connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive connection is used to join component parts, then the connection can be established between different materials, but the production costs increase due to separate production steps
Solution Approach 1:
The patent merges the joining operation with the molding process by injecting thermoplastic material directly into the mold cavity where the first component is already positioned. This combines two separate operations (molding and joining) into one continuous process, eliminating the need for separate adhesive application steps and reducing production costs while maintaining connection strength
Solution Approach 2:
The patent replaces the chemical adhesive bonding system with a mechanical interlocking system. The thermoplastic material is injected under pressure to fill the mold cavity and create a mechanical connection with the first component, substituting the chemical adhesion mechanism with a mechanical force-based connection that achieves both cost efficiency and structural reliability
2Ease of manufacture
If thermoplastic material is used for component parts, then production is simplified for complex geometries, but the connection strength with other components is insufficient
Solution Approach 1:
The patent implements a nesting structure where the thermoplastic second component is injected directly into the mold cavity surrounding the first component. The thermoplastic material nests around and interlocks with the first component's features, creating a strong mechanical connection while maintaining the manufacturing simplicity of injection molding for complex geometries
Solution Approach 2:
The patent creates a composite structure by joining the thermoplastic second component with the first component made of different material. The injection molding process creates a composite assembly where the thermoplastic material forms an integral part of the overall structure, combining the manufacturing advantages of thermoplastics with the structural requirements of the first component
3Productivity
If multiple component parts are produced separately, then production can be more cost-efficient, but the connection process becomes complex and costly
Solution Approach 1:
The patent applies preliminary action by positioning the first component in the mold cavity before injecting the thermoplastic material. This pre-positioning step is integrated into the molding process itself, allowing the connection to be formed automatically during injection without requiring separate complex assembly operations, thereby maintaining productivity while reducing connection process complexity
Solution Approach 2:
The injection molding process performs self-service by automatically creating the connection between components during the molding operation itself. The thermoplastic material self-locks into place as it cools and solidifies, forming the connection without requiring external joining operations, thus simplifying the overall process while maintaining production efficiency
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 method provides a strong and cost-effective connection between the elongate and planar elements, enhancing the resistance to mechanical loads and reducing production costs.
Implementation Method 1
the planar element is molded onto the elongate semi-finished product using injection molding, creating a strong and cost-effective connection
Data Source
AI summary
A piece of sports equipment, in particular a portable piece of sports equipment, including an elongate hollow semi-finished product and a planar element for transmitting force. The elongate semi-finished product has an opening at its first longitudinal end and is connected to the planar element at said first longitudinal end. According to the invention, the planar element includes thermoplastic material and is moulded onto the elongate hollow semi-finished product.