Thermosetting Polymeric Sidewall for Ski Durability
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Solution Overview
Problem
Current snowboard and ski sidewall construction methods, such as ABS sidewall, face issues with durability, repairability, and production complexity, while cap and half-cap constructions compromise on performance and cost-effectiveness.
Innovation Solution
A method involving routing a trench on a core, pouring a thermosetting polymeric solution into the trench, curing it to form a hardened mold, and removing the outer region to create an integrally formed sidewall made of thermosetting polymeric material, which surrounds the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ABS sidewall construction is used, then impact resistance and edge grip are improved, but device complexity and susceptibility to edge damage increase
Solution Approach 1:
The patent merges the sidewall and core into a single integrated structure formed from one continuous piece of thermosetting polymeric material. The molding process creates an integrated sidewall-core assembly where the sidewall is not a separate component but an integral part of the core structure, eliminating joints and interfaces that would compromise durability or add complexity.
Solution Approach 2:
The patent employs thermosetting polymeric material as a composite substance that combines the benefits of ABS (impact resistance, edge grip) with improved structural integrity. The thermosetting polymer provides both the structural strength needed for impact resistance and the monolithic structure that eliminates the complexity of separate sidewall components.
2Ease of manufacture
If cap construction is used, then manufacturing cost is reduced, but durability and edge damage resistance deteriorate
Solution Approach 1:
The integrated sidewall-core structure eliminates the need for separate cap components that pinch over the edge. Instead, the thermosetting polymeric material is molded to create a unified structure where the sidewall and core are inseparable, providing durability comparable to ABS while maintaining manufacturing simplicity similar to cap construction.
Solution Approach 2:
The thermosetting polymeric material serves multiple functions simultaneously: it forms the core structure, creates the sidewall, provides edge protection, and ensures structural integrity all in one material system. This self-sufficient approach eliminates the need for multiple components and assembly steps while maintaining high durability.
3Force
If half-cap construction is used, then pressure transmission to edges is improved, but manufacturing time and difficulty increase
Solution Approach 1:
The patent combines the advantageous features of both cap and half-cap constructions into a single integrated molding process. The thermosetting polymeric material is molded to create sidewalls that provide effective pressure transmission to the edges while eliminating the need for separate assembly operations required by half-cap construction.
Solution Approach 2:
The sidewall structure is pre-formed as an integral part of the core during the initial molding process, rather than being added as a separate component afterward. This preliminary formation of the sidewall within the molded core structure ensures proper pressure transmission geometry is built-in from the start, eliminating subsequent assembly time.
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 approach results in a stronger, more durable snowboard or ski with reduced production complexity and enhanced performance, addressing the limitations of existing sidewall constructions by providing improved impact resistance and stability.
Implementation Method 1
The thermosetting polymeric solution in the trench is cured to form a hardened, thermosetting polymeric mold
Data Source
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AI summary
A method of fabricating a snowboard or ski is provided. In one embodiment, a trench (220) is routed at the face of a core (210). A thermosetting polymeric solution (430) is poured into the trench. The thermosetting polymeric solution is cured to form a thermosetting polymeric mold. A region (350) between the outer perimeter of the core and the outer perimeter of the trench is removed without stripping the thermosetting polymeric mold so as to form a sidewall (560) integrally surrounding the core.