Segmented High-Angle Fiber Composite Bat Barrel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in developing a method to form barrel portions of ball bats using high angle fiber composite materials in a cost-effective, reliable, and high-quality manner that meets performance requirements like BBCOR certification without adding weight or wall thickness, while avoiding issues such as voids, low durability, and poor cosmetic appearance associated with bladder molding.
Innovation Solution
The solution involves using multiple plies of fiber composite material with high angle fibers, sectioned to not continuously extend around the full circumference, which are wrapped around a bladder and molded to form a tubular region with specific angles between 45 to 90 degrees, allowing for exceptional compaction and consistency without sacrificing stiffness or durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high angle fiber composite layers are used to provide hoop strength without adding thickness and weight, then barrel stiffness is improved, but manufacturing quality deteriorates due to voids, low durability and poor cosmetic appearance
Solution Approach 1:
The fiber composite layers are segmented into discrete sections along the longitudinal axis rather than being continuous. This segmentation allows the bladder to expand uniformly during molding without being constrained by continuous high-angle fibers, eliminating voids and improving manufacturing quality while maintaining barrel stiffness through strategic placement of fiber sections.
Solution Approach 2:
High angle fiber composite layers are applied only to specific regions where hoop strength is most needed, rather than uniformly throughout the entire barrel. This localized application provides the necessary stiffness while reducing manufacturing difficulties and improving overall quality in regions where high-angle fibers are not applied.
2Strength
If high angle fiber composite layers are used to achieve BBCOR certification without adding wall thickness, then barrel stiffness is improved, but production cost increases due to material costs and production time
Solution Approach 1:
Segmenting the fiber composite layers reduces material waste and allows for more efficient production. The segmented structure enables faster molding cycles compared to continuous high-angle fibers that require complex handling and positioning, thereby improving productivity while maintaining the necessary barrel stiffness for BBCOR certification.
Solution Approach 2:
Instead of applying high angle fiber composite layers throughout the entire barrel, the invention uses partial action by applying them only to specific sections where hoop strength is most critical. This reduces material costs and production time while still achieving the required barrel stiffness and BBCOR certification.
3Strength
If continuous high angle fibers are used around full circumference, then hoop strength is maximized, but material expansion is severely restricted during molding
Solution Approach 1:
The continuous fibers are divided into discrete sections that do not wrap completely around the circumference. This segmentation allows the bladder to expand freely during molding without being constrained by continuous high-angle fibers, improving material workability while maintaining hoop strength through the strategic arrangement of fiber sections.
Solution Approach 2:
The fiber orientation is changed from a continuous circumferential wrap to discrete sections distributed along the longitudinal axis. This dimensional change allows the material to expand radially during molding without being constrained by continuous circumferential fibers, while still providing the necessary hoop strength through the distributed fiber sections.
Data Source
AI summary
A ball bat extending about a longitudinal axis. The bat includes a barrel portion defining a primary tubular ball impact region. The barrel portion is formed of a fiber composite material. The fiber composite material includes at least first and second plies. The first and second plies include first and second pluralities first and second resins, respectively. Substantially all of the first and second pluralities of fibers of the first and second plies are generally aligned to define first and second angles with respect to the axis, respectively. The angles are each within the range of 45 to 90 degrees. Each of the plies is sized to extend about the full circumference of the barrel portion. The first and second pluralities of fibers are sectioned such that the fibers do not continuously extend about the full circumference of the impact region.