Segmented Fiber Composite Ball Bat Barrel
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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 prevent continuous extension around the circumference, which are molded and cured with a bladder and mandrel to achieve a tubular region with enhanced compaction and consistency, incorporating release materials like scrims to facilitate resin flow and prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high angle fiber composite layers are used to increase barrel stiffness, then hoop strength is improved, but manufacturing quality deteriorates due to voids and poor appearance
Solution Approach 1:
The fiber composite layers are segmented into discrete sections along the longitudinal axis rather than forming continuous wraps. 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 the hoop strength benefits of high-angle fiber orientation.
2Strength
If high angle fiber composite layers are used to increase barrel stiffness, then hoop strength is improved, but material cost increases due to production waste
Solution Approach 1:
By segmenting the fiber composite layers into discrete sections, the molding process achieves better material utilization. The bladder can expand uniformly without creating voids or defects that would require material removal or rejection of the entire component, significantly reducing production waste and material cost while maintaining the hoop strength advantages of high-angle fiber orientation.
3Strength
If high angle fiber composite layers are used to increase barrel stiffness, then hoop strength is improved, but manufacturing time increases
Solution Approach 1:
The segmented fiber composite layer configuration allows for more efficient molding cycles. The bladder can expand uniformly without being restricted by continuous high-angle fibers, eliminating the need for extended curing times or multiple processing steps to correct voids and defects. This reduces overall manufacturing time while maintaining the hoop strength benefits of high-angle fiber orientation.
Data Source
AI summary
A ball bat extending about a longitudinal axis. The bat includes a barrel portion defining a primary tubular region. The tubular region is formed of a fiber composite material having wall thickness of at least 0.100 inch. The fiber composite material includes at least first and second plies. The first and second plies include first and second pluralities of fibers and first and second resins, respectively. Substantially all of the first and second pluralities of fibers of the first and second plies are aligned to define first and second angles of 45 to 90 degrees with respect to the axis, respectively. The first and second plies have opposite polarities and are positioned with the second ply applied over the first ply. The first and second pluralities of fibers are sectioned such that the fibers do not continuously extend about the full circumference of the tubular region.