Segmented Gun Stock Core Manufacturing for Density Control
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Solution Overview
Problem
The existing methods for manufacturing gun stock cores using polyurethane foam lack control over density placement along the longitudinal length, leading to ergonomic challenges due to inconsistent balance and weight distribution.
Innovation Solution
A method involving a mold with multiple sections allows for varying properties such as strength, density, and weight along the gun stock core's length, using urethane and other materials, which can be customized by mixing and pouring different materials into each section while bonding them for a stronger, balanced core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polyurethane foam material is poured into an outer shell to manufacture a gun stock core, then the manufacturing process is simple and fast, but the density placement cannot be accurately controlled along the longitudinal length
Solution Approach 1:
The gun stock core is divided into multiple sections along its longitudinal length, with each section having a different density. The mold is segmented into corresponding sections that can be filled with different amounts of polyurethane foam material or different types of foam material, allowing precise control over density placement in each section while maintaining the simplicity of the pouring process.
Solution Approach 2:
Different sections of the gun stock core are assigned different density characteristics based on their specific functional requirements. The butt section may have higher density for balance, while the forearm section may have lower density for weight reduction. This local quality approach allows the manufacturing process to achieve both speed and precision by tailoring density to specific locations.
2Ease of manufacture
If constant density polyurethane foam is used throughout the gun stock core, then the manufacturing process is simple, but the ergonomics are challenging due to poor balance
Solution Approach 1:
The gun stock core is segmented into multiple density zones along its longitudinal length, with each zone optimized for specific ergonomic requirements. The segmentation allows the manufacturer to maintain a simple pouring process while creating variable density distribution that improves balance and ergonomics.
Solution Approach 2:
The density parameter of the polyurethane foam material is varied along the longitudinal length of the gun stock core. By changing the density parameter in different sections (e.g., higher density in the butt section for balance, lower density in the forearm section for weight reduction), the invention achieves improved ergonomics while maintaining manufacturing simplicity through the same basic pouring process.
3Ease of operation
If the gun stock core has variable strength and density in different sections, then the ergonomics and balance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The mold is segmented into multiple sections corresponding to different density zones in the final product. Each mold section can be filled independently with appropriate foam material or adjusted filling parameters, allowing variable density construction without requiring complex multi-step manufacturing processes or tooling changes.
Solution Approach 2:
A single mold design serves multiple functions by incorporating segmentation that allows different density configurations to be achieved through varying filling parameters or material selection, rather than requiring different molds for different density requirements. This universal approach reduces manufacturing complexity while enabling ergonomic optimization.
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 enables faster production with consistent customization of properties, ensuring balanced weight distribution and improved ergonomics by allowing for specific strength and density variations in different sections of the gun stock core.
Implementation Method 1
The poured or placed polyurethane foam material then cures or hardens in the outer shell
Implementation Method 2
pouring polyurethane foam material into an outer shell
Data Source
AI summary
Manufacturing a gun stock core using a curable material in a mold that includes a plurality of mold sections wherein each mold section defines a portion of a mold cavity of the mold. A first amount of curable material is poured into the mold cavity portion of the first mold section and cured to form a first portion of the gun stock core. A second amount of curable material is poured into the mold cavity portion of the second mold section, wherein the second mold cavity portion is fluidly connected to the first mold cavity portion to enable a bond to form between the poured material in the first and second mold cavity portions and cured for a predetermined time period to form a second portion of the gun stock core. The finished gun stock core has a variable specific gravity, weight, or strength along a longitudinal length and height.