Snowboard Upper Protective Layer with Cutout for Decorative Element
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Solution Overview
Problem
Current snow gliding boards face challenges in modifying their external shape for aesthetic reasons without incurring significant costs or altering their mechanical behavior, as the internal structure must often be redefined, and existing solutions like padding can lead to manufacturing defects such as deformations and cracks.
Innovation Solution
A snow gliding board design featuring an internal mechanical structuring beam with an upper protective layer that includes a cutout for a decorative element, allowing the shape of the top to be easily modified by replacing the decorative element without changing the internal beam's definition, and using an injection molded decorative element that can be overmolded on equipment for cost-effective and complex shape production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the shape of the top of the snowboard is modified for aesthetic reasons, then the external appearance is improved, but the internal structure must be redefined leading to increased costs
Solution Approach 1:
The snowboard is divided into distinct functional segments: the internal structure (core, reinforcements, base) and the upper protective layer with outer skin are separated as independent components. This segmentation allows the outer skin to be shaped independently for aesthetic purposes without requiring modifications to the internal structure, thereby maintaining manufacturing efficiency while achieving design flexibility.
Solution Approach 2:
The aesthetic shaping function is extracted from the internal structure and assigned to the outer skin layer. By removing the constraint that the internal structure must define the top shape, the design process can modify aesthetic features independently without triggering costly re-engineering of the mechanical core, reinforcements, or base.
2Stability of the object's composition
If padding is placed between the upper reinforcement and the skin to avoid shape modifications, then the internal structure remains stable, but appearance defects such as deformations and cracks occur during manufacturing
Solution Approach 1:
A dedicated intermediate layer is introduced between the upper reinforcement and the outer skin. This intermediate layer serves as a buffer that absorbs dimensional variations and prevents direct transmission of stresses that would cause deformations or cracks in the outer skin during manufacturing, thereby maintaining both structural stability and appearance quality.
Solution Approach 2:
The thickness and material properties of the intermediate layer are optimized to accommodate normal manufacturing tolerances. By adjusting these parameters, the system can absorb variations without transmitting them to the outer skin, preventing appearance defects while maintaining structural integrity.
3Shape
If the outer skin shape is modified to achieve aesthetic goals, then the visual appearance is improved, but the upper reinforcement shape must be重新defined increasing complexity
Solution Approach 1:
The snowboard structure is segmented into independent functional zones where the outer skin handles aesthetic shaping and the upper reinforcement handles structural support. This functional segmentation allows each component to be optimized for its specific purpose without compromising the other, reducing overall design complexity.
Solution Approach 2:
The aesthetic shaping requirement is extracted from the upper reinforcement and assigned exclusively to the outer skin. This extraction eliminates the need to redesign the reinforcement geometry when aesthetic changes are desired, maintaining structural simplicity while achieving design flexibility.
4Adaptability or versatility
If different internal structures are developed for different aesthetic requirements, then various aesthetic shapes can be achieved, but costs including referencing and storage increase
Solution Approach 1:
A universal internal structure design is created that can serve multiple aesthetic configurations. The core, reinforcements, and base are designed as standardized components that can be combined with different outer skin variations, allowing the same internal structure to support multiple aesthetic styles without requiring separate tooling or documentation for each variant.
Solution Approach 2:
The product is segmented into common internal components and variable external components. This segmentation allows the internal structure to be standardized and reused across different models, while only the outer skin needs to be varied to achieve different aesthetic goals, significantly reducing referencing and storage costs.
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
Enables easy modification of the board's external shape without affecting its mechanical behavior, reducing manufacturing complexity and costs, while allowing for harmonious integration of equipment and various decorative options, thus enhancing customization and reducing additional costs across different product ranges.
Implementation Method 1
using an injection molded decorative element that can be overmolded on equipment for cost-effective and complex shape production
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The board (1) has an upper protective layer (5) partially covering an internal beam (21), without significantly influencing the mechanical behavior defined by the internal beam (21), where the layer has a visible skin (7) pierced of a cutout. The layer (5) has a decorative element (6) that projects above the visible skin (7) while being fixed in the cutout perforated in the visible skin to close the cutout. The skin and the decorative element define together a visible top (4) of the gliding board.