Fiber-Reinforced Sporting Elements via Low-Temperature In-Situ Polymerization
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Solution Overview
Problem
Existing methods for forming fiber reinforced thermoplastic sporting implements require high processing temperatures and pressures, and the resulting structures are prone to delamination and impact resistance issues.
Innovation Solution
A method involving the use of in-situ polymerization of thermoplastic resin at low temperatures within a mold, combined with fibers, to form a fiber reinforced sporting element, which includes vacuum and gas purging to prevent contamination and enhance impregnation, resulting in improved impact and delamination resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high processing temperatures and pressures are used to form fiber reinforced thermoplastic sporting implements, then the fibers can be properly impregnated and the structure formed, but the processing costs increase and the resulting structures are prone to delamination and impact resistance issues
Solution Approach 1:
The patent changes the processing parameters by using low processing temperatures and atmospheric pressure instead of high temperatures and pressures. This is achieved through in-situ polymerization of thermoplastic resin that occurs at lower temperatures, allowing fiber impregnation and structure formation without the harmful effects of high heat and pressure that cause delamination and reduce impact resistance.
Solution Approach 2:
The patent replaces the mechanical compression system (high pressure and heat) with a chemical polymerization system. Instead of using mechanical pressure to impregnate fibers and form the structure, the invention uses in-situ polymerization of thermoplastic resin that naturally impregnates the fiber preform and cures at lower temperatures, eliminating the need for high-pressure compression equipment and the associated delamination problems.
2Ease of manufacture
If high processing temperatures and pressures are used to form fiber reinforced thermoplastic sporting implements, then the fibers can be properly impregnated and the structure formed, but the processing costs increase
Solution Approach 1:
The patent changes the processing parameters by using low processing temperatures and atmospheric pressure instead of high temperatures and pressures. This is achieved through in-situ polymerization of thermoplastic resin that occurs at lower temperatures, allowing fiber impregnation and structure formation without the harmful effects of high heat and pressure that cause delamination and reduce impact resistance.
Solution Approach 2:
The patent replaces the mechanical compression system (high pressure and heat) with a chemical polymerization system. Instead of using mechanical pressure to impregnate fibers and form the structure, the invention uses in-situ polymerization of thermoplastic resin that naturally impregnates the fiber preform and cures at lower temperatures, eliminating the need for high-pressure compression equipment and the associated delamination problems.
3Strength
If thermoset resins are used to form composite structures, then the structures can be formed, but they are not resistant to impact and may delaminate at the interface between fiber layers
Solution Approach 1:
The patent uses a composite material system consisting of fibers (carbon or glass) reinforced with thermoplastic resin that undergoes in-situ polymerization. This composite structure provides superior impact resistance and delamination resistance compared to traditional thermoset composites, as the thermoplastic matrix maintains flexibility and strong fiber-matrix bonding without the brittleness and interlaminar weakness of thermoset resins.
Solution Approach 2:
The patent changes the material parameter by switching from thermoset resin to thermoplastic resin that polymerizes in-situ. This material change fundamentally alters the mechanical properties, providing both impact resistance and delamination resistance simultaneously, as the thermoplastic matrix can absorb impact energy and maintains strong bonding at fiber layer interfaces.
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
The method allows for the production of sporting elements with complex geometries at reduced costs and improved mechanical properties, including impact and delamination resistance, while enabling recycling and repair of the implements.
Implementation Method 1
The inlet and outlet are closed, and the thermoplastic resin completely polymerizes so as to form a fiber reinforced sporting element in the chamber
Implementation Method 2
A second portion of the mold can be positioned in contact with the first portion such that the cavity cooperates with the second portion of the mold to define a chamber
Implementation Method 3
A method involving the use of in-situ polymerization of thermoplastic resin at low temperatures within a mold, combined with fibers, to form a fiber reinforced sporting element, which includes vacuum and gas purging to prevent contamination
Data Source
AI summary
A method of forming a sporting implement includes placing a plurality of fibers in a cavity formed in a first portion of a mold, the mold having an inlet and an outlet. A second portion of the mold is positioned in contact with the first portion such that the cavity cooperates with the second portion of the mold to define a chamber. A first material is mixed with a second material to form a thermoplastic resin. The thermoplastic resin is injected into the chamber through the inlet. The inlet and outlet are closed, and the thermoplastic resin completely polymerizes so as to form a fiber reinforced sporting element in the chamber, and the sporting element is removed from the chamber.