Thermoplastic Composite Fin Structure for Water Sports
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Solution Overview
Problem
Conventional water sports boards and fins are prone to breaking due to flexing forces during use, and their manufacturing processes are labor-intensive and environmentally harmful, lacking in strength and durability.
Innovation Solution
A thermoplastic composite structure is used, featuring an inner core bonded with outer fiber sheets, where the fiber sheets are impregnated with a thermoplastic material to enhance strength and durability without compromising the structure's weight ratio, and a method involving a pressure-forming device is employed to bond the fiber sheets to the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional construction techniques and materials (foam core with fiberglass laminate) are used, then the board and fin can be manufactured, but they lack sufficient strength and durability, leading to breaking during use
Solution Approach 1:
The patent employs a composite structure consisting of a foam core bonded to outer fiber sheets (such as fiberglass or carbon fiber) using a resin system. This multi-material composite construction combines the lightweight properties of foam with the high strength-to-weight ratio of fiber reinforcement, creating a structure that simultaneously achieves both strength and durability without excessive weight gain
Solution Approach 2:
The patent modifies the chemical and physical parameters of the bonding system by using a multi-component resin system (isocyanate, polyol, catalyst) that cures to form a strong adhesive bond. By controlling the resin composition and curing parameters, the patent achieves optimal bond strength between the fiber sheets and core, preventing delamination and structural failure during use
2Ease of manufacture
If conventional fiberglass laminate construction is used, then the board can be manufactured, but the manufacturing process is extremely labor intensive
Solution Approach 1:
The patent applies fiber sheets to the foam core before the core is fully shaped or before final assembly operations. By pre-positioning and pre-bonding the reinforcement layers during the molding process rather than applying them later as separate labor-intensive steps, the manufacturing process becomes more efficient and productive
Solution Approach 2:
The patent combines multiple manufacturing operations into a single integrated process. The fiber sheets are applied, bonded, and cured as part of the core molding operation itself, rather than as separate sequential steps. This merging of operations reduces labor requirements and increases manufacturing productivity
3Ease of manufacture
If conventional fiberglass laminate construction is used, then the board can be manufactured, but the process is harmful to the environment
Solution Approach 1:
The patent modifies the chemical composition parameters of the resin system by selecting components with lower environmental impact. The multi-component system (isocyanate, polyol, catalyst) is formulated to reduce volatile organic compound emissions and improve biodegradability compared to conventional single-component resins, thereby reducing environmental harm while maintaining manufacturability
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 solution provides enhanced strength, durability, and reduced weight, improving the performance and stability of water sports boards and fins, while also reducing environmental impact through more efficient manufacturing.
Implementation Method 1
The thermoplastic material is heated to cause the thermoplastic material to transition from the solid state to a molten state
Implementation Method 2
A pressure is applied within the pressure-forming device and the molten thermoplastic material flows through the first fiber sheet and the second fiber sheet and bonds the first fiber sheet and the second fiber sheet to the core
Implementation Method 3
A thermoplastic material impregnates the first fiber sheet and the second fiber sheet and bonds the first fiber sheet and the second fiber sheet to the core
Data Source
AI summary
A structure, such as a fin or water sports board, including a core having opposed first and second core outer surfaces. The structure further includes first and second fiber sheets, wherein the first fiber sheet extends along the first core outer surface and the second fiber sheet extends along the second core outer surface. A thermoplastic material impregnates the first fiber sheet and the second fiber sheet and bonds the first fiber sheet and the second fiber sheet to the core. The thermoplastic material defines an outer surface of the structure.