Method for Producing a Three-Dimensional Composite Article

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes an improved method for manufacturing three-dimensional composite objects, especially sports articles like balls or protective gear. The method uses a rotatable casting mold that is filled with two different materials—at least one being a polymer—and adapts specific process parameters (such as the rotation speed or temperature) during production. These adjustments ensure a homogeneous distribution of materials, allowing the final product to have enhanced mechanical properties, such as strength and durability.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of sports balls (e.g., soccer balls) with reinforced internal structure.
• Manufacture of shin guards or protective gear with enhanced resistance and lightweight construction.
• Fabrication of footwear (e.g., shoes or soles) with integrated fiber reinforcement for improved performance.
• Creation of composite bladders or casings for balls without the need for extra layers or adhesives.
• Manufacturing of other hollow or complex-shaped composite consumer goods using rotational molding.

BenefitsContent extracted from patent full text and abstract with AI.

• Ensures uniform (homogeneous) distribution of reinforcing materials, leading to consistent product quality.
• Allows integration of functional components (like fibers, sensors, or decorative elements) into the composite structure.
• Improved mechanical properties such as increased strength, toughness, dimensional stability, and resistance to impact.
• Enables multilayer composite structures in a single process, increasing manufacturing efficiency.
• Provides flexibility to design complex and custom geometries through control of mold movement and process parameters.
• Potential reduction in production steps, material waste, and requirement for additional adhesives or casings.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The present invention concerns a method for manufacturing a three-dimensional composite object (21a, 21b, 21c), especially a sports article, comprising the steps: (a.) preparing a rotatable casting mold (11); (b.) filling of a first material (14) into the casting mold (11); (c.) filling of a second material (15) into the casting mold (11), wherein at least one of the materials (14, 15) is a polymer material; (d.) moving of the casting mold (11); and (e.) adapting of at least one process parameter during the performance of one or more of the preceding steps, so that a homogeneous distribution of the second material (15) in the manufactured composite object (21a, 21b, 21c) is achieved.