Related Applications

[0001] This application is based on and claims the benefit of priority from United States Provisional Application No. 62/458,328 that was filed on 02/13/17, the contents of which are expressly incorporated herein by reference.

Technical Field

[0002] The present disclosure relates generally to sporting equipment and, more particularly, to sporting equipment made from a composite material via additive manufacturing.

Background

[0003] Unique equipment is available for most any sport. For example, a racket may be used to play tennis, a club may be used to play golf, body armor may be used for motocross, a gun may be used for skeet or biathlon events, etc. Often, a quality of the equipment used during a sporting event can affect an outcome of the event. For example, a weight of the equipment, a strength of the equipment, a shape of the equipment, a flexibility of the equipment, a hardness of the equipment, a durability of the equipment, a conformability of the equipment, etc., can directly affect an acceleration, a speed, a distance, a force, an accuracy, a repeatability, a longevity, and other performance parameters. Unfortunately, conventional manufacturing capabilities may limit the available quality of conventional sporting equipment.

[0004] Some sporting equipment is manufactured from composite materials, which can enhance the quality of the equipment. For example, the frame of a tennis racket, the handle of a golf club, and the stock of a gun have been made from fiberglass, Kevlar, and carbon fibers using a vacuum-mold technique or a pultrusion process. Thereafter, the composite components are joined to other non-composite components (e.g., to strings, a head, a grip, a barrel, an action, etc.) using conventional techniques (e.g., gluing, welding, mechanical fastening, etc.). Sporting goods made from composite materials may have a reduced weight and/or increased strength or stiffness. [0005] Although sporting equipment having composite components may have improved qualities, the associated benefits may be limited. In particular, the quality may be interrupted because of the conventional joining techniques used to connect the composite components to the associated non-composite components. In addition, conventional vacuum-mold techniques and pultrusion processes may limit the shape, size, and/or configuration possible within the composite components. In addition, it may be beneficial, in some applications, to receive feedback from the sporting equipment; and this may not be possible using conventionally manufactured equipment.

[0006] The disclosed sporting equipment is directed to overcoming one or more of the problems set forth above and/or other problems of the prior art.

Summary

[0007] In one aspect, the present disclosure is directed to a sporting equipment. The sporting equipment may include a barrel, an action connected to a base end of the barrel, and a stock connected to the action opposite the barrel. At least two of the barrel, the action, and the stock are fabricated from a plurality of fibers.

[0008] In another aspect, the present disclosure is directed to a method of fabricating a sporting equipment. This method may include wetting a continuous fiber with a matrix, and discharging a matrix-wetted continuous fiber through a nozzle. The method may also include moving the nozzle during discharging to extend the matrix-wetted continuous fiber through at least two of a barrel, an action, and a stock of a gun. The method may further include curing a matrix in the matrix-wetted continuous fiber.

Brief Description of the Drawings

[0009] Fig. 1 is a diagrammatic illustration of an exemplary system for manufacturing sporting equipment; and

[0010] Fig. 2 is an isometric illustration of an exemplary sporting equipment that can be manufactured utilizing the system of Fig. 1. Detailed Description

[0011] Fig. 1 illustrates an exemplary system 10 for additively manufacturing sporting equipment 12. System 10 may implement any number of different additive processes during manufacture of sporting equipment 12. For example, sporting equipment 12 is shown in Fig. 1 as being manufactured via a first additive process and via a second additive process. It should be noted that the first and second additive processes may be performed simultaneously or consecutively, as desired. It should also be noted that sporting equipment 12 may be manufactured utilizing only one of the first and second additive processes.

[0012] The first additive process (represented in the lower-left of Fig. 1) may be a pultrusion and/or extrusion process, which creates hollow tubular structures 14 from a composite material (e.g., a material having a matrix and at least one continuous fiber). One or more heads 16 may be coupled to a support 18 (e.g., to a robotic arm) that is capable of moving head(s) 16 in multiple directions during discharge of structures 14, such that resulting longitudinal axes 20 of structures 14 are three-dimensional. Such a head is disclosed, for example, in U.S. Patent Application Numbers 15/130,412 and 15/130,207, all of which are incorporated herein in their entireties by reference.

[0013] Head(s) 16 may be configured to receive or otherwise contain the matrix material. The matrix material may include any type of liquid resin (e.g., a zero-volatile organic compound resin) that is curable. Exemplary matrixes include thermosets, single- or multi-part epoxy resins, polyester resins, cationic epoxies, acrylated epoxies, urethanes, esters, thermoplastics, photopolymers, polyepoxides, thiols, alkenes, thiol-enes, and more. In one embodiment, the pressure of the matrix material inside of head(s) 16 may be generated by an external device (e.g., an extruder or another type of pump) that is fluidly connected to head(s) 16 via corresponding conduits (not shown). In another embodiment, however, the pressure may be generated completely inside of head(s) 16 by a similar type of device and/or simply be the result of gravity acting on the matrix material. In some instances, the matrix material inside head(s) 16 may need to be kept cool and/or dark, in order to inhibit premature curing; while in other instances, the matrix material may need to be kept warm for the same reason. In either situation, head(s) 16 may be specially configured (e.g., insulated, chilled, and/or warmed) to provide for these needs. [0014] The matrix material stored inside head(s) 16 may be used to coat any number of continuous fibers and, together with the fibers make up walls of composite structures 14. The fibers may include single strands, a tow or roving of several strands, or a weave of many strands. The strands may include, for example, carbon fibers, vegetable fibers, wood fibers, mineral fibers, glass fibers, metallic wires, ceramic fibers, basalt fibers, etc. The fibers may be coated with the matrix material while the fibers are inside head(s) 16, while the fibers are being passed to head(s) 16, and/or while the fibers are discharging from head(s) 16, as desired. In some embodiments, a filler material (e.g., chopped fibers) may be mixed with the matrix material before and/or after the matrix material coats the fibers. The matrix material, the dry fibers, fibers already coated with the matrix material, and/or the filler may be transported into head(s) 16 in any manner apparent to one skilled in the art. The matrix-coated fibers may then pass over a centralized diverter (not shown) located at a mouth of head(s) 16, where the resin is caused to cure (e.g., from the inside-out, from the outside-in, or both) by way of one or more cure enhancers (e.g., UV lights, ultrasonic emitters, microwave generators, infrared heaters, chillers, etc.) 22.

[0015] In embodiments where sporting equipment 12 is made up of multiple structures 14, each structure 14 may be discharged adjacent another structure 14 and/or overlap a previously discharged structure 14. In this arrangement, subsequent curing of the liquid resin within neighboring structures 14 may bond structures 14 together. Any number of structures 14 may be grouped together and have any trajectory, shape, and size required to generate the desired shape of sporting equipment 12.

[0016] In some embodiments, a fill material (e.g., an insulator, a conductor, an optic, a surface finish, etc.) could be deposited inside and/or outside of structures 14, while structures 14 are being formed. For example, a hollow shaft (not shown) could extend through a center of and/or over any of the associated head(s) 16. A supply of material (e.g., a liquid supply, a foam supply, a solid supply, a gas supply, etc.) could then be connected with an end of the hollow shaft, and the material forced through the hollow shaft and onto particular surfaces (i.e., interior and/or exterior surfaces) of structure 14. It is contemplated that the same cure enhancer(s) 22 used to cure structure 14 could also be used to cure the fill material, if desired, or that additional dedicated cure enhancer(s) (not shown) could be used for this purpose. The fill materials could allow one or more of structures 14 to function as tanks, passages, conduits, ducts, etc. [0017] The second additive manufacturing process (represented in the upper-right of Fig. 1) may also be a pultrusion and/or extrusion process. However, instead of discharging hollow tubular structures 14, the second additive manufacturing process may be used to discharge tracks, ribbons, and/or sheets of composite material (e.g., over tubular structures 14 and/or over other features of sporting equipment 12). In particular, one or more heads 24 may be coupled to a support 26 (e.g., to an overhead gantry) that is capable of moving head(s) 24 in multiple directions during fabrication of sporting equipment 12, such that resulting contours of sporting equipment 12 are multi-dimensional (e.g., three-dimensional).

[0018] Head 24 may be similar to head 16 and configured to receive or otherwise contain a matrix material (e.g., the same matrix material contained within head 16 or a different matrix material). The matrix material stored inside head(s) 24 may be used to coat any number of separate fibers, allowing the fibers to make up centralized reinforcements of the discharging tracks, ribbons, and/or sheets. The fibers may include single strands, a tow or roving of several strands, or a weave of multiple strands. The strands may include, for example, carbon fibers, vegetable fibers, wood fibers, mineral fibers, glass fibers, metallic wires, etc. The fibers may be coated with the matrix material while the fibers are inside head(s) 24, while the fibers are being passed to head(s) 24, and/or while the fibers are discharging from head(s) 24, as desired. The matrix material, the dry fibers, and/or fibers already coated with the matrix material may be transported into head(s) 24 in any manner apparent to one skilled in the art. The matrix-coated fibers may then pass through one or more circular orifices, rectangular orifices, triangular orifices, or orifices of another curved or polygonal shape, where the fibers are pressed together and the matrix is caused to cure by way of one or more cure enhancers 22.

[0019] As described above, the first and second additive manufacturing processes can be extrusion or pultrusion processes. For example, extrusion may occur when the liquid matrix and the associated continuous fibers are pushed from head(s) 16 and/or head(s) 24 during the movement of supports 18 and/or 26. Pultrusion may occur after a length of matrix-coated fibers is connected to an anchor (not shown) and cured, followed by movement of head(s) 16 and/or head(s) 24 away from the anchor. The movement of head(s) 16 and/or head(s) 24 away from the anchor may cause the fibers to be pulled from the respective head(s), along with the coating of the matrix material. [0020] In some embodiments, pultrusion may be selectively implemented to generate tension in the fibers that make up sporting equipment 12 and that remains after curing. In particular, as the fibers are being pulled from the respective head(s), the fibers may be caused to stretch. This stretching may create tension within the fibers. As long as the matrix surrounding the fibers cures and hardens while the fibers are stretched, at least some of this tension may remain in the fibers and function to increase a strength of the resulting composite structure.

[0021] Structures fabricated via conventional pultrusion methods may have increased strength in only a single direction (e.g., in the single direction in which fibers were pulled through the corresponding die prior to resin impregnation and curing). However, in the disclosed embodiment, the increased strength in sporting equipment 12 caused by residual tension within the corresponding fibers may be realized in the axial direction of each of the fibers. And because each fiber could be pulled in a different direction during discharge from head(s) 16 and/or 24, the tension-related strength increase may be realized in multiple (e.g., innumerable) different directions.

[0022] Structures fabricated via conventional pultrusion methods may have strength increased to only a single level (e.g., to a level proportionate to an amount in which the fibers were stretched by a pulling machine prior to resin impregnation and curing). However, in the disclosed embodiment, because the matrix surrounding each fiber may be cured and harden immediately upon discharge, the force pulling on the fiber may be continuously varied along the length of the fiber, such that different segments of the same fiber are stretched by different amounts. Accordingly, the residual tensile stress induced within each of the different segments of each different fiber may also vary, resulting in a variable strength within different areas of sporting equipment 12. This may be beneficial in variably loaded areas of sporting equipment 12.

[0023] Fig. 2 illustrates an exemplary embodiment of sporting equipment 12. In this embodiment, sporting equipment 12 is a gun, such as a firearm, a paintball marker, an air gun, etc. that can be used for hunting, paintball, skeet, biathlon, and other shooting-related sporting events. Sporting equipment 12 of Fig. 2 could be used for non-sporting (e.g., military and/or police) activities, if desired.

[0024] As a gun, sporting equipment 12 may include, among other things, a barrel 28, an action 30, a stock 32, and a foregrip 34. Barrel 28 may be received by action 30 at a base end, and stock 32 may connect to action 30 at a side opposite barrel 28. Foregrip 34 may annularly surround barrel 28 and be cantilevered from action 30. Each of these components may be available in a variety of configurations, shapes, sizes, colors, and calibers.

[0025] Each of the components of sporting equipment 12 may be formed via any combination of the first and second additive processes described above, and may consist of any number of different fibers (e.g., fibers of different materials, sizes, colors, and/or cross-sectional shapes) F overlapping and/or interweaving with each other in any pattern, at any location, and with any desired density. For example, single fibers or groupings of fibers may be coated with a matrix M and strategically discharged as tracks from head 24 (referring to Fig. 1) to create the general structure of sporting equipment 12, while other fibers or groupings of fibers may be interwoven to create hollow tubes that are coated with matrix and strategically discharged from head 16.

[0026] Each of the components of sporting equipment 12 may be separate from each other or integral, as desired. For example, barrel 28 is shown via a cutaway in foregrip 34 as being integral with action 30 (e.g., integral with an upper receiver portion of action 30). In this example, some or all of the fibers discharging from head(s) 16 and/or 24 (referring to Fig. 1) may be continuous through each of these components, such that thousands (if not millions) of fibers extend through intersections between the components, thereby creating strong mechanical connections without requiring the use of specialized hardware, glues, and/or heavy fasteners. Stock 32 and/or foregrip 34 may additionally or alternatively be integrally manufactured with action 30, if desired.

[0027] In one exemplary embodiment, some of the fibers within the composite material making up one or more portions of sporting equipment 12 have unique characteristics. For example, while a majority of sporting equipment 12 may comprise a structural type fiber F _s (e.g., carbon fibers, fiberglass, or Kevlar fibers), some portions of sporting equipment 12 may include another type of fiber Ff (e.g., electrically conductive fibers, optical fibers, shape memory fibers, etc.). The functional type of fibers Ff may be selectively interwoven with the structural type fibers F _s at strategic locations. For example, electrically conductive fibers Ff may be located at high-stress regions (e.g., within barrel 28 and/or action 30) and used as strain gauges to detect loading conditions (e.g., discharging) of sporting equipment 12.

[0028] In a similar manner, optical fibers Ff may be located at the same or other high-stress regions, and an energy beam may be passed therethrough. As these regions flex, the optical fibers Ff may be squeezed and/or closed, thereby generating an optical feedback signal indicative of the flexing. This information may be used to determine shot initiation, a recoil effect on the user, a shot and/or recoil strength or direction, etc. In some embodiments, a receiving and/or interpreting device (e.g., an interrogator) may be embedded within the sporting equipment 12 to receive, interpret, respond to, and/or remotely transmit the information.

[0029] The electrically conductive fibers Ff and/or the optical fibers Ff may be coated with another material (e.g., insulation, a strength enhancing layer, etc.), if desired. Other electrical components (e.g., resistors, capacitors, LEDs, switches, batteries, filters, RFID tags, etc.) 62 may be extruded through heads 16, 24 and/or automatically picked-and-placed (e.g., via attachments associated with heads 16 and/or 24) during discharge of the fibers Ff. Operation of these components may then be tuned and monitored to identify the user and/or to determine conditions of sporting equipment 12 and/or the user.

[0030] The configuration of fibers within any of the components of sporting equipment 12 (and/or the location/orientation relationship between the components) may be adjustable and/or user-customizable. Specifically, it has been determined that the material type, fiber size, color, shape, pattern, location, orientation, and/or density may be selectively adjusted to provide a desired performance of sporting equipment 12. These adjustments may be manually selected by an end-user and/or automatically selected based on characteristics of the user (e.g., based on a body scan of the user, monitored performance of the user, etc.).

[0031] As shown in the left-most enlargement of Fig. 2, because the matrix surrounding each fiber may be cured and harden immediately upon discharge, the fibers may not be required to lie in parallel flat layers on top of each other. Accordingly, the fibers making up barrel 28 (or another component of sporting equipment 12) may be oriented in any desired direction (e.g., parallel, spiraling, crisscrossing, etc.) and in any number of flat or concentric (or eccentric) annular layers. This may allow for interlocking and/or overlapping of unique fiber layers and/or for the creation of customizable (e.g., strengthening, rigidity-enhancing, flexibility-enhancing, vibration-dampening, impact-resisting) features.

[0032] As also shown in the left-most enlargement of Fig. 2, any number of riflings 36 may be formed within barrel 28. Riflings 36 maybe formed during an additive manufacturing process (e.g., during either or both of the first and second additive processes described above), for example by creating elongated voids (e.g., by inhibiting discharge of fibers and/or matrix) at the riflings' locations. Riflings 36 may also be formed during a subsequent subtractive process, for example by cutting away material from barrel 28. In the latter approach, head(s) 16 and/or 24 may deposit a layer of only matrix at an inner-most annular surface of barrel 28, such that the fibers making up barrel 28 are not damaged during the subtractive process used to make riflings 36.

[0033] In the exemplary embodiment shown in Fig. 2, the matrix within the composite material making up one or more portions of sporting equipment 12 has unique characteristics. For example, while a majority of sporting equipment 12 may comprise a structural-type matrix M _s , some portions of sporting equipment 12 (e.g., the inner annular surface of barrel 28, a butt portion of stock 32, and/or an outer surface of foregrip 34) may include another type of matrix Mf (e.g., a pyrolized matrix that provides greater impact resistance, a rubberized matrix that provides impact cushioning or improved gripping, etc.). The other type of matrix Mf may be selectively used to coat the fibers at strategic locations.

[0034] In some embodiments, one or more hardpoints 38 may be fabricated (e.g., via either the first or second additive processes described above) at predetermined sites within sporting equipment 12. Each hardpoint 38 may be generally devoid of fibers and fabricated in anticipation of a subsequent subtractive (e.g., drilling, reaming, tapping, etc.) process. An exemplary hardpoint 38 is shown in the right- most enlargement of Fig. 2. In this example, hardpoint 38 is intended as a mounting location for a buffer tube 40 contained within stock 32. As shown in this enlargement, hardpoint 38 has been drilled and tapped to receive corresponding threads of buffer tube 40. By creating hardpoint 38 generally devoid of fibers, the likelihood of the subsequent subtractive process damaging fibers may be low. In addition, the subtractive process may be simpler to complete (e.g., easier, quicker, and/or less equipment-damaging) without fibers present.

[0035] Hardpoints 38 may be manufactured to have a perimeter formed from fibers in a particular configuration. That is, instead of simply avoiding fiber discharge at the intended locations of hardpoints 38, head 24 may be cause to follow a predetermined trajectory around hardpoints 38 while discharging extra fibers, such that one or more walls of fibers are created at the perimeter. This may allow for increased strength, increased rigidity, and/or improved geometrical tolerances at hardpoints 38. Hardpoints 38 may have the same general thickness of surrounding regions or protrude from one or both opposing sides, as desired. [0036] In some embodiments, hardpoint 38 may be fabricated from a material that is different than a surrounding material of sporting equipment 12. For example, hardpoint 38 may be fabricated from a different matrix material (e.g., a softer, harder, and/or more-easily machined matrix), from a different material type of fiber, and/or from a different form of fiber (e.g., chopped fiber or another filler). These differences may allow hardpoint 38 to have properties tailored for particular applications.

Industrial Applicability

[0037] The disclosed arrangement and design of sporting equipment 12 may be used in connection with any sporting event. Sporting equipment 12 may be light-weight and low-cost, due to a reduction in the number of fasteners required to join the various components to each other. In addition, sporting equipment 12 may be light-weight do to the use of composite materials. High-performance may be provided in the unique ways that particular fibers, resins, and functional components are used and laid out within sporting equipment 12.

[0038] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed sporting equipment. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed sporting equipment. For example, although sporting equipment 12 is described above as being fabricated from matrix-wetted reinforcements, it is contemplated that portions (e.g., structurally insignificant areas and/or an outer skin) of sporting equipment 12 may be fabricated from only the matrix, if desired. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.