Abstract

A method of forming a composite member comprises placing a heat formable resin adjacent fibers to form a fiber member or members and forming the same into a plurality of, for example tubular members. The fiber member is placed against a first mold part. An expandable material is distributed into a distributed configuration and expands under the application of heat. The distributed material is optionally stabilized in the distributed configuration to form an expandable member, which is placed said expandable member adjacent said fiber member. A second mold parts seals the mold forming a closed cavity containing the fiber member and the expandable member. The mold parts are heated, causing the expandable material to expand and form a pressure, which drives the fiber member against one of the mold parts, the mold parts also heating the resin adjacent the fibers. The resin then hardens to form the composite member.

IPC Classes  ?

• A63B 49/10 - Frames made of non-metallic materials, other than wood

Abstract

The inventive fiber manufacturing process is particularly adapted for demanding applications such as sports racquets, including tennis racquets, badminton racquets and other sports applications The inventive fiber, for example graphite fiber) racquet frame is filled with a plastic foam and is formed using, for example, microencapsulation technology to time, generate and apply the pressure used to form the graphite composite matenal of which the racquet is composed This compares to the standard industry technique of air injection The racquet is thus not hollow like conventional graphite racquets, and the walls therefore can be made thinner than those of existing graphite racquets still being of the same strength or being stronger, which gives the racquet exceptional performance In addition, the overall dimensions of, for example the cross-section, of the racquet can also be reduced while still maintaining performance characteristics

IPC Classes  ?

• B29C 44/06 - Making multilayered articles