Method of manufacturing games rackets

Claim 1

A method of making a frame for a games racket, said frame comprising a head and a shaft, in which at least said head is a molding formed by the steps of placing a fusible core material in a mold, said fusible core material containing holes oriented in a radial direction from the center of said mold, placing a plurality of pins in said injection mold, said pins passing centrally through at least some of the holes in said core material, said pins having a smaller diameter than said holes, injecting a thermoplastics material into said mold around said fusible core, said core having a melting point below the injection temperature, the holes of said core causing the injected thermoplastics material to form internal support means between the wall of said molding that is to lie at the outer circumference of said head and that wall of said molding that is to lie at the inner circumference of said head, at least some of said support means being hollow due to the presence of said pins, allowing said molding to set, removing said pins from the core, raising the temperature of said molding to an amount sufficient to melt said core but insufficient to melt or deform said molding, and, removing the molten core from said molding.

Claim 2

A method of making a frame for a games racket, said frame comprising a head and a shaft, in which at least said head is a molding formed by the steps of placing a fusible core material in a mold, said fusible core material containing holes oriented in a radial direction from the center of said mold, placing a plurality of pins in said injection mold, said pins passing centrally through at least some of the holes in said core material, said pins having a smaller diameter than said holes, injecting a thermoplastics material into said mold around said fusible core, said core having a melting point below the injection temperature, the holes of said core causing the injected thermoplastics material to form internal support means between the wall of said molding that is to lie at the outer circumference of said head and that wall of said molding that is to lie at the inner circumference of said head, at least some of said support means being hollow due to the presence of said pins, allowing said molding to set, removing said pins from the core, raising the temperature of said molding to an amount sufficient to melt said core but insufficient to melt or deform said molding, and, removing the molten core from said molding.

Claim 4

A method according to claims 1 or 2, in which locating pins are positioned in the mold in the shoulder and crown areas of said frame, these locating pins passing through holes through said core which they completely fill.

Claim 6

A method of making a frame for a games racket, said frame comprising a head and a shaft, in which at least said head is a molding formed by injecting a thermoplastics material around a fusible core provided in a mold, said core having a melting point below the injection temperature and being shaped to cause the injected thermoplastics to form internal support means between that wall of said molding that is to lie at the outer circumference of said head and that wall of said molding that is to lie at the inner circumference of said head, said internal support means being formed by said core as a series of abutments projecting from a sidewall of said molding which interconnects said inner and outer circumferential walls, at least some of said abutments being formed as hollow portions extending between said inner and outer circumference walls by pins which are passed through portions of said core, allowing said molding to set, then raising the temperature of said molding to an amount sufficient to melt said core but insufficient to melt or deform said molding, and, removing the molten core from said molding.

Claim 7

A method of making a frame for a games racket, said frame comprising a head and a shaft, in which at least said head is a molding formed by injecting a thermoplastics material around a fusible core provided in a mold, said core having a melting point below the injection temperature and being shaped to cause the injected thermoplastics to form internal support means between that wall of said molding that is to lie at the outer circumference of said head and that wall of said molding that is to lie at the inner circumference of said head, said internal support means being formed by said core as a series of abutments projecting from a sidewall of said molding which interconnects said inner and outer circumferential walls, at least some of said abutments being formed as hollow portions extending between said inner and outer circumference walls by pins which are passed through portions of said core, allowing said molding to set, then raising the temperature of said molding to an amount sufficient to melt said core but insufficient to melt or deform said molding, and, removing the molten core from said molding.

Claim 8

A method according to claims 5 in which said abutments alternately extend from opposite sidewalls of said molding which interconnect said inner and outer circumference walls.

Claim 9

A method according to claims 1 or 5 in which at least the head of said frame is foam filled in the areas of said core after said molten core is removed.