Filament wound fiber reinforced thermoplastic frame for a game racquet

Claim 1

In a method of making a frame for a game racquet in which a tow of filament material is helically wound over a portion of an elongated mandrel to form a tube, the tow comprising reinforcing fibers and thermoplastic material, the steps of: helically winding the circuits of the first set the circuits of the first set being wound at ± a first angle relative to the longitudinal axis of the mandrel and the number of circuits in the first set being less than the number of circuits which is required to form a closed pattern at said first angle, helically winding a second set of circuits of the tow over the first set of circuits, the circuits of the second set being wound at ± a second angle which is different than the first angle and the number of circuits in the second set being less than the number of circuits which is required to form a closed pattern at said second angle, helically winding a third set of circuits of the tow over the second set of circuits, the circuits of the third set being wound at ± a third angle which is different than the second angle and the number of circuits in the third set being less than the number of circuits which is required to form a closed pattern at said third angle, continuing to wind circuits of the tow until said portion of the mandrel is covered by the tow, removing the tube from the mandrel, bending the tube and placing the tube in a mold having the shape of a game racquet, heating the tube to melt the thermoplastic material while pressurizing the interior of the tube, allowing the tube to cool and harden to form a molded racquet frame, and removing the racquet frame from the mold.