Rolled fiber composite racquet

Abstract

A fiber composite racquet may include a loop providing a head portion of the fiber composite racquet. The loop is formed from a rolled sheet wound about a centerline by at least 720 degrees. The head portion further includes at least one of: (1) a layer joined to the rolled sheet along a fold and sandwiched between adjacent overlapping portions of the rolled sheet, and (2) a completely surrounded aperture in the rolled sheet. The head portion includes a fiber composite material.

Description

BACKGROUND

[0001] Sports racquets may have a variety of different shapes and sizes depending upon the particular sport in which they are used. In some sports, the racquets may have other names, such as paddles. Examples of sports in which racquets are used include, but are not limited to, tennis, badminton, squash, racquetball, pickle ball, table tennis, padel and the like.

[0002] Tennis racquet frames are sometimes formed from discrete fiber composite pieces. Each discrete piece comprises a resin or polymer reinforced with fibers, such as carbon or glass fibers. The discrete fiber composite pieces are individually cut out of a sheet and manually laid upon one another on a mandrel prior to molding and fusing / curing of the fiber composite pieces to form the tennis racquet frame.SUMMARY

[0003] According to the first aspect of the disclosure there is a fiber composite racquet comprising: a handle portion; and a head portion coupled to the handle portion and forming a loop, wherein the head portion comprises a fiber composite material, and wherein at least the head portion comprises: a rolled sheet wound about a centerline by at least 720 degrees; and at least one of: (1) a layer joined to the rolled sheet along a fold and sandwiched between adjacent overlapping portions of the rolled sheet; and (2) a completely surrounded aperture in the rolled sheet.

[0004] The handle portion and the head portion may be formed from the rolled sheet.

[0005] The fiber composite material may form the rolled sheet, and the aperture may be completely surrounded.

[0006] The fiber composite racquet may further comprise a throat portion between the head portion and the handle portion, wherein the completely surrounded aperture coincides with the throat portion.

[0007] The rolled sheet is a fiber composite sheet may comprise inwardly extending perimeter notches.

[0008] The rolled sheet may be a rolled fiber composite sheet and wherein the fiber composite racquet may further comprise a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0009] The second fiber composite sheet may wrap about the rolled fiber composite sheet.

[0010] The rolled fiber composite sheet may wrap around the second fiber composite sheet.

[0011] The fiber composite racquet may comprise the layer sandwiched between adjacent overlapping portions of the rolled sheet.

[0012] The layer may be wound at least 720° about the centerline.

[0013] The layer may comprise a fiber composite layer.

[0014] The layer may omit fibers.

[0015] The rolled sheet may be a rolled fiber composite sheet having a first material characteristic and wherein the layer may have a second material characteristic different than the first material characteristic.

[0016] The layer may be joined to the rolled fiber composite sheet along a fold.

[0017] The layer may comprise a fiber composite piece distinct from the rolled fiber composite sheet.

[0018] The fiber composite raquet may comprise a second layer captured between second adjacent overlapping portions of the rolled sheet. The rolled sheet may be a rolled fiber composite sheet having a first material characteristic, wherein the layer may have a second material characteristic different than the first material characteristic and wherein the second layer may have a third material characteristic different than the first material characteristic and the second material characteristic.

[0019] The rolled sheet may comprise a rolled fiber composite sheet; and the fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the rolled fiber composite sheet, wherein the layer may be joined to the rolled fiber composite sheet along a first fold at a first angle and wherein the second layer may be joined to the rolled fiber composite sheet along a second fold at a second angle different than the first angle.

[0020] The rolled sheet may comprise a rolled fiber composite sheet, wherein the fiber composite sheet may comprise a completely surround aperture and wherein the layer may comprise a flap jointed to the rolled fiber composite sheet by a fold along an edge of the completely surrounded aperture.

[0021] Further aspects and features of the present disclosure are set out below.

[0022] According to a further aspect of the disclosure, there is a fiber composite racquet comprising: a handle portion; and a head portion coupled to the handle portion and forming a loop, wherein at least the head portion comprises: a rolled fiber composite sheet wound about a centerline by at least 720 degrees.

[0023] The handle portion and the head portion may be each formed from the rolled fiber composite sheet.

[0024] The rolled fiber composite sheet may comprise completely surrounded apertures.

[0025] The fiber composite racquet may further comprise a throat portion between the head portion and the handle portion, wherein the completely surrounded apertures may coincide with the throat portion.

[0026] The rolled fiber composite sheet may comprise inwardly extending perimeter notches.

[0027] The fiber composite racquet may further comprise a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0028] The second fiber composite sheet may be rolled and has overlapping portions extending at least 720° about the centerline.

[0029] The second fiber composite sheet may be wrapped about the rolled fiber composite sheet.

[0030] The rolled fiber composite sheet may wrap around the second fiber composite sheet.

[0031] The rolled fiber composite sheet may form a tube having an interior. The interior may be void. The interior ma be filled.

[0032] The fiber composite racquet may further comprise a layer captured between adjacent overlapping portions of the rolled fiber composite sheet. The layer may be wound at least 720° about the centerline. The layer may comprise a fiber composite layer. The layer may omit fibers.

[0033] The rolled fiber composite sheet may have a first material characteristic, and the layer may have a second material characteristic different than the first material characteristic. The first material characteristic may be a first thickness and the second material characteristic may have a second thickness different than the first thickness.

[0034] The first material characteristic may be a first + / - fiber composite ply arrangement angle and the second material characteristic may be a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0035] The first material characteristic may be a first type of fiber material and the second interior characteristic may be a second type of fiber material different than the first type of fiber material.

[0036] The rolled composite sheet and the layer may have identical material characteristics.

[0037] The layer may be joined to the rolled fiber composite sheet along a fold.

[0038] The layer may comprise a fiber composite panel distinct from the rolled fiber composite sheet.

[0039] The fiber composite racquet may further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions.

[0040] The second layer may have a third material characteristic different than the first material characteristic and the second material characteristic.

[0041] The first material characteristic may be a first thickness and the third material characteristic may be a second thickness different than the first thickness.

[0042] The first material characteristic may be a first + / - fiber composite ply arrangement angle and the third material characteristic may be a second + / - fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0043] The second material characteristic of the layer may be a third + / - fiber composite ply arrangement angle different than the second + / -fiber composite ply arrangement angle.

[0044] The first material characteristic may be a first type of fiber material and the third material characteristic may be a second type of fiber material different than the first type of fiber material.

[0045] The rolled composite sheet and the second layer may have identical material characteristics.

[0046] The second layer may be joined to the rolled fiber composite sheet along a second fold.

[0047] The second layer may comprise a fiber composite panel distinct from the rolled fiber composite sheet.

[0048] The fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the overlapping portions, the layer may be joined to the rolled fiber composite sheet folded along a first fold at a first angle, and the second layer may be joined to the rolled fiber composite sheet folded at along a second fold at a second angle different than the first angle.

[0049] The layer may extend perpendicular to the centerline, and the second layer may extend parallel to the centerline.

[0050] The fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the overlapping portions, the layer may form a 9 o'clock region of the head portion and the second layer may form a 3 o'clock region of the head portion.

[0051] The layer may be joined to the rolled fiber composite sheet along a first fold to form the 9 o'clock region of the head portion, and the second layer may be joined to the rolled fiber composite sheet along a second fold to form the 3 o'clock region of the head portion.

[0052] The fiber composite racquet may further comprise: a third layer joined to the rolled fiber composite sheet along a third fold to form a first side of the handle portion; and a fourth layer joined to the rolled fiber composite sheet along a fourth fold to form a second side of the handle portion.

[0053] The third fold and the fourth fold may extend parallel.

[0054] The first fold and the second fold may be oblique to the third fold and the fourth fold.

[0055] The fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the overlapping portions, wherein the layer may form a first side, and wherein the second layer may form a second opposite side of the handle portion.

[0056] The layer may be joined to the rolled fiber composite sheet along a first fold, and the second layer may be joined to the rolled fiber composite sheet along a second fold.

[0057] The fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the overlapping portions, and the layer may be joined to the rolled fiber composite sheet along a first fold extending parallel to the second fold, and the second layer may be joined to the rolled fiber composite sheet along a second fold oblique to the centerline.

[0058] The fiber composite sheet may comprise a completely surrounded aperture, and the layer may comprises flap jointed to the fiber composite sheet by a fold along an edge of the completely surrounded aperture.

[0059] The head portion, the throat portion, and the handle portion may be formed from the rolled fiber composite sheet, wherein at least one of the head portion, the throat portion and the handle portion may comprise the layer.

[0060] The fiber composite racquet may further comprise a second layer sandwiched between the layer and one of the overlapping portions.

[0061] The second layer may be joined to the first linear along a fold between the layer and the second layer.

[0062] The rolled fiber composite sheet may comprise completely surrounded apertures and a layer sandwiched between adjacent overlapping portions of the rolled fiber composite sheet.

[0063] The head portion may comprise a beam extending at least partially about and forming a racquet head opening, and the beam may be formed from the rolled fiber composite sheet.

[0064] The racquet head opening may comprise a string bed area, and the beam may comprise a series of frame openings through the beam for receiving strings to extend across the string bed area.

[0065] The fiber composite racquet may further comprise a panel coupled to the beam and extending across the racquet head opening.

[0066] The fiber composite racquet may further comprise a yoke portion forming the racquet head opening.

[0067] The yoke portion may comprise a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a second centerline.

[0068] The fiber composite racquet may further comprise a throat portion extending between the handle portion and the head portion.

[0069] The head portion and the throat portion may be formed from the rolled fiber composite sheet.

[0070] According to a futher aspect of the present disclosure, there is a method for forming a fiber composite racquet, the method comprising: rolling a fiber composite sheet about a mandrel; fusing the overlapping portions of the rolled fiber composite sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0071] The method may further comprise cutting an aperture in the fiber composite sheet prior to the rolling of the fiber composite sheet about the mandrel.

[0072] The fiber composite racquet may comprise a head portion, a handle portion and a throat portion between the head portion and the handle portion, wherein the aperture may have a location and size through the fiber composite sheet and a location along the mandrel corresponding to a location of the throat portion of the fiber composite racquet.

[0073] The method may further comprise removing the mandrel.

[0074] The mandrel may have a linear centerline, and the rolled fiber composite sheet may be shaped following removal of the mandrel.

[0075] The method may further comprise positioning the rolled fiber composite sheet within a mold, following removal of the mandrel, to shape the rolled fiber composite sheet into at least a portion of the fiber composite racquet.

[0076] The method may further comprise pressurizing an interior of the rolled fiber composite sheet while within the mold, and the interior may be formed by the removal of the mandrel.

[0077] The fiber composite sheet may be rolled about an inflatable bladder positioned about the mandrel, wherein upon the removal of the mandrel and the positioning of the rolled fiber composite sheet within the mold, the rolled fiber composite sheet may be heated within the mold and the interior of the rolled fiber composite sheet may be pressurized while within the mold by pressurizing an interior of the inflatable bladder.

[0078] The method may further comprise pressurizing an interior of the rolled fiber composite sheet during the fusing of the overlapping portions.

[0079] The fiber composite sheet may be rolled about an inflatable bladder positioned about the mandrel, and the mandrel may be removed, wherein the interior of the rolled fiber composite sheet may be pressurized during the fusing of the overlapping portions by pressurizing an interior of the inflatable bladder.

[0080] The method may further comprise heating the mandrel during rolling of the fiber composite sheet about the mandrel.

[0081] The method may further comprise: coupling an end portion of the fiber composite sheet to the mandrel so as to rotate with rotation of the mandrel; and rotating the mandrel with the coupled end portion of the fiber composite sheet to roll the fiber composite sheet about the mandrel.

[0082] The overlapping portions of the rolled fiber composite sheet may be fused while shaped to form the head portion and a handle portion of the fiber composite racquet.

[0083] The loop may form the first portion of a racquet head opening, and the method may further comprise forming a second portion of the racquet head opening comprising a yoke portion along the racquet head opening.

[0084] The yoke portion may comprise a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a centerline.

[0085] The fiber composite racquet may comprise a handle portion and a throat portion extending between the handle portion and the head portion.

[0086] The head portion and the throat portion may be formed from the rolled fiber composite sheet.

[0087] The fiber composite racquet may comprise a handle portion, the handle portion being formed from the rolled fiber composite sheet.

[0088] The head portion of the fiber composite racquet may comprise a racquet head opening having a string bed area and wherein the rolled fiber composite sheet may form a beam about the racquet head opening, and the method may further comprise forming a series of frame openings through the beam for receive strings that are to extend across the string bed area.

[0089] The head portion of the fiber composite racquet may comprise racquet head opening and wherein the rolled fiber composite sheet may form a beam about the racquet head opening, and the method may further comprise securing a panel coupled to the beam and extending across the racquet head opening.

[0090] The method may further comprise rolling a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0091] The second fiber composite sheet may be rolled and may have overlapping portions extending at least 720° about a centerline.

[0092] The second fiber composite sheet may wrap about the rolled fiber composite sheet.

[0093] The rolled fiber composite sheet may wrap around the second fiber composite sheet.

[0094] The rolled fiber composite sheet may form a tube having an interior. The interior may be void. Alternatively, the method may further comprise filling the interior.

[0095] The fiber composite racquet may comprise a head portion having a beam at least partially surrounding a racquet head opening, wherein the beam may be formed by the rolled fiber composite sheet, wherein the method may further comprise filling the racquet head opening with a fluid composition and solidifying the fluid composition.

[0096] The fiber composite racquet may comprise a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, wherein the method may further comprise: securing a first plate to the beam to cover a first side of the racquet head opening; securing a second plate to the beam to cover a second side of the racquet head opening, the second plate being spaced from the first plate by a void; injecting a fluid composition into the void; and solidifying the fluid composition within the void.

[0097] The fiber composite racquet may comprise a head opening having a beam at least partially surrounded by racquet head opening, the beam may be formed by the rolled fiber composite sheet, wherein the method may further comprise: securing first plate I'd the racquet opening; filling the racquet head opening with a fluid composition; securing a second plate to the beam to cover a second side of the racquet head opening; and solidifying the fluid composition.

[0098] The method may further comprising sandwiching a layer between overlapping portions of the rolled fiber composite sheet.

[0099] The method may further comprise forming a marking on the fiber composite sheet that indicates a designated positioning and orientation of the layer on fiber composite sheet.

[0100] The sandwiching of the layer between overlapping portions of the rolled fiber composite sheet may comprise folding a portion of the fiber composite sheet prior to the rolling of the fiber composite sheet to form the layer.

[0101] The method may further comprise cutting a perimeter of the portion of the fiber composite sheet prior to the folding and prior to the rolling of the fiber composite sheet.

[0102] The cutting of the perimeter of the portion of the fiber composite sheet may comprise forming a pair of cuts having offset ends such that the portion is folded along an angled fold such that the layer is angled.

[0103] The method may further comprise: cutting a perimeter of a second portion of the fiber composite sheet; and folding the second portion prior to the spiral rolling of the fiber composite sheet to form a second layer, wherein the second layer is sandwiched between overlapping portions of the rolled fiber composite sheet.

[0104] The second portion may be folded along a fold such that the formed second layer is angled differently than the layer.

[0105] The layer may have a first size and / or shape, and the second layer may have a second size and / or shape different than the first size and / or shape.

[0106] The method may further comprise depositing a liquid second layer on fiber composite sheet and solidifying the second layer between the overlapping portions of the rolled fiber composite sheet.

[0107] The layer may further comprise a fiber composite layer. The layer may omit fibers.

[0108] The rolled fiber composite sheet may have a first material characteristic, and the layer may have a second material characteristic different than the first material characteristic.

[0109] The first material characteristic may be a first thickness and the second material characteristic may have a second thickness different than the first thickness.

[0110] The first material characteristic may be a first + / - fiber composite ply arrangement angle and the second material characteristic may be a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0111] The first material characteristic may be a first type of fiber material and the second interior characteristic may be a second type of fiber material different than the first type of fiber material.

[0112] The rolled composite sheet and the layer may have identical material characteristics.

[0113] The method may further comprise sandwiching a second layer between the overlapping portions, wherein the layer may be joined to the rolled fiber composite sheet folded along a first fold at a first angle and wherein the second layer may be joined to the rolled fiber composite sheet folded at along a second fold at a second angle different than the first angle.

[0114] The layer may extends perpendicular to the centerline, and the second layer may extend parallel to the centerline.

[0115] The method may further comprisr sandwiching a second layer between the layer and one of the overlapping portions.

[0116] The second layer may be joined to the first linear along a fold between the layer and the second layer.

[0117] The method may further comprise sandwiching a second layer between overlapping portions of the overlapping portions, wherein the layer form a 9 o'clock region of a head portion and the second layer may form a 3 o'clock region of the head portion.

[0118] The layer may be joined to the rolled fiber composite sheet along a first fold to form the 9 o'clock region of the head portion, and the second layer may be joined to the rolled fiber composite sheet along a second fold to form the 3 o'clock region of the head portion.

[0119] The method may further comprise: forming a third layer joined to the rolled fiber composite sheet along a third fold to form a first side of the handle portion; and forming a fourth layer joined to the rolled fiber composite sheet along a fourth fold to form a second side of the handle portion.

[0120] The third fold and the fourth fold may extend parallel.

[0121] The first fold and the second fold may be oblique to the third fold and the fourth fold.

[0122] The method may further comprise sandwiching a second layer between adjacent overlapping portions of the overlapping portions, wherein the layer may form a first side of a handle portion of the fiber composite racquet, and the second layer may form a second opposite side of the handle portion of the fiber composite racquet.

[0123] The layer may be joined to the rolled fiber composite sheet along a first fold, and wherein the second layer may be joined to the rolled fiber composite sheet along a second fold.

[0124] The method may further comprise sandwiching a second layer between adjacent overlapping portions of the overlapping portions, wherein the layer may be joined to the rolled fiber composite sheet along a first fold extending parallel to an axis, and wherein the second layer may be joined to the rolled fiber composite sheet along a second fold oblique to the axis.

[0125] The fiber composite racquet may comprise a head portion that may comprise a beam extending at least partially about and forming a racquet head opening, the beam being formed from the rolled fiber composite sheet.

[0126] The method may further comprise forming a yoke portion along the racquet head opening. The yoke portion may comprise a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a centerline.

[0127] The fiber composite racquet may comprise a throat portion extending from the head portion, wherein the head portion and the throat portion may be formed from the rolled fiber composite sheet.

[0128] The fiber composite racquet may comprise a handle portion and a throat portion between the head portion and the handle portion, wherein the handle portion may be formed from the rolled fiber composite sheet, and wherein at least one of the head portion, the throat portion and the handle portion may comprise the layer.

[0129] The head portion may comprise a racquet head opening having a string bed area, wherein the method further comprises forming a series of frame openings through the beam for receive strings that are to extend across the string bed area.

[0130] The head portion may comprise a racquet head opening, and wherein the rolled fiber composite sheet may form a beam at least partially about the racquet head opening, wherein the method may further comprise securing a panel coupled to the beam and extending across the racquet head opening.

[0131] The method may further comprise sandwiching a second layer between the layer and one of the overlapping portions.

[0132] The second layer may be joined to the first linear along a fold between the layer and the second layer.

[0133] The method may further comprise rolling a second fiber composite sheet extending about the centerline by at least 360°, wherein the second fiber composite sheet may form at least one of the head portion and the handle portion.

[0134] The second fiber composite sheet may be rolled and may have overlapping portions extending at least 720° about a centerline.

[0135] The second fiber composite sheet may wrap about the rolled fiber composite sheet.

[0136] The rolled fiber composite sheet may wrap around the second fiber composite sheet.

[0137] The rolled fiber composite sheet may form a tube having an interior. The interior may be void. Alternatively, the method may further comprise filling the interior.

[0138] The fiber composite racquet may comprise a head portion having a beam at least partially surrounding a racquet head opening, wherein the beam may be formed by the rolled fiber composite sheet, wherein the method further comprises filling the racquet head opening with a fluid composition and solidifying the fluid composition.

[0139] The fiber composite racquet may comprise a head opening having a beam at least partially surrounded by racquet head opening, wherein the beam may be formed by the rolled fiber composite sheet, wherein the method may further comprise: securing a first plate to the beam to cover a first side of the racquet head opening; securing a second plate to the beam to cover a second side of the racquet head opening, the second plate being spaced from the first plate by a void; injecting a fluid composition into the void; and solidifying the fluid composition within the void.

[0140] The fiber composite racquet may comprise a head opening having a beam at least partially surrounded by racquet head opening, the beam may be formed by the rolled fiber composite sheet, wherein the method may further comprise: securing first plate in the racquet opening; filling the racquet head opening with a fluid composition; securing a second plate to the beam to cover a second side of the racquet head opening; and solidifying the fluid composition.

[0141] The fiber composite racquet may comprise a head opening having a beam at least partially surrounded by racquet head opening, wherein the beam may be formed by the rolled fiber composite sheet, wherein the method may further comprise forming a non-string layer within the racquet head opening across the racquet head opening.

[0142] According to a further aspect of the disclosure, described is a fiber composite racquet comprising: a handle portion; and a head portion extending from the handle portion, wherein at least the head portion comprises: a sheet wound about a centerline; and a fiber composite layer sandwiched between adjacent overlapping portions of the sheet.

[0143] The handle portion and the head portion may each be formed from portions of the rolled sheet and portions of the fiber composite layer.

[0144] The sheet may be wound at least 720° about the centerline.

[0145] The layer may be wound less than 720° about the centerline.

[0146] The rolled sheet may omits fibers.

[0147] The fiber composite racquet may further comprise a second fiber composite layer sandwiched between adjacent overlapping portions of the sheet.

[0148] The fiber composite layer may be part of a first piece and the second fiber composite may be part of a second piece discrete from the first piece.

[0149] The first piece and the second may not radially overlap. Alternatively, the first piece and the second piece may radially overlap.

[0150] The fiber composite layer may have a first material characteristic and the second fiber composite layer may have a second material characteristic different than the first material characteristic.

[0151] The first material characteristic may be a first thickness and the second material characteristic may have a second thickness different than the first thickness.

[0152] The first material characteristic may be a first + / - fiber composite ply arrangement angle, and the second material characteristic may be a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0153] The first material characteristic may be a first type of fiber material, and the second interior characteristic may be a second type of fiber material different than the first type of fiber material.

[0154] The layer and the second layer may have identical material characteristics.

[0155] The fiber composite racquet may further comprise a second fiber composite layer sandwiched between adjacent overlapping portions of the sheet, wherein the sheet may comprise a fiber composite sheet, wherein the first fiber composite layer may be joined to the sheet along a fold and wherein the second fiber composite layer may be part of a piece discrete from the sheet and the fiber composite layer.

[0156] The fiber composite sheet and the fiber composite layer may have a first material characteristic, and the second fiber composite layer may have a second material characteristic different than the first material characteristic.

[0157] The first material characteristic may be a first thickness, the second material characteristic may be a second thickness different than the first thickness.

[0158] The first material characteristic may be a first + / - fiber composite ply arrangement angle, and the second material characteristic may be a second + / - fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0159] The first material characteristic may be a first type of fiber material, and wherein the second material characteristic may be a second type of fiber material different than the first type of fiber material.

[0160] The fiber composite racquet may further comprise a marking on the sheet that indicates a designated positioning and orientation of the fiber composite layer on sheet.

[0161] The fiber composite racquet may further comprise a non-fiber composite piece sandwiched between adjacent overlapping portions of the sheet.

[0162] The sheet may comprise a fiber composite sheet, wherein the fiber composite layer may be joined to the fiber composite sheet along a fold, and wherein the non-fiber composite piece may be discrete from the sheet and the fiber composite layer.

[0163] According to a further aspect of the disclosure, there is a method for forming a fiber composite racquet, the method comprising: positioning at least one fiber composite piece on a sheet; rolling the sheet about a mandrel; and fusing the overlapping portions of the sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0164] The sheet may comprise a fiber composite sheet. The sheet may be a non-fiber composite sheet or omits fibers.

[0165] According to a further aspect of the disclosure there is a method for forming a fiber composite racquet, the method comprising: folding a portion of fiber composite sheet to form a fiber composite layer; positioning a piece discrete from the fiber composite sheet and the fiber composite layer on the fiber composite sheet; rolling the sheet with a folded portion forming the fiber composite layer and with the piece about a mandrel; and fusing the overlapping portions of the rolled fiber composite sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0166] The piece may comprise a second fiber composite layer. The piece may comprise a non-fiber composite material or omits fibers.

[0167] According to a further aspect of the disclosure, there is a fiber composite racquet comprising: a handle portion; and a head portion coupled to the handle portion and forming a loop, wherein at least the head portion comprises: a rolled sheet wound about a centerline by at least 720 degrees, and wherein the head portion comprises a fiber composite material.

[0168] The handle portion and the head portion may each be formed from the rolled sheet.

[0169] The fiber composite material may form the rolled sheet.

[0170] The rolled sheet may comprise completely surrounded apertures.

[0171] The fiber composite racquet may further comprise a throat portion between the head portion and the handle portion, wherein the completely surrounded apertures may coincide with the throat portion.

[0172] The rolled sheet may be a fiber composite sheet comprising inwardly extending perimeter notches.

[0173] The rolled sheet may be a rolled fiber composite sheet, and wherein the fiber composite racquet may further comprise a second fiber composite sheet extending about the centerline by at least 360°, wherein the second fiber composite sheet may form at least one of the head portion and the handle portion.

[0174] The second fiber composite sheet may wrap about the rolled fiber composite sheet.

[0175] The rolled fiber composite sheet may wrap around the second fiber composite sheet.

[0176] The fiber composite racquet may further comprise a layer sandwiched between adjacent overlapping portions of the rolled sheet.

[0177] The layer may be wound at least 720° about the centerline. The layer may comprise a fiber composite layer. The layer may omit fibers.

[0178] The rolled sheet may be a rolled fiber composite sheet having a first material characteristic, and wherein the layer may have a second material characteristic different than the first material characteristic.

[0179] The layer may be joined to the rolled fiber composite sheet along a fold.

[0180] The layer may comprise a fiber composite piece distinct from the rolled fiber composite sheet.

[0181] The fiber composite racquet may further comprising a second layer captured between second adjacent overlapping portions of the rolled sheet. The rolled sheet may be a rolled fiber composite sheet having a first material characteristic, wherein the layer may have a second material characteristic different than the first material characteristic, and wherein the second layer may have a third material characteristic different than the first material characteristic and the second material characteristic.

[0182] The rolled sheet may comprise a rolled fiber composite sheet, and the fiber composite racquet may further comprise a second layer captured between second adjacent overlapping portions of the rolled fiber composite sheet, wherein the layer may be joined to the rolled fiber composite sheet along a first fold at a first angle, and wherein the second layer may be joined to the rolled fiber composite sheet at along a second fold at a second angle different than the first angle.

[0183] The rolled sheet may comprise a rolled fiber composite sheet, wherein the fiber composite sheet may comprise a completely surrounded aperture, and wherein the layer may comprise a flap jointed to the rolled fiber composite sheet by a fold along an edge of the completely surrounded aperture.

[0184] It will be appreciated that any feature described in relation to a single aspect of the disclosure may be used in combination with any other aspect of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0185] Figure 1 is a front view of an example sports racquet at least partially formed by a rolled sheet. Figure 2 is a perspective view of the example sports racquet of Figure 1. Figure 3 is a side the example sports racquet of Figure 1. Figure 4A is a perspective view of an example fiber composite layer in the form of an example composite fiber ply arrangement. Figure 4B is a perspective view of an example fiber composite layer. Figure 5 is a flow diagram of an example method for forming a sports racquet from a rolled sheet. Figure 6 the diagram schematically illustrating an example layout of fiber composite pieces for placement upon an example sheet to be rolled pursuant to the method of Figure 5 to form an example rolled tube for forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 7 is a side view of a sheet rolled about a bladder and a mandrel to form a rolled tube about the mandrel. Figure 8 is a top perspective view of the rolled tube of Figure 7 following removal of the mandrel, following the shaping of the rolled tube and the provision of an example yoke. Figure 9 is a top perspective view of the shaped and rolled tube of Figure 8 joined to the example yoke. Figure 10 is an exploded perspective view of the joined rolled tube and yoke of Figure 9 being placed into a sports racquet forming mold. Figure 11 is a flow diagram of an example method for forming a sports racquet from a rolled sheet. Figure 12 is a diagram schematically illustrating an example sheet to be rolled about an example mandrel and bladder pursuant to the method of Figure 11 to form an example rolled tube for forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 13 is a sectional of the example rolled tube formed by rolling of the example sheet shown in Figure 12, wherein the rolled tube may be used to form the example sports racquet of Figure 1 pursuant to the shaping and molding process shown in Figures 7-10. Figure 14 is a diagram illustrating an example sheet to be rolled about an example mandrel to form an example yoke for the example sports racquet of Figure 1. Figure 15 is a diagram illustrating the example yoke of Figure 14 following the rolling of the example sheet of Figure 14 about the example mandrel, wherein the yoke may be included as part of a sports racquet such as the example tennis racquet of Figure 1 pursuant to the process shown in Figures 8-10. Figure 16 is a sectional view of the example sports racquet of Figure 1 taken along line 16-16, in one implementation where the example sports racquet is formed from the example rolled tube of Figure 13. Figure 17 is a sectional view of the example sports racquet of Figure 1 taken along line 17-17, in one implementation where the example sports racquet is formed from the example rolled tube of Figure 13. Figure 18 is a sectional view of the example sports racquet of Figure 1 taken along line 18-18, in one implementation where the example sports racquet is formed from the example rolled tube of Figure 13. Figure 19 is a sectional view of the example sports racquet of Figure 1 taken along line 18-18, in another implementation where the example sports racquet is formed from the example rolled tube of Figure 13. Figure 20 is a flow diagram of an example method for forming a sports racquet from a rolled sheet. Figure 21 is a diagram illustrating an example lay up of pieces for placement upon an example fiber composite sheet to be rolled about an example bladder and mandrel pursuant to the method of Figure 20 to form an example rolled tube for forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 22 is a sectional view of the example rolled tube formed by rolling of the example sheet shown in Figure 21 with the example lay-up of pieces, wherein the rolled tube may be used to form the example sports racquet of Figure 1 pursuant to the shaping and molding process shown in Figures 7-10. Figure 23 is a diagram illustrating an example sheet to be rolled about an example mandrel to sandwich layer pieces to form an example yoke for the example sports racquet of Figure 1. Figure 24A is a diagram illustrating the example yoke of Figure 23 following the rolling of the example sheet of Figure 23 about the example mandrel with the sandwiched layer pieces, wherein the yoke may be included as part of a sports racquet such as the example sports racquet of Figure 1 pursuant to the process shown in Figures 8-10. Figure 24B is a sectional view of the yoke of Figure 24A taken along line 24B-24B. Figure 25 is a diagram illustrating an example fiber composite sheet having example folded layers and placed layer pieces which are to be rolled about an example bladder and mandrel pursuant to the method of Figure 20 to form an example rolled tube for forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 26A is a fragmentary view illustrating a portion of another example implementation of the fiber composite sheet of Figure 25, the portion comprising a folded layer, wherein an angle of the folded layer is controlled by cutting of the fiber composite sheet. Figure 26B is a perspective view illustrating the example fiber composite sheet of Figure 25 with the placed layers underlying an example template for additional placed pieces prior to rolling. Figure 27 is a sectional view of the example rolled tube formed by rolling of the example sheet shown in Figure 25 with the example folded layers and placed layer pieces, wherein the rolled tube may be used to form the example sports racquet of Figure 1 pursuant to the shaping and molding process shown in Figures 7-10. Figure 28 is a diagram illustrating an example fiber composite sheet having cut portions for forming example folded layers which are to be rolled about an example bladder and mandrel pursuant to the method of Figure 20 to form an example rolled tube for forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 29 is a diagram of the example fiber composite sheet of Figure 27 following folding of the cut portions to form the example folded layers. Figure 30 is a sectional view of the example rolled tube formed by rolling of the example sheet shown in Figure 25 with the example folded layers, wherein the rolled tube may be used to form the example sports racquet of Figure 1 pursuant to the shaping and molding process shown in Figures 7-10. Figure 31 is a diagram of example fiber composite sheets having cut and folded layers which are to be rolled about an example bladder and mandrel pursuant to method 22 form example rolled tube forming a sports racquet, such as the example sports racquet shown in Figure 1. Figure 32 is a diagram illustrating an example method for rolling a sheet about an example bladder and an example mandrel. Figure 33 is an exploded view of an example sports racquet having an example head portion and an example throat portion formed by rolling a sheet to form a rolled tube and formed according to the example method of Figure 5, the example method of Figure 11 or the example method of Figure 20, the example sports racquet further comprising a separately formed handle portion. Figure 34 is an exploded view of an example sports racquet having an example head portion formed by rolling a sheet to form a rolled tube and formed according to the example method of Figure 5, the example method of Figure 11 or the example method of Figure 20, the example sports racquet further comprising a separately formed handle portion and a separately formed throat portion. Figure 35 is a front view of an example sports racquet formed by rolling a sheet to form a rolled tube and formed according to the example method of Figure 5, the example method of Figure 11 or the example method of Figure 20. Figure 36 is a sectional view of one example implementation of the example sports racquet of Figure 35taken along line 36-36. Figure 37 is a sectional view of another example implementation of the example sports racquet of Figure 35 taken along line 36-36. Figure 38 is a front view of an example sports racquet formed by rolling a sheet to form a rolled tube and formed according to the example method of Figure 5, the example method of Figure 11 or the example method of Figure 20.

[0186] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and / or implementations consistent with the description; however, the description is not limited to the examples and / or implementations provided in the drawings.DETAILED DESCRIPTION OF EXAMPLES

[0187] Disclosed example sports racquets and example method for forming sports racquets. The example sports racquets and methods may be utilized to form racquets for a variety of different sports such as tennis, badminton, squash, racquetball, pickle ball, table tennis, padel and the like. In contrast to many existing tennis racquet frames, at least a portion of the example sports racquets comprises a rolled sheet wound at least 720° (at least two revolutions) about a centerline.

[0188] In some implementations, the rolled sheet comprises a fiber composite sheet. In some implementations, the fiber composite sheet comprises folded layers sandwiched between overlapping portions of the rolled composite fiber sheet. In some implementations, the rolled fiber composite sheet with the folded layers additionally comprises fiber composite pieces and / or non-fiber composite pieces. In some implementations, the rolled sheet comprises a fiber composite sheet supporting fiber composite pieces and / or non-fiber composite pieces which become sandwiched between overlapping portions of the rolled sheet. In some implementations, the rolled sheet comprises a non-fiber composite sheet supporting fiber composite pieces which become sandwiched between overlapping portions of the rolled sheet.

[0189] In some implementations, the rolled sheet forms the head portion of the sports racquet. In some implementations, the rolled sheet additionally forms a throat portion of the sports racquet. In some implementations, the rolled sheet further forms a handle portion of the sports racquet.

[0190] In some implementations the rolled sheet forms a beam which at least partially surrounds a racquet head opening. The racquet head opening may form a string bed (such as in the case of a tennis racquet, a badminton racquet, a racquetball racquet or the like), wherein a series of openings extend through the beam, wherein the strings are strung through the openings and across the string bed. In some implementations, a panel (perforate or imperforate) may be positioned across the racquet head opening (such as in the case of a pickle ball paddle / racquet or a padel racquet). In some implementations, one or more layers of material may at least partially fill the racquet head opening formed by the beam. The one or more layers may be foamed or non-foamed materials. The one or more layers may be formed by injecting or filling the racquet opening with a fluid material that is solidified or may be formed by securing an already solid layer or group of layers within the racquet head opening.

[0191] Because portions of the racquet are formed from a rolled sheet wound about a centerline rather than individual discrete pieces laid upon one another, the racquet construction is more unitary. This more unitary construction may provide enhanced performance for the racquet. For example, in at least implementations where the rolled sheet is a fiber composite sheet, this construction may offer enhanced torsional stability when employed to form portions of a tennis racquet frame.

[0192] Moreover, because portions of the racquet are formed from sheet wound about a centerline rather than individual discrete pieces laid upon one another, fewer discrete pieces need to be cut and individually placed. As result, this racquet construction facilitates faster and less labor-intensive manufacturing of the racquet. This construction may also facilitate more automation of the racquet construction and reduce human prone assembly errors and variability, resulting in a lower cost racquet with greater performance consistency from one racquet to another.

[0193] Forming at least portions of the racquet from a rolled sheet with folded layers eliminates or reduces the number of individual pieces which are typically manually located. As a result, manufacturing speed is enhanced to likewise improve manufacturing efficiency with less work in process. In addition, consistency from one racquet to another racquet may also be improved. In particular, stiffness and weight characteristics of a racquet are more uniform and more predictable with less variation. Skilled tennis players can often notice even a 1 g difference in a racquet or a shifting of a balance point of the racquet by as little as 0.1 mm. The example rackets can address such issues.

[0194] Moreover, because the example racquets and the disclosed example manufacturing processes eliminate or reduce the number of individual pieces (by folding portions of the sheet), the rolled tube which forms at least the racquet head has been found to include fewer voids or pits in the wound layers, ultimately reducing finishing or postprocessing time and cost. The elimination or reduction in the number of individual pieces has been further found to potentially reduce wrinkles in the rolled tube along an inner diameter of the racquet hoop. Such reduction of wrinkles further reduces the time and cost of finishing a manufactured racquet while enhancing final racquet appearance.

[0195] In some implementations, the rolled sheet is rolled so as to have an interior along the centerline. In some implementations, the interior is void or empty such that the beam provided by the rolled sheet is hollow and lighter in weight. In some implementations, the interior is filled with material for strength or noise dampening. For example, the interior may be filled or injected with a foaming material or other material.

[0196] In some implementations where the rolled sheet is a fiber composite sheet, wherein portions of the fiber composite sheet are removed or cut out. As result, when the fiber composite sheet is subsequently rolled and shaped into a portion of the sports racquet, corresponding portions of the sport racquet have fewer windings or overlapping portions. The fewer number of overlapping portions may alter the performance characteristics in such portions. For example, in implementations where the rolled fiber composite sheet forms a throat portion of a sports racquet, removing those portions of the fiber composite sheet prior to rolling at locations that correspond to the throat may result in the throat being less stiff and more flexible.

[0197] In some implementations, a second sheet may be rolled about the centerline by at least 360° and, in some implementations, by at least 720° (two revolutions). The sheet may be rolled about the rolled second sheet or the second sheet may be rolled about the rolled fiber composite sheet. The second sheet may have a physical composition different than that of the fiber composite sheet. The second sheet may not comprise a fiber composite sheet. The second sheet may omit fibers. In some implementations, the first sheet may comprise a first fiber composite sheet while the second sheet may comprise a second fiber composite sheet that may have other different material characteristics than that of the first fiber composite sheet. The two rolled sheets may have different thicknesses. The two sheets may have different ply arrangement angles. The two sheets may have different material compositions such as different fiber materials and / or different resin or polymer materials encapsulating the fiber materials.

[0198] In some implementations, construction and performance characteristics of the racquet are controlled and varied by additionally sandwiching at least one layer between adjacent overlapping portions of the rolled fiber composite sheet. The added layer or layers may vary material properties are performance characteristics of particular portions of the racquet. For example, a layer may be added to a particular portion of the fiber composite racquet to increase the stiffness or other properties of the particular portion of the fiber composite racquet.

[0199] In implementations where a plurality of layers are sandwiched or captured within the roll of fiber composite material, multiple layers may be sandwiched between the same overlapping portions of the roll of fiber composite material and / or may be sandwiched between different pairs of adjacent overlapping portions of the rolled fiber composite material. For example, two different layers may be provided between adjacent overlapping portions of the fiber composite sheet roll, wherein the two layers are at the same radial location (the same radial distance from a center or centerline of the roll), but at different axial locations along a centerline the row. A first layer may be provided between adjacent overlapping portions of the fiber composite sheet roll at a first radial position within the roll and a second layer may be provided between adjacent overlapping portions of the fiber composite sheet roll at a second radial position within the roll, radially outward of the first radial position. The different radial positions of the first and second layers may be at the same or different axial locations relative to the centerline of the roll.

[0200] The added layer or layers may have material or physical characteristics different than that of the material or physical characteristics of the fiber composite sheet. For example, the added layer or layers may have plies or ply arrangements that have different angles as compared to the that of the fiber composite sheet. A ply arrangement refers to a pair of plies having a respective pair of + / -angles. For example, ply arrangement may comprise a first ply having a positive 30° angle and a second adjacent overlapping ply having a -30° angle. In some implementations, the fiber composite sheet may have a first ply arrangement having a first + / -angle and the layer may comprise a second ply arrangement having a second different + / -angle.

[0201] In some implementations, the added layer or layers may have a different thickness than that of the fiber composite sheet. In some implementations, the fiber composite sheet may have fibers that reinforce a first resin or material while the layer or layers comprise the same fibers that reinforce a second different type of resin or material. In some implementations, the fiber composite sheet may comprise a first type of fiber that reinforces a type of resin or material while the layer comprises a second type of fiber that reinforces the same type of resin or material. In some implementations, the fiber composite sheet may comprise a first type of resin that reinforces a first type of resin or polymer while the layer or layers comprises a second different type of fiber that reinforces second different type of resin or material. In some implementations, the layer or layers may comprise fiber composite layers having multiple different types of fibers or fiber clusters. In some implementations, the layer layers may omit fibers.

[0202] In implementations where more than one layer is sandwiched between overlapping portions of the rolled fiber composite sheet, the different layers themselves may have different material characteristics. The different layers may have different sizes and shapes. The different layers may have different thicknesses. The different layers may have different ply arrangement angles. The different layers may have different material compositions such as different fiber materials and / or different resin or polymer materials encapsulating the fiber materials. In some implementations, some of the layers may be in the form of a fiber composite layer while other layers omit fibers. The different layers may be at particular locations to modify or control performance characteristics of different portions of the fiber composite racquet. For example, the fiber composite racquet may be provided with perimeter weighting by sandwiching two layers at locations corresponding to the 3 o'clock and 9 o'clock positions of the head of the racquet. The fiber composite racquet may be provided with a heavier weighted handle portion by providing or sandwiching additional layers at locations corresponding to the handle portion of the fiber composite racquet.

[0203] In some implementations, the sandwiching of the layer (or layers) between adjacent overlapping portions of the rolled fiber composite sheet comprises positioning a discrete panel (layer piece) of material on the fiber composite sheet prior to rolling of the fiber composite sheet. The discrete panel or layer piece may comprise a fiber composite panel or a panel having other constructions or formed from other materials. For example, the panel may omit fibers. In such implementations, indicia or markings may be formed on a surface of the fiber composite sheet to assist in the proper manual or automated (computer vision assisted) location and orientation of the discrete panel or piece of material on the fiber composite sheet. For example, the fiber composite sheet may be printed with printed outlines of the layer piece, the outline indicating both the location and orientation for the layer / piece. In some implementations, the printing may additionally include a text (numbers and such or words) or graphics (bar code, QR code or other images) identifying the particular layer piece that is to be positioned at the particular location. In some implementations, the marking may be scanned or otherwise captured with a computer vision system / camera to facilitate the subsequent automated positioning of the layer piece on fiber composite sheet prior to folding. In some implementations, the fiber composite sheet and / or the layer piece may be heated to a temperature such that at least portions of the fiber composite sheet and / or the layer piece is tacky to facilitate securement of the layer piece on the fiber composite sheet prior to rolling. In some implementations, the layer piece may be provided with an adhesive layer or film to facilitate its securement once positioned on the fiber composite sheet prior to rolling.

[0204] In some implementations, the sandwiching of the layer between adjacent overlapping portions of the rolled fiber composite sheet comprises folding a portion of the fiber composite sheet (and / or folding a portion of the second fiber composite sheet that is to be rolled when provided) along a fold to form the layer. For example, an edge portion or perimeter portion of the fiber composite sheet may be folded over and along a fold to form the layer. Portions of the fiber composite sheet may be cut or severed while leaving such portions connected to a remainder of the fiber composite sheet along a fold along which the portions are to be folded to form the layer. The cut may have endpoints that guide the folding to form the layer. In some implementations, the cuts of such portions may have aligned end such that the portion is folded along a fold that is perpendicular to a centerline of the portion that was severed. In some implementations, the ends of the cuts of such portions may be offset such that the portion is folded along a fold that is oblique to a centerline of the portion that was severed. In such implementations, despite the unfolded partially severed portion having the same ply arrangement angle as that of the remaining fiber composite sheet, the layer formed by the folded portion of the fiber composite sheet may be provided with a different ply arrangement (+ / -) angle.

[0205] In those implementations where the layer is formed by folding of the fiber composite sheet, the number of separate or discrete layer pieces that must be cut is reduced, further reducing manufacturing time and cost. Moreover, in implementations with a layer is formed by folding of the fiber composite sheet, the angle of the fold and the resulting orientation of the layer as well as its ply arrangement (plus / minus) angle is further controlled or dictated by the alignment or offsetting of the ends of the cut that partially severed the portion to be folded. As result, operator or human induced error or variability during the manufacture of different sports racquets is reduced. In such example implementations, the forming of the beam / rolled tube that is to be fused and shape to form the head portion of a sports racquet may simply involve folding those partially severed portions of the fiber composite sheet and rolling the sheet about a centerline. The tedious, time-consuming and error-prone task of individually laying sometimes dozens of discrete fiber composite pieces on a mandrel is eliminated.

[0206] Disclosed are example fiber composite racquets and example methods for forming fiber composite racquets, wherein a sheet is wound or rolled about a centerline; and wherein a fiber composite layer is sandwiched between adjacent overlapping portions of the sheet. In some implementations, the sheet may not be a fiber composite sheet or may omit fibers, wherein the fiber composite layer is part of a piece that is discrete from the sheet and that is placed on a surface of the sheet prior to rolling of the sheet about the centerline. In some implementations, the sheet may comprise a marking or markings indicating a designated position and / or orientation of the piece to assist in assembly or manufacture of the racquet. In some implementations, the sheet may comprise a fiber composite sheet.

[0207] In some implementations, the fiber composite layer may have a length, extending along the centerline about which is sheet is rolled, that is sufficiently long to form an entirety of the head portion of the racquet. In some implementations, fiber composite layer has a length, extending along the centerline about which the sheet is rolled, that is sufficiently long to form an entirety of the head portion and a throat portion of the racquet. In some implementations, the fiber composite layer has a length, extending along the centerline about which issues rolled, that is sufficiently long to form an entirety of the head portion and at least portions (if not an entirety) of a handle portion of the racquet.

[0208] In some implementations, the example fiber composite racquet may comprise a second layer provided by a piece of material or a piece formed from one or more layers that is sandwiched between adjacent overlapping portions of the sheet. In some implementations, the second layer comprises a second fiber composite layer. In some implementations, the second fiber composite layer forming the second layer may have a material characteristic different than the material characteristic of the fiber composite layer. In some implementations, the second layer may comprise a material that is not a fiber composite layer or may omit fibers.

[0209] In some implementations, the sheet and the fiber composite layer are both formed from a fiber composite material. In some implementations, the sheet and the fiber composite layer are integrally formed as part of a single unitary body, wherein the fiber composite layer is joined to the sheet along a fold. In such implementations, the racquet may comprise a second layer sandwiched between overlapping portions of the sheet. In some implementations, the second layer is a non-fiber composite layer or piece. In some implementations, the second layer may be a second fiber composite layer. In some implementations, the second fiber composite layer may have a material characteristic different than that of the material characteristic of the first fiber composite layer.

[0210] For purposes of this disclosure, the term "rolled" refers to the winding, rolling or wrapping of a sheet, layer, panel or the like about the centerline or axis and about itself. The rolled sheet, layer, panel or the like may have multiple rounds or windings which may form a two-dimensional spiral where the overlapping portions do not translate along the axis or the centerline, or may form a three-dimensional spiral, a helix, where the overlapping portions additionally translate along the axis or the centerline. The rolled sheet, layer, panel or the like may have a cross-section similar to that of a jellyroll. In some implementations, the sheet, layer, panel or the like may be rolled about a mandrel having a circular, or oval cross-sectional shape. In some implementations, sheet, layer, panel like be rolled about a mandrel having a polygonal cross-section, such as a square, rectangle or the like which may or may not include protuberances and / or grooves or other cavities along or at least partially along its length which provides the centerline.

[0211] For purposes of this disclosure, the term "coupled" shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

[0212] For purposes of this disclosure, the phrase "configured to" denotes an actual state of configuration that fundamentally ties the stated function / use to the physical characteristics of the feature proceeding the phrase "configured to".

[0213] For purposes of this disclosure, the term "releasably" or "removably" with respect to an attachment or coupling of two structures means that the two structures may be repeatedly connected and disconnected to and from one another without material damage to either of the two structures or their functioning.

[0214] In each of the drawings of this entire disclosure, various mandrels are schematically shown for ease of illustration and may have other lengths, diameters and proportions other than those schematically depicted. Likewise, the number of revolutions or windings of the depicted sheets after being rolled about the mandrel, the proportionality of the length and width of each sheet, and the depicted thickness of each sheet are also schematically illustrated in that the exact number of windings, the compactness / density of windings, the lengths and widths of the sheets, and the thicknesses of the sheets (unless otherwise explicitly specified in each case) may vary from what is schematically depicted.

[0215] Referring to FIGS. 1 through 3, a sports racquet is indicated generally at 10. The racquet 10 of FIG. 1 is configured as a tennis racquet. The racquet 10 includes a frame 12 extending along a longitudinal axis 16 and including a head portion 18, a handle portion 20, and a throat portion 22 coupling the head and handle portions 18 and 20. The frame 12 is a tubular structure formed of a lightweight, durable material, preferably a fiber composite material.

[0216] The head portion 18 is a tubular structure that includes inner and outer peripheral walls 24 and 26. The head portion 18 can be broken down into regions, such as, a distal region 28, first and second side regions 30 and 32, and a proximal region 34, which collectively define a hoop 36 having a string bed area 38 for receiving and supporting the string bed 14. In one preferred implementation, the proximal region 34 includes a yoke 40. The string bed area 38 is also referred to as the head size of the racquet 10. In a preferred implementation, the head size or string bed area 38 of the racquet 10 is within the range of 93 to 120 square inches. In other implementations, the head size of the racquet 10 can be within the range 98 to 115 square inches. In other implementations, other head sizes can also be used and are contemplated under the present invention. The string bed area 38 has a maximum longitudinal dimension, a, and a maximum transverse dimension, b. The hoop 36 can be any closed curved shape including, for example, a generally oval shape, a generally tear-drop shape, a generally circular, a generally pear shape, and combinations thereof. In some implementations, the maximum longitudinal dimension a can be at least 1.2 times the maximum transverse dimension b (a ≥1.2*b). In other implementations, the maximum longitudinal dimension a can be at least 1.25 times the maximum transverse dimension b (a ≥1.25*b). In other implementations, the maximum longitudinal dimension a can be less than 1.2 times the maximum transverse dimension b.

[0217] The yoke 40 is an elongate tubular structural member that extends from the first side region 30 to the second side region 32 of the head portion 18. In one implementation, the yoke 40 is integrally formed with the frame 12 defining the proximal region 34. For example, the yoke can be formed of a fiber composite material and molded and cured with the frame 12 of the racquet 10. In alternative preferred implementations, the yoke 40 can be connected through use of adhesives, fasteners, bonding and combinations thereof. The yoke 40 is formed of a lightweight, durable material, such as a carbon-fiber composite material. Alternatively, the yoke 40 can be formed of other materials, such as, for example, other composite materials, metallic alloys, a polymeric material, wood and combinations thereof.

[0218] In a preferred implementation, the first and second side regions 30 and 32 downwardly extend from the head portion 18 to form first and second throat tubes 42 and 44 of the throat portion 22. The first and second throat tubes 42 and 44 converge and further downwardly extend to form the handle portion 20. Accordingly, in such implementations, the frame 12 can be formed of one continuous tube of material (e.g., fiber composite material) that is curved at its middle region to form the head portion 18 then each side of the continuous tube of material can converge toward each other in the throat region 22 and the end regions of the continuous tube can be arranged side by side to form the base structure of the handle portion 20. In such implementations, the frame 12 is formed as a one-piece integral structure. The handle portion 20 can further include a pallet 46, a grip 48 and a butt cap 50. In other implementations, the handle portion 20 can be a tubular structure that does not include an extension of the first and second throat tubes. In such implementations, the handle portion can be a tubular structure separate from either the throat portion or the head portion of the frame and attached to the throat portion through use of conventional fasteners, molding techniques, bonding techniques, adhesives or combinations thereof. In other implementations, the handle portion can be formed in the shape of an outer surface of a conventional pallet, thereby eliminating the need for the use of a pallet.

[0219] In other implementations, the head portion 18 can be directly connected to one or both of the throat portion 22 and the yoke 40 through the use of conventional fasteners, adhesives, mechanical bonding, thermal bonding, or other combinations thereof. In one implementation, the head portion 18 can be separated from one or both of the throat portion and the yoke by a vibration and shock absorbing material, such as an elastomer.

[0220] The racquet 10 is configured for supporting a string bed 14 and is formed by a plurality of main string segments 52 alternately interwoven or interlaced with a plurality of cross string segments 54. The string bed 14 is preferably generally uniform with constant spacing between the string segments 52 and 54. Alternatively, the string bed 14 can have some spacing variability provided that the spacing of the main and cross string segments of the string bed is most dense at the center of the string bed 14 (or near the geometric center of the string bed or string bed area). The main and cross string segments 52 and 54 can be formed from one continuous piece of racquet string, or from two or more pieces of racquet string. The racquet string is formed of a high tensile strength, flexible material. In preferred implementations, the racquet string can be formed of a polyester material, a nylon, a natural gut material and / or a synthetic gut material. The racquet string can be formed in a monofilament construction or in a multiple filament construction, and can be formed of various different diameters (or gauges). Preferably, the diameter of the racquet string is within the range 1.10 to 1.55 mm.

[0221] The inner and outer peripheral walls 24 and 26 of the hoop 36 can include string holes 59 for receiving the racquet string. The string holes 59 can be sized to be just larger than the diameter of the racquet string, or the combination of the racquet string and a grommet, or a size that is larger to accommodate movement or deflection of the racquet string and / or grommet. The head portion 18 of the racquet 10 can also include one or more grommets or bumper guards for supporting and protecting the racquet string as it extends from one string hole to another. Additionally, the number of string holes 59 can be varied to produce different string arrangements or numbers of main string segments 52 and cross string segments 54 resulting in different string patterns. Referring to FIG. 3, the inner and outer peripheral walls 24 and 26 of the head portion 18 can define a maximum beam height distance d measured from a forward hoop surface 25 to a rearward hoop surface 27. In one implementation, the maximum beam height distance d is at least 19 mm. In other implementations, the maximum beam height distance d can be at least 20 mm. In other implementations, the maximum beam height distance d can be at least 21 mm. In still other implementations, the maximum beam height distance d can be at least 22 mm.

[0222] Referring to FIGS. 1 through 3, the main and cross string segments 52 and 54 refer to the portions of the racquet string that make up the string bed 14. The string bed 14 extends about and generally defines a string bed plane 56 (or a first plane). The string bed plane (or first plane) 56 extends through the longitudinal axis 16. A second plane 58, perpendicular to the sting bed plane (or the first plane) 56, also extends through the longitudinal axis 16. The sting bed plane 56 exists on a racquet whether it is strung or unstrung.

[0223] Conventional tennis racquets are typically formed of fiber composite material and / or aluminum, and are typically formed to be stiff structures that resist deflection about the longitudinal axis of the racquet. A stiff racquet construction is generally considered to be desirable because it is believed to improve the power and / or control of the racquet. Conventionally, the stiffness of a racquet generally refers to the racquet's resistance to bending along the longitudinal axis of the racquet and with respect to the string bed plane in a forward / rearward direction with respect to the string bed. Racquet stiffness is typically measured in a forward / rearward bending test (or a racquet stiffness test) wherein the handle portion of the racquet is fixedly secured in a test fixture with the string bed (and the string bed plane) positioned generally horizontal to the ground, a load is applied to the distal region of the head portion in a direction that is perpendicular to the string bed plane. The load causes the racquet to bend, flex or deflect with respect to the longitudinal axis and the string bed plane. The amount of deflection is measured to ascertain the stiffness level of a racquet.

[0224] High quality racquets are also typically designed to provide high levels of torsional stability. A torsionally stable racquet resists rotational movement of the head portion of the racquet upon an off-center impact with a tennis ball which improves the control of the racquet. Accordingly, conventional racquet design seeks to produce racquets with high levels of racquet stiffness and torsional stability at a predetermined racquet weight or weight range.

[0225] The shape and geometry of the head portion 18 and the throat portion 22 of the frame 12 of the racquet 10 also contributes to the racquet's stiffness level and / or torsional stability. For example, racquets with high racquet beam heights are generally stiffer than racquets with lower racquet beam heights. The shape and geometry of the throat tubes 42 and 44 can also affect the stiffness of the racquet.

[0226] As used herein, the term "fiber composite material" or "composite material" refers to a plurality of fibers within and permeated throughout a resin. The fibers can be co-axially aligned in sheets, layers or plies, or braided or weaved in sheets or layers, and / or chopped and randomly dispersed in one or more layers. A single ply typically includes hundreds or thousands of fiber bundles that are initially arranged to extend coaxially and parallel with each other through the resin that is initially uncured. Each of the fiber bundles includes a plurality of fibers. The fibers are formed of a high tensile strength material such as carbon. Alternatively, the fibers can be formed of other materials such as, for example, glass, graphite, boron, basalt, carrot, Kevlar ®< , Spectra ®< , poly-para-phenylene-2, 6-benzobisoxazole (PBO), hemp, flax, other natural fibers and combinations thereof. In one set of preferred implementations, the resin is preferably a thermosetting resin such as an epoxy or a polyester resin. In other sets of preferred implementations, the resin can be a thermoplastic resin. The composite material is typically wrapped about a mandrel and / or a comparable structure, and cured under heat and / or pressure. While curing, the resin is configured to flow and fully disperse and extend throughout the matrix of fibers. In multiple layer or ply constructions, the fibers can be aligned in different directions with respect to the longitudinal axis 16, and / or in braids or weaves from layer to layer.

[0227] Referring to FIG. 4A, a portion of a layer 60 of fiber composite material is illustrated. The layer 60 is formed by one or two plies 62 (62a and 62b) of fiber composite material. A ply 62 of fiber composite material refers to an arrangement of fibers 64 and fiber bundles 66 in a resin 68, wherein the fibers 64 and the fiber bundles 66 are arranged and aligned such that the fibers 64 and the fiber bundles 66 generally extend coaxially with respect to each other and are generally parallel to one another. The fibers 64 or fiber bundles 66 are preferably formed such that they extend along the ply 62 and form generally the same angle with respect to an axis, such as a composite axis 70. The plies 62 are typically identified, at least in part, by the size and polarity of the angle defined by the fibers 64 or fiber bundles 66 with respect to the axis 70. As shown in FIG. 4A, the ply 62a has fibers 64 and fiber bundles 66 aligned at a positive 45 degree angle ply, and the ply 62b has fibers 64 and fiber bundles 66 aligned at a negative 45 degree angle ply. In other implementations, the plies 62 can include fibers 64 or fiber bundles 66 defining a positive 30 degree angle ply, a negative 30 degree angle ply, a positive 45 degree angle ply, a negative 45 degree angle ply, a positive 40 degree angle ply, a negative 40 degree angle ply, a positive 35 degree angle ply, a negative 35 degree angle ply, a 90 degree angle ply (extending perpendicular to the axis), and a 0 degree angle ply (or extending parallel to the axis). Other positive or negative angles for plies can also be used. Accordingly, in the present application, a single ply 62 refers to a single layer of fiber composite material in which the fiber bundles 66 extend in substantially the same direction with respect to a longitudinal axis along the single layer, such as plus or positive 45 degrees or minus or negative 30 degrees. A layer 60 formed of a pair of plies 62 having fibers 64 of generally the same angle but arranged with opposite polarities is also referred to a ply arrangement. This pattern typically extends throughout a fiber composite material. The alternating angular arrangement of the fiber bundles 66 and fibers 64 is important to achieving and maintaining the structural integrity of the component or structure being formed of the fiber composite material. The overlapped region of the two plies 62a and 62b can be essential for ensuring that, once cured, the fiber composite material has the desired strength, durability, toughness and / or reliability.

[0228] During heating / molding and curing, the resin 68 can flow between plies 62 and within the fiber bundles 66. The plies 62 preferably typically have a thickness within the range of 0.002 to 0.015 inch. In other implementations, other thickness ranges can also be used.

[0229] Referring to FIG. 4B, in other implementations, one or more of the layers 60 can include a plurality of braided fibers 62c. The braided fibers 62c can extend at angles with respect to the lay-up axis 70 of at least 35 degrees with positive and negative polarities. In other implementations, the braided fibers 62c can extend at angles with respect to the lay-up axis 70 of at least 40 degrees (with positive and negative polarities).

[0230] Tennis racquets similar to racquet 10 described above are often formed with a lay-up of multiple discrete individually cut fiber composite pieces which are placed directly upon a mandrel, wherein the mandrel is subsequently removed to form a hollow fiber composite tube. The hollow fiber composite tube is then positioned within a mold where the discrete fiber composite pieces are fused / cured to form the frame of the tennis racquet. However, as described above, this process of placing discrete fiber composite pieces directly upon a mandrel is tedious, time-consuming and error prone.

[0231] In contrast, racquet 10 is formed by one of various below described methods which avoid or reduce an extent to which discrete individually cut fiber composite pieces need to be placed directly upon the mandrel. In contrast to typical racquet fabrication processes, racquet 10 is formed by one of various below described methods in which a sheet is wound or rolled about a centerline or about a mandrel. The use of the rolled sheet (1) may reduce manufacturing time, complexity and cost by reducing the number of, or eliminating the need for, individually cut fiber composite pieces and / or (2) may reduce manufacturing variability and error by assisting in ensuring that fiber composite layers and / or fiber composite pieces are more consistently and more accurately positioned and oriented when the racquet is being formed. It has been further discovered that in some implementations, racquet 10 formed from one of the various below described methods may have a more unitary construction that may offer enhanced stiffness characteristics and / or torsional stability.

[0232] Figure 5 is a flow diagram of an example method 200 for forming a fiber composite racquet, such as racquet 10. As should be appreciated, method 200 may likewise be used to form other tennis racquets having other shapes or dimensions. Method 200 may be used to form other sports racquets such as those used for badminton, squash, racquetball, pickle ball, table tennis, padel and the like.

[0233] As indicated by block 204, fiber composite layer pieces are placed or positioned on a sheet. Figure 6 illustrates an example lay-up 300 of individual, discrete pieces ready to be placed upon an example sheet 304. Lay-up 300 may comprise both fiber composite pieces and non-fiber composite pieces. Each fiber composite piece comprises a fiber composite layer. The fiber composite layer may comprise a fiber composite ply arrangement formed by a pair of adjacent plies having different fiber composite ply angles. In some implementations, the fiber composite layer may comprise a fiber composite ply arrangement formed by a pair of adjacent plies having a plus / minus (+ / -) fiber composite ply arrangement angle. An example of such fiber composite ply arrangement is shown in Figure 4A.

[0234] In the example illustrated, at least one of the fiber composite pieces has a longitudinal length L (which is to extend parallel to the axis about which sheet 304 is to be rolled) that is sufficiently long so as to extend along an entire perimeter of the head portion of the racquet. In some implementations, the length is sufficiently long so as to additionally form or extend along each of the beams of the throat portion of the racquet. In some implementations, length is sufficiently long so is additionally form or extend along at least portions of, if not the entirety of, the handle portion of the racquet 10 when formed. This length of the at least one fiber composite piece provides continuous uninterrupted fiber strength or fiber reinforcement along the length while serving as a continuous substrate, foundation or base along which and to which other, potentially shorter, pieces (whether fiber composite pieces or non-fiber composite pieces) may be secured, fused or cured.

[0235] In some implementations, at least some of the discrete pieces of lay-up 300 may omit fibers or may not comprise a fiber composite composition. For example, a piece may be a cut homogenous polymeric panel or a panel formed from multiple different polymeric layers. In some implementations, the non-fiber composite composition of the piece may be used to establish a desired weight or weight distribution or desired particular dimensions for particular portions of the racquet.

[0236] In the example shown in Figure 6, lay-up 300 comprises discrete fiber composite pieces 320-1, 320-2, 320-3, 320-4, 320-5, 320-6, 320-7, 320-8, 320-9 and 320-10 (collectively referred to as pieces 320) and non-fiber composite pieces 322-1 and 322-2 (collectively referred to as pieces 322). In the example illustrated, each of pieces 320 comprises a fiber composite ply arrangement, a pair of individual plies of opposite polarity (+ / composite ply angles or orientations). For example, fiber composite piece 320-1 comprises a layer formed by a first ply having a +30° fiber orientation and a second adjacent ply having a -30° fiber orientation. Similarly, pieces 320-2, 320-3, 320-5, 320-6, 320-7, 320-9 and 320-10 each comprise a layer comprising a ply arrangement comprising pair of adjacent plies having a + / - 30° fiber composite ply arrangement angle. Fiber composite piece 320-4 comprise a composite ply arrangement having a + / -45° angle or orientation. Fiber composite piece 320-8 comprises a ply arrangement having a 0 / 90 ply arrangement angle, wherein one ply is at 0° and the other ply is at 90°. As should be appreciated, other arrangements of pieces 320 including other numbers of pieces 320, other lengths of pieces 320, other widths of pieces 320, other shapes of pieces 320, other fiber angle values of pieces 320, other sequences of pieces, and combinations thereof are contemplated. The number of pieces 322 used to form a frame 12 can be within the range of 2 to 150. In a preferred implementation, the number of pieces 322 used to form the frame 12, or the head portion 18 and throat portion 22 thereof, is at least 10 plies. In other implementations, other numbers of pieces or other numbers of composite ply arrangements can be used.

[0237] In the example illustrated, pieces 320-1, 320-4, 320-9 and 320-10 each have a length (measured in a direction parallel to the axis about which sheet 304 is rolled) generally extending along an entire length of the lay-up 300, a length near or equal to the width of sheet 304. In some implementations, the length of the high angle layers (at least 35 degree angle layers, at least 40 degree angle layers, or at least 45 degree angle layers) extend over at least 40 percent of the total length of the lay-up the head portion 18 of the racquet 10. In other implementations, the length of the high angle layers extend over at least 50 percent of the total length of the lay-up the head portion 18 of the racquet 10. In other implementations, the length of the high angle layers extend over at least 70 percent of the total length of the lay-up the head portion 18 of the racquet 10. In some implementations, the length of the layers 60 or ply arrangements can be sufficiently long such that, when molded and cured, the high angle layers (at least 35 degree angle layers, at least 40 degree angle layers, or at least 45 degree angle layers) extend over at least the head portion 18 of the racquet 10. In other implementations, the length of the pieces 320 or ply arrangements can be sufficiently long such that, when molded and cured, the high angle layers (at least 35 degree angle layers, at least 40 degree angle layers, or at least 45 degree angle layers) extend over at least the head portion 18 and the throat portion 22 of the racquet 10.

[0238] In some implementations, at least 50 percent of the pieces 320 of a of lay-up 300 are be formed with carbon fibers. In another implementation, at least 75 percent of the pieces 320 in lay-up 300 can be formed of carbon fibers. In one implementation, each of the high angle layers (at least 35 degree angle layers, at least 40 degree angle layers, or at least 45 degree angle layers) in the lay-up 300 include a resin and have a fiber area weight of at least 100 g / m2. In another implementation, each of the high angle pieces fiber composite (at least 35 degree angle layers, at least 40 degree angle layers, at least 45 degree angle layers, or at least 60 degrees) in the lay-up 300 include a resin and have a fiber area weight of at least 120 g / m2.

[0239] Non-fiber composite pieces 322 comprise pieces formed from one or more layers of non-fiber or fiber embedded materials. Non-composite five pieces 322 may comprise one or more layers of polymeric material or materials (thermoplastic or thermoset), may comprise a polymer resin encapsulating fibers which are not oriented (randomly oriented) or may comprise metal layers or films, such as iron. In some implementations, layer 300 may comprise a fewer greater number of such non-fiber composite pieces or pieces 322 may be omitted.

[0240] In one implementation, sheet 304 is a ply arrangement of fiber composite material that serves as a table or platform upon which each of the pieces 320, 322 of layer 300 may be positioned and secured prior to rolling of sheet 304. Sheet 304 facilitates inspection to ensure that all of the pieces 320, 322 designated for the racquet 10 have been included prior to the pieces forming the fiber composite tube used to form racquet 10. Rather than the individual discrete pieces being wrapped about the mandrel and stacked on top of one another where such pieces may be placed at the wrong angles, out of order or completely omitted, a human assembler or a computer vision inspection system (trained to inspect sheets 304 with the positioned pieces 320, 322 of lay-up 300 prior to rolling of the sheet 304) can easily view and inspect the assembled lay-up 300 on sheet 304 prior to rolling of sheet 304.

[0241] Sheet 304 may comprise a thin sheet of fiber composite material including fibers extending at a predetermined angle and a resin or polymer (thermoset or thermoplastic) material. In some implementations, sheet 304 is formed from the same fiber composite material as contained in the fiber composite pieces 320. Sheet 304 may have a thickness sufficient to withstand rolling about a centerline or rolling about a mandrel, yet thin enough so as to not substantially alter the dimension or construction of the roll fiber composite tube used to form racquet 10. Sheet 304 has a length L so as to extend at least 720° about the axis 331 of mandrel 330 (at least two revolutions) when rolled or wound about mandrel 330. Sheet 404 has a width W (measured in a direction parallel to axis 331 of mandrel 330 when rolled or parallel to the centerline about which sheet 304 is rolled) sufficiently long so as to extend along an entire perimeter of the head portion of the racquet. In some implementations, the length is sufficiently long so as to additionally form or extend along each of the beams of the throat portion of the racquet. In some implementations, length and sufficiently long so is additionally former extend along at least portions of, if not the entirety of, the handle portion of the racquet 10 when formed. This length of sheet 304 provides continuous uninterrupted fiber strength or fiber reinforcement along the length of rolled tube.

[0242] As further shown may Figure 6, in some implementations, sheet 304 may include windows or openings 307 which completely extend through sheet 304 and are completely surrounded by other portions of sheet 304. Such openings 307 may be provided on sheet 304 in regions where pieces 320-322 are not being supported to reduce cost and weight of the resin or other material of sheet 304. In some implementations, such multiple opening 307 may be provided between each location where a piece 320, 322 is to be supported by sheet 304. In some implementations, at least some of the openings 310 located between consecutive piece supporting portions of sheet 304 (and between pieces 320, 322 when positioned on sheet 304) may connect to one another. In some implementations, such openings 310 may continuously surround piece supporting "islands" 311 provided by sheet 304, wherein each of such islands 311 of sheet 304 are sized and shaped to support a piece 320, 322 and wherein such islands are connected to one another and to a remaining solid portion of sheet 304 by connecting bridges 313 such that all of the "islands" 311 supporting pieces 320, 324 are interconnected by the remaining portions of sheet 304 when sheet 304 is rolled about mandrel 330.

[0243] As further shown by Figure 6, in some implementations, sheet 304 may be perforated throughout to reduce its weight, wherein such perforations 309 are sized and shaped such that an overlying piece 320, 322 may still be supported over such perforations. So long as sheet 304 is sufficiently strong to support pieces 320, 322 and be wrapped about mandrel 330 without tearing, perforations 309 may be as large as possible or may be highly concentrated to reduce the added weight of sheet 304. In some implementations, the size of the perforations, the shape of the perforations or the concentration of perforations in different regions of sheet 304 may vary. For example, the number, concentration or size of perforations may be reduced in those particular regions of sheet 304 where sheet 304 may be subject to tearing during rolling. In the example illustrated, regions sheet 304 which are to underlie a piece 320, 322 may have larger size perforations and / or a greater concentration of perforations to enhance weight reduction and to potentially facilitate a greater degree of fusing or curing between adjacent overlapping pieces 320, 322 during curing or fusing of the rolled tube when forming the racquet. An example of this is shown in Figure 6 with respect to those regions to receive pieces 320-1, 320-6 and 320-7.

[0244] As shown in Figure 6, sheet 304 may have formed thereon markings 326-1, 326-2, 326-3, 326-4, 326-5, 3286-6, 326-7, 326-8, 326-9, 326-10, (collectively referred to as markings 326) and markings 328-1 and 328-2 (collectively referred to as markings 328). Markings 326, 328 may each have a size and shape identifying or matching that of the particular piece 320, 322 that is to be received at the location of the marking. In some implementations, the markings 326, 328 may additionally include alphanumeric markings 329 or other graphics 335 (examples of which are shown) which further identify the particular piece to be positioned at the location of the particular marking. Each of such markings may further be provided with an orientation for the particular piece. Markings 328 may be printed upon a face of sheet 324. Markings 326, 328 further assist in the positioning or placement of the pieces 320, 322 of layer 300 on sheet 304 prior to the rolling of sheet 304. Such placement may be performed in a manual fashion with a human operator or may be performed with robotic system using robotic vision.

[0245] Referring to Figure 5, once the pieces have been placed or positioned on a sheet, such as sheet 304, the sheet 304 is rolled about a mandrel as indicated by block 208. The rolling creates a two-dimensional in some implementations, the rolling forms a two-dimensional spiral (non-helical) cross-section of windings or portions wrapped about the mandrel 330. In some implementations, the rolling may have movement along a longitudinal axis of the mandrel so as to form a three-dimensional spiral, helical spiral about the mandrel.

[0246] Figure 6 illustrates an example mandrel 330 about which sheet 304 and the positioned pieces 320, 322 may be rolled as indicated by arrows 337 and 339. In some implementations, as shown by broken lines, the mandrel 330 may be coated with a no-stick film or layer or may be enclosed with a thin bladder 332 prior to rolling of sheet 304 about mandrel 330. Because the individual pieces 320, 322 of lay-up 300 are secured in place upon the surface of 304, the individual pieces 320, 322 are likewise wrapped or rolled. In implementations where the mandrel is enclosed within a bladder 332 prior to rolling, a vacuum may be applied to bladder 332 to form a tight fit between bladder 332 and the internally received mandrel 330.

[0247] As indicated by block 212 in Figure 5, following rolling the sheet about the mandrel 330, the overlapping portions (or windings) of the rolled sheet 304 (and the secured pieces 320, 322) are fused while the rolled sheet a sheet and a loop to form at least a head portion of the fiber composite racquet being performed, such as racquet 10. Such shaping may be carried out with the assistance of a mold which may then apply heat and pressure for a predefined period of time to facilitate fusing of the overlapping portions of the roll sheet. In implementations where the resin supporting the oriented fibers is a thermoset material, such fusing may be in the form of curing of the resin.

[0248] Figures 6-9 illustrate one example process or method by which the rolled sheet resulting from block 208 may be shaped and fused to form the head portion, the throat portion and portions of the handle portion of fiber composite racquet 10. Referring to FIG. 7, when the sheet 304 and the carried pieces 320, 322 are rolled about the mandrel 330 (over the bladder 332), the pieces 320, 322 are no longer arranged in a flat sheet, and therefore, the fiber bundles 66 and fibers 64 (shown in Figure 4A) no longer follow or define generally parallel lines. Rather, the fiber bundles 66 and fibers 64 are adjacent to one another, and are curved or otherwise formed so that they follow substantially the same adjacent paths. For example, when sheet 304 is rolled about the bladder 76 and the mandrel 74, pieces 320, 322 can take a generally cylindrical or tubular shape and the fiber bundles 66 and fibers 64 can follow the same cylindrical path or define a helical path (depending upon their angle within the ply arrangement). The fibers 64 remain adjacent to one another, are aligned with each other and follow substantially similar paths that are essentially parallel (or even co-axial) for example, when viewed in a sectional view in a single plane or other small finite segment of the plies of the piece 320.

[0249] In one implementation, the mandrel 330 may include a pull tab 338 for facilitating the pulling or removal of the mandrel 330 from the rolled sheet 304 and pieces 320, 322 wrapped about the bladder 332 and the mandrel 330. The lay-up 300 of FIG. 6 is uncured. In one implementation, the mandrel 330, using the pull tab 338, can be drawn, pulled or otherwise removed from the bladder and the lay-up 300.

[0250] Referring to FIGS. 8 and 9, once the mandrel 330 is removed from the bladder 332 and the rolled sheet 304 with lay-up 300, the rolled sheet 304 and the uncured lay-up 300 can be gently positioned into the shape of a racquet frame. An uncured yoke 350 of fiber composite material can be prepared for positioning next to the curved sheet 304 and lay-up 300. As shown in FIG. 9, the lay-up can be shaped to resemble a racquet frame, and the yoke 350 can be attached to the rolled sheet 304 and lay-up 300. In one implementation, additional relatively short ties or tying plies can be applied over the connection points of the yoke 350 to the roll sheet 300. In other implementations, the yoke may be replaced with a preformed yoke structure that is added attached to the rolled sheet 304 and lay-up 300 prior to molding.

[0251] Referring to FIG. 10, the uncured rolled sheet 304 with the internally wound pieces 320, 322 of lay-up 300 and the uncured yoke 350 is positioned within a mold cavity 388 of a racquet forming mold 390. A supply line 386 can be attached to the bladder 332 for supplying air or other gas to the bladder, and the pieces of the racquet forming mold 90 can be positioned around the lay-up 80 and the yoke 84. The bladder 76 can be pressurized by air or other gas to a predetermined pressure, and the racquet forming mold 90 can then be heated in an oven or furnace to a predetermined temperature. Once subjected to heat and pressure, the viscosity of the resin 68 in the lay-up 80 and the yoke 350 drops and the resin 68 (shown in Figure 4A) flows through out the plies of pieces 320 of the lay-up 300 and yoke 350 in the mold cavity 388 creating a more uniform structure and the fibers 64 are positioned into the shape of the mold cavity. After a first predetermined amount of time, the racquet forming mold 390 is removed from the heat and the rolled sheet 304 with lay-up 350 and yoke 350 are allowed to cool. After a second pre-determined amount of time, the racquet forming mold 390 is opened and the racquet frame 12 is removed from the mold 390. The frame 12 of the racquet 10 can have a weight within the range of 260 gm to 355 gm. In other implementations, the frame of the racquet can have a weight outside of the 180 gm to 370 gm range.

[0252] Figure 11 is a flow diagram illustrating an example method 400 that may be used to form the example racquet 10 described above or other sports racquets. As indicated by block 408, a fiber composite sheet is rolled about a mandrel. Figures 12 and 13 illustrate an example fiber composite sheet 404 prior to and after being rolled about mandrel 330, respectively. As with the method shown in Figure 6, in some implementations, the mandrel 330 may be enclosed within an inflatable bladder 332 (shown in broken lines). In some implementations, inflatable bladder 332 may be omitted.

[0253] The fiber composite sheet 404 comprises a panel or sheet of a fiber composite material, such as the fiber composite material shown and described above in Figure 4A or 4B. Sheet 404 has a length L so as to extend at least 720° about the axis 331 of mandrel 330 (at least two revolutions) when rolled or wound about mandrel 330. Sheet 404 has a width W (measured in a direction parallel to axis 331 of mandrel 330 when rolled or parallel to the centerline about which sheet 404 is rolled) sufficiently long so as to extend along an entire perimeter of the head portion of the racquet. In some implementations, the length is sufficiently long so as to additionally form or extend along each of the beams of the throat portion of the racquet. In some implementations, length and sufficiently long so is additionally former extend along at least portions of, if not the entirety of, the handle portion of the racquet 10 when formed. This length of sheet 404 provides continuous uninterrupted fiber strength or fiber reinforcement along the length of rolled tube shown in Figure 13.

[0254] Although sheet 404 is illustrated as a rectangular sheet without openings or perforations, in other implementations, sheet 404 may have other shapes and / or may include openings or cut outs. For example, as shown by broken lines in Figure 12, in some implementations, fiber composite sheet 404 may have snipped corners 405, one or more notches 406 or may include windows or openings 407. Such corners, notches or openings may be cut from sheet 404 prior to rolling. Such corners, notches or openings may be via locations where fiber strength is less of a priority or where less stiffness or greater flexibility is desired. In the example illustrated, Windows 407 may be symmetrically provided applications corresponding to the throat portions of the racquet, such as the throat portions of racquet 10 described above where less stiffness may be desired.

[0255] Figure 13 illustrates sheet 404 after being rolled about mandrel 330 with the overlying bladder 332. Before molding and curing, the fiber composite material has a natural tacky state such that the two-dimensional spiral roll maintains its rolled configuration. At such time, mandrel 330 may be withdrawn as described above and the two formed by the roll sheet 404 may be shaped as shown in Figure 8 and nine in place in the mold shown in Figure 10 to form the frame of the racquet. In some implementations where the racquet is to include a yoke, the yoke insert 350 described above may be further positioned within the mold390 in Figure 10 as described above.

[0256] Figures 14 and 15 illustrate an example method by which the yoke 350 shown in Figures 8 and 9 may be formed in a similar fashion. As shown by Figure 14, yoke 350 may be formed from a fiber composite sheet 504 which is to be rolled body centerline, such as about a mandrel 530. In some implementations, mandrel 533 is removed resulting in a hollow tube forming yoke 350. In other implementations, mandrel 530 is not removed, forming a core filling the otherwise hollow interior of the rolled yoke 350. Mandrel 530 may be a bendable or flexible piece configured to be bent into the shape of yoke 350 when placed in mold 390. In some implementations, mandrel 530 may comprise a foam piece about which sheet 504 is rolled. In other implementations, yoke 350 may have a non-circular cross-section and / or may be formed from other materials.

[0257] Sheet 504 has a length L sufficient long so as to wrap or extend about mandrel 530 by at least 720° (two revolutions). Sheet 504 has a width W corresponding to the length of yoke 350. In the example illustrated, sheet 504 is further shaped so as to form tie-ins 511. Tie-ins 511 comprise projections extending from a body of sheet 504, wherein the tie-ins are configured to facilitate enhanced connection of the yoke 350 to the throat portion of the racquet formed by sheet 404.

[0258] As indicated by arrow 513, mandrel 530 may be rolled or sheet 504 may be rolled about the centerline or axis 331 of mandrel 530. Such rolling occurs in the direction indicated by arrow 515. Figure 15 illustrates the rolled sheet 504 and the internal mandrel 530. Once formed, yoke 350 may be incorporated into the racquet as described above with respect to Figures 8-10. As should be appreciated, 350 may be omitted in sports racks where yoke is not provided or the racquet may not include throat portion. As should further be appreciated, the yoke shown in Figure 15 may be utilized as a yoke in racquet 10 or other racquets regardless of how the head portion, the throat portion (when provided) and the handle portion are formed. For example, the yoke shown in Figure 15 may be utilized as a yoke in current conventionally formed racquets independent of whether the remaining portions of such racquets are formed pursuant to the methods of this disclosure.

[0259] Referring to Figure 11, as indicated by block 412, following rolling the sheet about the mandrel 330, the overlapping portions (or windings) of the rolled sheet 404 are fused while the rolled sheet is shaped to form a loop to form at least a head portion of the fiber composite racquet being performed, such as racquet 10. Such shaping may be carried out with the assistance of a mold (as shown in Figures 8-10) which may then apply heat and pressure for a predefined period of time to facilitate fusing of the overlapping portions of the roll sheet. In implementations where the resin supporting the oriented fibers is a thermoset material, such fusing may be in the form of curing of the resin.

[0260] Figure 16 is a sectional view of an implementation of racquet 10 formed pursuant to method 400. Figure 16 is a sectional view of a head portion of racquet 10 taken along line 16-16 of Figure 1. As shown by Figure 16, in the example illustrated, the mold forms an outer recessed channel 57 in the rolled tube formed by sheet 404. After molding and curing of the assembly, string openings 59 may be drilled or otherwise formed in the rolled tube formed by sheet 404.

[0261] Figure 17 is a sectional view of an implementation of racquet 10 formed pursuant to method 400. Figure 17 is a sectional view of a throat portion of racquet 10, taken along line 17-17 of Figure 1. As shown by Figure 17, throat portion has a hollow interior or void 61. As indicated by broken lines, in some implementations, the hollow or otherwise empty void 61 may be filled with a filler 73. In some implementations, filling material may be a foam material. In some implementations, filling window may be injected into the void 61 through a fill port 75 which may be drilled and subsequently filled or closed. In some implementations, the fill ports and five may be omitted where or 61 is filled through an open end of the tube formed by sheet 404.

[0262] Figure 18 is a sectional view of an implementation of racquet 10 formed pursuant to method 400. Figure 18 is a sectional view of a handle portion of racquet 10, taken along line 18-18 of Figure 1. As shown by Figure 18, to end portions of the rolled tube formed by sheet 404 are shaped in mold 390 such that the mutually facing in her surfaces 490 of the two about one another and fuse or joined to one another. In the example illustrated, mold 390 further provides the outer facing surfaces of the end portions of the tube formed by the rolled sheet 404 with an octagon shaped outer profile 492. Each of the end portions of the tube have hollow interiors 63. During molding, pressurized air or other gas may be provided into the bladder 332 to force the end portions of the tube against the sheet forming surfaces of mold 390, producing interiors 63. As shown by broken lines, in some implementations, the otherwise hollow interior void 63 may be filled with a filler 73. The filler 73 may be the same or different than that of the filler, if applied, in void 61. The filler 73 may be a foam cereal or a foaming material. The filler 73 may be injected through end portions of the bladder 332 or end portion of the tube formed by the rolled sheet 404. In some implementations, filler 73 and / or filler 73 may be injected or otherwise provided to void 61 and / or void 63 prior to shaping of the tube or prior to the fusing step of block 412 (following movable of the mandrel 330).

[0263] Figure 19 illustrates an alternative shaping of the tube formed by the rolled sheet 404 and an alternative configuration of handle portion 20 of racquet 10. In figure 19 is a sectional view of an implementation of racquet 10 formed pursuant to method 400. Figure 19 is a sectional view of handle portion 20 of racquet 10, taken along line 18-18. As shown by Figure 19, the two end portions of the tube formed by the rolled sheet 404 are substantially collapsed to form a pair of hairpins 77. Thereafter, a pallet 79 may be formed around the hairpins 77 form handle portion 20. The pallet may be formed from a foam material or other materials. In other implementations, the handle portion 20 may be formed in other fashions.

[0264] As with each of Figures 16-19, it should be appreciated that certain portions are omitted for ease of illustration. For example, additional outer coatings, lacquers, paint, varnishes or other materials are not shown. With respect to Figures 18 and 19, additional outer wrappings forming the grip or cushioning layers are omitted.

[0265] Figure 20 is a flow diagram of an example method 600 for forming a sports racquet, such as the example supports racquet 10. Method 600 is similar to method 200 described above. Sheet 600 that is rolled about the mandrel is a fiber composite sheet. As result, the sheet 704 itself forms the continuous unitary fiber structure along the length of the rolled tube that is to form the racquet. As result, each of the discrete pieces of fiber composite material or non-fiber composite material may have lengths less than the length of the rolled tube that is to form the racquet. As indicated by block 608, a fiber composite sheet is rolled about a mandrel. Figure 21 illustrates an example fiber composite sheet 704 prior to being rolled about mandrel 330 received within bladder 332. Sheet 704 may have the same fiber composite composition as described above with respect to fiber composite sheet 404. Sheet 704 also has a length and width as described above with respect to sheet 304. In some implementations, sheet 704 may include any of the perforations or openings described above with respect to sheet 304. In some implementations, sheet 704 may omit openings 307, perforations 309, and / or island forming openings 310 which are optionally provided in the sheet 304. Although illustrated as a rectangle, sheet 704 may have other shapes.

[0266] As indicated by block 610 in Figure 20, a layer (at least one layer) is sandwiched between overlapping portions of the rolled fiber composite sheet. The sandwiching of the layer occurs during the rolling of the sheet 704 as shown in Figure 22. To facilitate such sandwiching, the layer is positioned on or formed upon a surface of sheet 704 prior to such rolling. In the example illustrated, a lay-up 700 of discrete fiber composite pieces and non-fiber composite pieces are positioned upon sheet 704 prior to sheet 704 being rolled.

[0267] In the example illustrated, lay-up 700 comprises fiber composite pieces 720-1, 720-2, 720-3, 720-4, 720-5, 720-6 (collectively referred to as pieces 720) and non-fiber-composite piece 720-7. In the example illustrated, each of pieces 720 comprises a fiber composite ply arrangement, a pair of individual plies of opposite polarity (+ / -composite ply angles or orientations). For example, fiber composite pieces 720-1 and 720-2 may each comprise a layer formed by a first ply having a +30° fiber orientation and a second adjacent ply having a -30° fiber orientation. Likewise, pieces 720-3 and 720-4 may each comprise a layer formed by a first ply having a +30° fiber orientation and a second adjacent ply having a -30° fiber orientation. However, because piece 721-1 and 720-2 are positioned on sheet 704 at a different angle as compared to sheet 720-3 and 720-4, pieces 720-1 and 729-2 have a different resulting + / - fiber oriented paired to pieces 720-3 and 720-4. Pieces 720-5 720-6 each have + / - 45 degree angle and have different shapes as compared to the other pieces which are rectangular.

[0268] Non-fiber composite piece 722 comprises a discrete piece formed from one or more layers of non-fiber or fiber embedded materials. Non-fiber composite pieces 722 may comprise one or more layers of polymeric material or materials (thermoplastic or thermoset), may comprise a polymer resin encapsulating fibers which are not oriented (randomly oriented) or may comprise metal layers or films, such as iron. In some implementations, lay-up 700 may comprise a fewer or greater number of such non-fiber composite pieces or piece 722 may be omitted.

[0269] As shown in Figure 21, sheet 704 may have formed thereon markings 726-1, 726-2, 726-3, 726-4, 726-5, 726-6, (collectively referred to as markings 726) and marking 727. Markings 726, 727 may each have a size and shape identifying or matching that of the particular piece 720, 722 that is to be received at the location of the marking. In some implementations, the markings 726, 727 may additionally include alphanumeric markings 729 or other marking graphics 735 (examples of which are shown) which further identify the particular piece to be positioned at the location of the particular marking. Each of such markings may further be provided with an orientation for the particular piece. Markings 726, 727, 729 and 735 may be printed upon a face of sheet 704. Markings 726, 727, 729 and 735 further assist in the positioning or placement of the pieces 720, 722 of lay-up 700 on sheet 704 prior to the rolling of sheet 704. Such placement may be performed in a manual fashion with a human operator or may be performed with robotic system using robotic vision. Because sheet 704 is uncured, sheet 704 is inherently tacky or sticky state to retain each of the pieces 720, 722 once placed.

[0270] As shown by Figure 22, once the pieces 720, 722 have been placed or positioned on sheet 704, the sheet 704 is rolled about a mandrel as indicated by block 608. The rolling creates a two-dimensional spiral (non-helical) cross-section of windings or portions wrapped about the mandrel 330. In some implementations, the rolling may have movement along a longitudinal axis of the mandrel so as to form a three-dimensional spiral, helical spiral about the mandrel.

[0271] As indicated by block 612 in Figure 20, following the rolling of the sheet 704 with the pieces 720, 722 about the mandrel 330, the overlapping portions (or windings) of the rolled sheet 304 (and the secured pieces 320, 322) are fused while the rolled sheet is shaped to form a loop to form at least a head portion of the fiber composite racquet, such as racquet 10. Such shaping may be carried out with the assistance of a mold 390 which may then apply heat and pressure for a predefined period of time to facilitate fusing of the overlapping portions of the roll sheet. In implementations where the resin supporting the oriented fibers is a thermoset material, such fusing may be in the form of curing of the resin. In some implementations, the tube formed by the rolled sheet 704 may be shaped and molded, and combined with yoke 350, as shown in Figures 6-10.

[0272] Figures 23, 24A and 24B illustrate an example method by which the yoke 350 shown in Figures 8 and 9 may be formed in a similar fashion. The method by which yoke 350 is formed in Figures 23 and 24 is similar to the method shown in Figures 14 and 15 except that the yoke formed in Figures 23 and 24 additionally comprises discrete pieces 820-1, 820-2, and 820-3.

[0273] As shown by Figure 23, yoke 350 may be formed from a fiber composite sheet 804 which is to be rolled about a centerline, such as about axis 731 of mandrel 530. In some implementations, mandrel 533 is removed resulting in a hollow tube forming yoke 350. In other implementations, mandrel 530 is not removed, forming a core occupying the otherwise hollow interior of the rolled yoke 350. Mandrel 530 may be a bendable or flexible piece configured to be bent into the shape of yoke 350 when placed in mold 390. In some implementations, mandrel 530 may comprise a foam piece about which sheet 804 is rolled. In other implementations, yoke 350 may have a non-circular cross-section and / or may be formed from other materials.

[0274] Sheet 804 has a length L sufficient long so as to wrap or extend about mandrel 530 by at least 720° (two revolutions). Sheet 804 has a width W corresponding to the length of yoke 350. In the example illustrated, sheet 804 is further shaped so as to form tie-ins 511. Tie-ins 511 comprise projections extending from a body of sheet 504, wherein the tie-ins are configured to facilitate enhanced connection of the yoke 350 to the throat portion of the racquet formed by sheet 704.

[0275] As further shown by Figure 23, sheet 804 may additionally include markings 826-1, 826-2 and 826-3 (collectively referred to as markings 826) which are located, size and oriented to indicate the designated positions for discrete pieces 820-1, 820-2 and 820-3, respectively. Markings 826 functions similar to markings 326, 328 and 726, 728 described above. Markings 826 may be printed upon a face of sheet 804. Markings 826, 828 assist in the positioning or placement of the pieces 820 on sheet 804 prior to the rolling of sheet 804. Such placement may be performed in a manual fashion with a human operator or may be performed with robotic system using robotic vision.

[0276] In some implementations, the resin or polymer of sheet 804 may be in a tacky or sticky state to retain each of the pieces 820 once placed. In some implementations, the surface of sheet 804 or a surface of the discrete pieces 820 may be provided with a thin adhesive film or layer to facilitate retention and securement once a piece 820 is placed upon sheet 804.

[0277] In some implementations, each of pieces 820 comprises a fiber composite piece, a piece having a fiber composite layer. In some implementations, the fiber composite layer may comprise a ply arrangement in the form of a pair of adjacent plies having opposite polarities. In some implementations, some of pieces 820 may comprise non-fiber composite pieces as described above. Although Figure 23 illustrates three discrete pieces eight, the yoke being formed in Figures 23 and 24 may alternatively comprise a greater or fewer number of such pieces. In some implementations, such pieces may be omitted.

[0278] As indicated by arrow 513, mandrel 530 may be rolled or sheet 704 may be rolled about the centerline or axis 331 of mandrel 530. Such rolling occurs in the direction indicated by arrow 515. Figure 15 illustrates the rolled sheet 504 and the internal mandrel 530. Once formed, yoke 350 may be incorporated into the racquet as described above with respect to Figures 8-10. As should be appreciated, 350 may be omitted in sports racks where yoke is not provided or the racquet may not include throat portion. As should further be appreciated, the yoke shown in Figure 15 may be utilized as a yoke in racquet 10 or other racquets regardless of how the head portion, the throat portion (when provided) and the handle portion are formed. For example, the yoke shown in Figure 15 may be utilized as a yoke in current conventionally formed racquets independent of whether the remaining portions of such racquets are formed pursuant to the methods of this disclosure.

[0279] Figure 25 illustrates another example of how a sports racquet, such as the tennis racquet 10 described above, may be formed pursuant to method 600 outlined in Figure 20. In the method shown in Figure 25 at least some of layers ultimately sandwiched between overlapping portion of the rolled composite fiber sheet 704 per block 610 are formed by folded over portions 924 of sheet 704 prior to sheet 704 being rolled about mandrel 330 (and bladder 332). The use of folded over portions of sheet 704 to form at least some of the layers that are alternately sandwiched between the roll sheet 704 further reduces manufacturing time, manufacturing labor, manufacturing cost, manufacturing complexity and manufacturing inconsistency. In addition, because at least some of the layers are formed by folded over portions 924 of the rolled sheet 704, the composition is more unitary. It has been found that, in some implementations, the resulting sports racquet may achieve enhanced torsional stability. In the example illustrated, the tube formed by the rolling of sheet 704 and the sandwiched layers comprises sheet 704, discrete pieces 920-1, 920-2, (collectively referred to as pieces 920), discrete pieces 922 and folded layers 924-1, 924-2, 924-3 and 924-4 (collectively referred to as layers 924).

[0280] Pieces 920 may be compositionally similar to pieces 720 described above. Pieces 920 may comprise a fiber composite layer which may comprise a fiber ply arrangement having adjacent plies of opposite polarity. Pieces 922 may be compositionally similar to piece 722 described above in that piece 722 comprises a non-fiber composite layer. The provision of pieces 920, 922 on sheet 704 prior to its rolling may provide greater design flexibility. For example, pieces 920, 922 may have material compositions different than that of sheet 704 and / or fiber composite orientation / angles / polarities that cannot be achieved through the selective folding of portions of sheet 704 to form folded layers 924. Moreover, pieces 920, 922 may provide additional sandwiched layers at locations where the option to provide a sandwiched folded layer may not be available due to adjacent or proximal portions of sheet 704 having already been cut and folded to form other folded, layers. As should be appreciated, the example numbers, size, shape and locations of pieces 920, 922 on sheet 704 may be different from the illustrated example.

[0281] As with sheet 704 in Figure 21, sheet 704 in Figure 25 may additionally comprise markings 926-1, 926-2 (collectively referred to as markings 926) and 927 that serve as indicia indicating designated positions and orientations for pieces 920-1, 920-2 and 922, respectively. Such markings 926, 927 may be printed upon sheet 704. For example, in some implementations, sheet 704 to be run through a printer which print such markings on a surface of sheet 704 prior to the cutting and folding of portions of sheet 704 to form folded layers 924 and prior to the rolling of sheet 704. In some implementations, markings 926, 927 may be omitted. In some implementations, markings 926, 927 as well as one or more of pieces 920, 922 may be omitted.

[0282] As further shown by Figure 25, in some implementations, sheet 704 may additionally comprise completely surrounded openings 906-1, 906-2 (collectively referred to as openings 906). Such openings 906 extend completely through sheet 704, wherein none of the edges of the openings 906 extend adjacent to or are bordered by a fold (in contrast to apertures 997). Such openings 906 may remove weight and stiffness from particular portions of the formed racquet without transferring weight or stiffness, in contrast to folded layers 924-3 and 924-4 which do shift weight and stiffness when forming apertures 997. Although not illustrated, in some implementations, sheet 704 may include edge notches or cutouts (similar to snipped corners 405 and / or notch 406 shown in Figure 11).

[0283] Folded layers 924 comprise portions of sheet 704 which have been folded over so as to overlap other portions of sheet 704 prior to the rolling of sheet 704. In some implementations, such folded portions may comprise perimeter edge portions, such as corners or side edges, which are folded inwardly. In the example illustrated, each of folded layers 924 is formed by partially cutting sheet 704 to partially separate those portions of sheet 704 which are to be folded over to form folded layers 924. As shown by Figure 25, portions of the fiber composite sheet 704 may be cut or severed while leaving such portions connected to a remainder of the fiber composite sheet along a fold 945, 955, 965 along which the portions are to be folded to form the layer 924.

[0284] The cut may have endpoints that guide the folding to form the layer. In some implementations, the cuts of such portions may have aligned end such that the portion is folded along a fold that is perpendicular to a centerline of the portion that was severed. In some implementations, the ends of the cuts of such portions may be offset such that the portion is folded along a fold 945, 955 that is oblique to a centerline of the portion that was severed. In such implementations, despite the unfolded partially severed portion having the same ply arrangement angle as that of the remaining fiber composite sheet, the layer 924 formed by the folded portion of the fiber composite sheet may be provided with a different ply arrangement (+ / -) angle.

[0285] In the example illustrated, folded layer 924-1 is formed by severing or cutting sheet 704 along its perimeter along cut lines 940-1 and 940-2 (collectively referred to as cut lines 940. Cut lines 940 partially cut out the portion 943 of sheet 704 which is to be folded, leaving an end portion of portion 943 overlying or integral with the remainder of sheet 704. As shown by arrow 946, the portion 943 is folded about and along a fold line or fold 945, wherein the folded layer 924-1 is connected to the remainder sheet 704 by and along the fold 945. In the example illustrated, fold 945 is oblique to axis 331 (in the example, at a 45 degree angle) and the folded layer 924-1 extends along an axis that is perpendicular to axis 331. The angle of the folded layer 924-1 may vary depending on the angles of the fold 945. Accordingly, by adjusting the size and length of the cut lines 940 and adjusting the angle of the fold 945, portion 943 can be sized and positioned at a number of different locations relative to the sheet 704.

[0286] Folded layer 924-2 is formed in a similar fashion as folded layer 924-1, but where the cut lines 940 mirror those used to cut out portion 943 to form layer 924-1. Folded layer 924-2 is formed by severing or cutting sheet 704 along its perimeter along cut lines 950-1 and 950-2 (collectively referred to as cut lines 950. Cut lines 950 partially cut out the portion 953 of sheet 704 which is to be folded, leaving an end portion of portion 953 overlying or integral with the remainder of sheet 704. As shown by arrow 956, the portion 953 is folded about and along a fold line or fold 955, wherein the folded layer 924-2 is connected to the remainder sheet 704 by and along the fold 955. In the example illustrated, fold 955 is oblique to axis 331 (in the example, at a 45 degree angle) and the folded layer 924-2 extends along an axis that is perpendicular to axis 331. The angle of the folded layer 924-2 may vary depending upon the angle of fold 955.

[0287] As further shown by Figure 25, in some implementations, the folded layers, themselves, may be additionally folded to form a secondary folded layer. In the example illustrated, each of folded layers 924-1, 924-2 is to be folded about a fold line 925. In some implementations, the fold line 925 is designated on each of the folded layers 924-1, 924-2 by markings. For example, each of the fold lines 925 may be printed on sheet 704 prior to the folding of layers 924-1, 924-2. In the example illustrated, the printing is placed on the back face of sheet 704 (the opposite side or face as that of marking 729 or 730) prior to folding. In yet other implementations, the fold line 925 may be indicated by a scoring of the back surface of sheet 704. In the example illustrated, the fold lines 925 are perpendicular to the longitudinal axis of each of folded layers 924-1, 924-2 such that the folded portions of layers 924-1, 94-2 fold back on top of (or beneath) themselves with aligned side edges. In other implementations, the fold lines 925 may be angled or oblique to the longitudinal axis of folded layers 924-1, 924-2 such that the secondary folded layer or portion angles away from the primary folded portion that extends from fold 945 or fold 955.

[0288] Folded layers 924-3 and 924-4 are formed by cutting and folding interior portions of sheet 704. Folded layer 924-3 is formed by cut lines 960-1, 960-2 and 960-3 (collectively referred to as cut lines 960) within the interior of sheet 704. Cut lines 960 partially cut out the portion 963 of sheet 704 which is to be folded, leaving an end portion of portion 963 overlyng or integral with the remainder of sheet 704. As shown by arrow 966, the portion 963 is folded about and along a fold line or fold 965, wherein the folded layer 924-3 is connected to the remainder sheet 704 by and along the fold 965. Cut lines 960-1 and 960-3 have ends or endpoints 961 and 962 which are vertically aligned relative to the axis 331 of mandrel 330. The endpoints 961 and 962 define the angle of the fold 965 and the angle of the layer 924-3 relative to the axis 331 about which the sheet 704 is to be rolled. In other implementations, the endpoints 961 and 962 may be horizontally offset such that the fold 965 is not perpendicular to axis 331, but is oblique to axis 331, resulting in the folded layer 924-3 also being oblique to axis 331. The angle of the folded layer 924-3 may vary depending on the angle of fold 965. Because the angle of the fold 965 is controlled by the offset between the endpoints 961, 962 of the cuts, the angle the fold in the angles of the folded layer may be controlled during the cutting of sheet 704, reducing the opportunity for errors in the orientation of layer 924-3.

[0289] Folded layer 924-4 may be formed in a fashion similar to folded layer 924-3, but wherein the cuts and folds mirror that of folded layer 924-3. Folded layer 924-4 is formed by cut lines 970-1, 970-2 and 970-3 (collectively referred to as cut lines 970) within the interior of sheet 704. Cut lines 970 partially cut out the portion 973 of sheet 704 which is to be folded, leaving an end portion of portion 973 overlying or integral with the remainder of sheet 704. As shown by arrow 976, the portion 973 is folded about and along a fold line or fold 975, wherein the folded layer 924-4 is connected to the remainder sheet 704 by and along the fold 975. Cut lines 970-1 and 970-3 have ends or endpoints 971 and 972 which are vertically aligned relative to the axis 331 of mandrel 330. The endpoints 971 and 972 define the angle of the fold 975 and the angle of the layer 924-4 relative to the axis 331 about which the sheet 704 is to be rolled. In other implementations, the endpoints 971 and 972 may be horizontally offset such that the fold 965 is not perpendicular to axis 331, but is oblique to axis 331, resulting in the folded layer 924-4 also being oblique to axis 331. The angle of the folded layer 924-4 may vary depending on the angle of fold 965. Because the angle of the fold 975 is controlled by the offset between the endpoints 971, 972 of the cuts, the angle the fold in the angles of the folded layer may be controlled during the cutting of sheet 704, reducing the opportunity for errors in the orientation of layer 924-4.

[0290] Figure 26A illustrates an alternative implementation of that which is shown in Figure 25 where an interior portion of sheet 704 is additionally provided with cut lines 980-1, 980-2 and 980-3 to partially cut out portion 983 which dangles from the remainder sheet 704. Figure 26A further illustrates the folding of portion 983 to form a folding layer 924-5. In the example shown, cut lines 980-1 and 980-3 have horizontally offset endpoints 981 and 982 which result in portion 983 being folded about a fold 985 which is oblique to axis 331 and oblique to the centerline of the cut out opening in sheet 704. As should be appreciated, the relative positioning of endpoints 981 and 982 may have other offsets or positions relative to one another to form other fold angles which result in the folded layers extending at other angles.

[0291] The location of the layers and the location of the folds on sheet 704 control where additional fiber content is provided along the axial length of the rolled tube 900 shown in Figure 27. Likewise, those regions where a portion of sheet 704 has been cut out folded over to create an aperture have less fibers. As shown by Figures 7-10, different axial segments of the tube, when shaped, form different portions of the racquet. In the example illustrated, the center 990 of sheet 704 corresponds to the longitudinal center of the rolled tube 900 shown in Figure 27 which corresponds to the apex 989 of the head portion 18 of racquet 10 (shown in Figure 1). The location of the layers and the locations of the fold on sheet 704 and along tube 900 control what part of the sports racquet is provided with additional layering of fiber composite material or non-fiber material to vary the performance properties of different portions of the sports racquet.

[0292] In the example illustrated where the rolled tube shown in Figure 27 forms each of the head portion, the throat and the handle portion of the racquet 10, the closer positioning of layers 924-1 and 924-2 to center 990 results in greater fiber content in the head portion of racquet 10. In the example illustrated, folded layers 924-1 and 924-2 are each equidistantly spaced from a center 990 of sheet 704 and are spaced from center 990 such that when sheet 704 is rolled into the tube 900 shown in Figure 27, and when the tube 900 is then shaped and molded as shown in Figures 7-10, the sandwiched layers 924-1 and 924-2 are at locations corresponding to the 3 o'clock position 991 and the 9 o'clock position 992 of the head portion of racquet 10 (both positions of which is shown in Figure 1) to provide the racquet 10 with perimeter weighting.

[0293] The apertures 997 (formed by the cutting out and outward folding of portions 963 and 973) are at locations along the rolled tube, that when shaped in Figures 7-10, correspond to the throat portions 22 of racquet 10 and result in such throat portions 22 having less fiber content and being less stiff. The positioning of the layers 924-3 and 924-4 most distant from center 990 result in such layers forming end portions of the rolled tube shown in Figure 26 to provide additional fiber content to the handle portion 20 of racquet 10 and to provide additional stiffness and weight to the handle portion 20.

[0294] As shown by Figure 25, the example construction of the racquet formed by sheet 704 and pieces 920, 922 additionally comprises an outermost layer 998 of fiber composite material. In some implementations, the outermost layer 998 may comprise a ply arrangement having adjacent plies of opposite polarity. In some implementations, the ply arrangement may have the same + / -(opposite polarity) fiber composite ply orientation or angles as that of sheet 704. As shown by Figure 25, layer 998 has a width less than that sheet 704. As shown by Figure 27, layer 998 has a length sufficient to wrap about the rolled sheet 704 by at least 360° and less than or equal to 720°. In some implementations, layer 998 may be omitted.

[0295] In some circumstances, different variations of a racquet may have different weight distributions or degrees of stiffness in different portions of the racquet. The racquet variations may accommodate different preferences of different players. Figure 26B illustrates an example of how an example fiber composite sheet folded portions and with the placed layers may be tweaked or modified using an example template which guides the placement of additional placed pieces prior to rolling. Figure 26B illustrates an example template 704' temporarily overlaid on top of sheet 704. In some implementations contemplate 704'may include a bottom face coated with a tacky but releasable coating or adhesive permits template 704'to be temporally retained in place on sheet 704 as the additional pieces are placed, wherein upon placement of the additional pieces, the template 704' may be released, peeled away, or lifted, leaving the additionally placed pieces in place on sheet 704, ready for being rolled.

[0296] In the example illustrated, template 704' comprises window openings 931-1, 931-2, 931-3, 931-4 and 931-5 (collectively referred to as openings 931). Openings 931 extend completely through the sheet serving as template 704'. In the example illustrated, openings 931 each have a shape corresponding to that of the piece to be received by the particular one of openings 931. As result, the shapes of the openings 931 intuitively identify which piece goes in which opening.

[0297] In the illustrated example, opening 931-1, 931-2, 931-3, 931-4 and 931-5 are each sized and shaped to receive correspondingly shaped and slightly proportionally smaller sized supplemental pieces 933-1, 933-2, 933-3, 923-4 and 933-5, respectively. In the example illustrated, sheet 704 may include an additional piece identification marking 939 which is printed, scored upon or otherwise provided on the face of sheet 704 proximate to opening 931-5. In the example illustrated, the piece 933-5 includes a corresponding marking 941 printed, scored upon otherwise provided on the face of piece 933-5. As should be appreciated, the other openings 931 and pieces 933 may include similar corresponding pairs of markings to assist in identifying which piece goes in which opening. As should be appreciated, each of the openings in each of the pieces may have a variety of different sizes, shapes, locations and configurations other than the examples being illustrated.

[0298] In the example illustrated, openings 931-1 and 931-2 are located on template 704' such that when template 704 'is aligned with and positioned on top of sheet 704 (such as with edge-to edge alignment or alignment of template 704'with particular markings provided on sheet 704), openings 931-1 and 931-2 overlie folded layers 924-1 and 924-2, respectively. As a result, the placed pieces 933-1 and 933-2 will also overlie and extend across and beyond the side edges of folded layers 924-1 and 924-2. The additional pieces 933-1 and 933-2 provide enhanced stiffness and enhanced weight at their respective locations in the subsequently rolled tube and in the subsequently formed racquet. In some implementations, the openings 931-1, 931-2 and their associated pieces 933-1 and 933-2 may be sized smaller than the underlying folded layers 924-1, 924-2 so as to not extend beyond edges of folded layers 924-1, 924-2.

[0299] In the example illustrated, openings 931-4 and 931-5 are located on template 704' such that when template 704 'is aligned with and positioned on top of sheet 704 (as shown) (such as with edge-to edge alignment or alignment of template 704' with particular markings provided on sheet 704), openings 931-3 and 931-4 overlie and bridge across the openings 997 formed by folded layers 924-3 and 924-4, respectively. As a result, by folding portions to create an opening and then laying completely new or different pieces in such openings, completely different material properties may be provided by the supplemental pieces in such particular locations. In the example illustrated, opening 931-5 is located on template 704' such that when template 704 'is aligned with and positioned on top of sheet 704 (as shown) (such as with edge-to edge alignment or alignment of template 704' with particular markings provided on sheet 704), opening 931-5 overlies an unfolded or blank region of sheet 704. The piece 933-5 may then be positioned within the window opening 931-5. As a result, the weight or stiffness properties for the particular portions of the racquet corresponding to location of opening 931-5 may be increased. As noted above, following placement of pieces 933, template 704' the way, leaving the pieces 933 in place on sheet 704, wherein sheet 704 is then subsequently rolled.

[0300] Although template 704' is described as being overlaid upon sheet 704 that has folded layers, in some implementations, template 704' may be laid upon a sheet lacking folded layers. Although template 704' is described as being overlaid upon sheet 704 having markings 926, 928, in other implementations, template 704' may be laid upon a sheet lacking such markings 926, 928. In some implementations, rather than sheet 704 having markings 926, an overlying template, such as template 704', may include piece designating openings for each of the pieces to be added or placed upon sheet 704. In some implementations, where the sheet 704 is to include folded layers, the template 704'may include slits for guiding a blade or knife as well as indicating where cuts (such as cut lines 940, cut lines 950, cut lines 960, cut lines 970) are to be made in the underlying sheet 704 to facilitate subsequent folding form the folded layers are to form openings such as openings 906. In some implementations, the cut lines may be formed by a die or die cutter which concurrently cuts each of the cut lines.

[0301] Figures 28-30 illustrate the forming of an example rolled fiber composite tube which may then be shaped and molded to form a sports racquet, such as the tennis racquet 10 described above. Figures 28-30 illustrate an example where the rolled tube used to form a sports racquet is formed from a fiber composite sheet without the use of discrete fiber composite or non-fiber composite pieces. Figure 28 illustrates an example fiber composite sheet 1004 with cuts forming various portions which are to be folded so as to form folded layers. Figure 29 illustrates the fiber composite sheet 1004 after the cut portions are folded to form folded layers. Once such portions are folded, the fiber composite sheet 1004 is configured to be rolled about a centerline, such as a centerline of mandrel 330, to form a rolled tube shown in Figure 30 which may then be flattened, shaped and molded as shown in Figure 7-10. As further shown by Figure 28, in some implementations, the mandrel 330 may be received within the bladder 332.

[0302] In the example illustrated, sheet 1004 comprises interior portions 1043-1, 1043-2 (collectively referred to as portions 1043), interior portions 1045-1, 1045-2 (collectively referred to as portions 1045) and interior portions 1047-1 and 1047-2 (collectively referred to as portions 1047). Each of such portions is cut on three sides with the fourth side uncut for forming folds about which such portions 1043, 1045 and 1047 are to be folded prior to rolling of sheet 1004 about the illustrated example mandrel 330 and enclosing bladder 332. In some implementations, such cuts may be formed by a CNC cutting table or machine. In other implementations, the cuts of sheet 1004 can be made through other conventional means.

[0303] Portions 1043 mirror one another on opposite sides of a center 990 of sheet 1004 which corresponds to the longitudinal center point of the rolled tube be performed. As with the example shown in Figure 28, the center 990 also corresponds to the apex 989 of the racquet 10 shown in Figure 1. As indicated by arrows 1063 in Figure 28 and shown in Figure 29, portions 1043 are folded away from one another outwardly and away from centerline 990 to form folded layers 1063-1 and 1063-2 (collectively referred to as layers 1063) and apertures 1073-1 and 1073-2 (collectively referred to as apertures 1073), respectively. Such folded layers 1063 are at locations along the axial length of tube 1090 that when shaped into the frame of racquet 10, correspond to the 3 o'clock and 9 o'clock positions 991 and 992 of racquet 10 shown in Figure 1. Folded layers 1063 provide racquet 10 with perimeter weighting.

[0304] Portions 1045 mirror one another and opposite sides of center 990 and are at locations so as to form folded layers 1065-1, 1065-2 (collectively referred to as layers 1065) and apertures 1075-1, 1075-2 (collectively referred to as apertures 1075) as shown in Figure 29. Folded layers 1063 are locations corresponding to handle portion 20 of racquet 10 will apertures 165 are locations correspond to throat portions 22 of racquet 10.

[0305] Portions 1047 mirror one another on opposite sides of center 990 and are locations so as to form folded layers 1073-1, 1073-2 (collectively referred to as layers 1067) and apertures 1077-1 and 1077-2 (collectively referred to as apertures 1077), respectively, as shown in Figure 29. Folded layers 1073 are at locations along the axial length of the rolled tube 1090 that when shaped, form handle portion 20 of racquet 10.

[0306] As shown by Figure 28 the endpoints of the cuts forming portions 1043, 1045 and 1047 are longitudinally or horizontally offset such that each of the folded layers 1053, 1063 and 1073 are connected to the remainder of sheet 1004 along folds that are oblique to the longitudinal centerline of sheet 1004 and the axis 331 of mandrel 330 when sheet 1004 is rolled about mandrel 330. As result, the folded layers 1053, 1063 1073 are also oblique to axis 331 such that the folded layers have different fiber angles or polarities as compared to those portions of sheet 1004 which are not folded prior to being rolled. As with the above examples, once the sheet 1004 has been rolled about mandrel 330, mandrel 330 may be removed and the rolled tube formed by sheet1004 may be shaped and molded as described above with respect to Figures 7-10.

[0307] The method described above of making discrete cuts in a sheet 1004 of fiber composite material before it is molded and cured, and then folding over portions of the sheet 1004 (folded layers 1053, 1063 and 1073) before applying the sheet to a mandrel and curing the fiber composite material provides an exceptionally efficient and cost-effective manner for making a fiber composite sports racquet. The cutting and folding of the folded layers 1053, 1063 and 1073 about the sheet 1004 allows for a great deal of design flexibility in designing a fiber composite racquet. The method also allows for material to be readily and consistently positioned at desired locations within the sports racquet construction. The method significantly reduces the likelihood of human error and inconsistencies in sports racquet production. The cuts can be made in a very consistent, fast and reliable manner, and the folding over of specific folded layers in specific directions also provides for a fast, consistent and reliable manner of producing a sports racquet. The method reduces the time to produce the sports racquet, and it significantly increases the accuracy and consistency of the sports racquet production. Sports racquet frames produced in accordance with the present invention allow for racquets to be produced within very tight specification and tolerances. The above-described method enables fiber composite sports racquet frames to be consistently produced within very tight specifications and tolerances, as low as plus or minus 1 gram as opposed to plus or minus 5-10 grams of many conventional racquet designs. The present method of producing a sports racquet also enables a sports racquet to be consistently produced in a significantly lower amount of time, thus allowing more racquets to be produced in a specific amount of time, at less cost and with fewer inaccuracies.

[0308] Figures 25-30 illustrate examples where a single fiber composite sheet is rolled body centerline or rolled the body mandrel. Figure 31 illustrates an example where a plurality of composite fiber sheet may be rolled about a centerline or about mandrel 330, one on the top of the other. Each of such sheets may be rolled so as to wrap or extend at least 720° about the centerline or mandrel. Figure 31 illustrates an example where the fiber composite sheet 704 described above with respect to Figure 25 is divided into two sheets, sheet 704-1 and 704-2. In such an implementation, pieces 920 and 922 may additionally be provided as shown in Figure 25 or may be omitted. Such sheets 704-1 and 704-2 may be sequentially rolled about mandrel 330 (and bladder 332). In some implementations, sheet 704 may first be rolled about mandrel 330 followed by sheet 702.

[0309] In other implementations, this order may be reversed. In yet other implementations, more than two fiber composite sheets having folded layers and / or pieces may be rolled about a centerline or about mandrel 330.

[0310] Figure 32 further illustrates one example of how one or more sheets 304, 404, 704 or 1004 may be rolled about a centerline or rolled about mandrel 330. In some implementations, mandrel 330 may be releasably connected to a rotary actuator 1200 which rotates mandrel 330. Portions of the first sheet to be rolled about mandrel 330 may be secured to an exterior of mandrel 330 prior to and at the start of such rolling.

[0311] Figure 32 is a schematic diagram illustrating another example method by which sheets 304, 404, 704 or 1004 may be rolled about a centerline or rolled about mandrel 330. Figure 32 schematically illustrates a table roller which comprises a table 1202, and roller 1204. As shown by Figure 32, mandrel 330 and the closing bladder 332 with the sheet 304, 404, 704, 1004 partially rolled about mandrel 330 are positioned between table 1200 and roller 1204. Roller 1204 is lowered to apply pressure to a top of mandrel 330 and is moved in the direction indicated by arrow 1208. During such time, mandrel 330 is rolled about its axis 331 in the direction indicated by arrow 1209. In implementations where the travel of roller 1204 is insufficient to fully roll the sheet about mandrel 330, table 1202 may be lifted as indicated by arrow 1210, retracted as indicated by arrow 1212 and once again lowered as indicated by arrow 12 14, wherein the cycle is repeated. In some implementations, table 1200 may concurrently move relative to roller 1204. For example, roller 1204 may be moved in the direction indicated by arrow 1208 while table 1202 may concurrently move in the direction indicated by arrow 1216. Once table 1202 is moved through its full travel distance, table 1202 may be lowered, retracted in the direction indicated by arrow 1208 and raised before repeating the cycle.

[0312] Although each of the above examples are described in the context of rolling a sheet to form a tube that is shaped and molded to form a head portion, through portion and handle portion of a tennis racquet, such as tennis racquet 10 described above, in other implementations, each of the above-described methods may likewise be utilized to form lesser extents of a sport racquet or lesser extents of a tennis racquet. In such implementations, the axial length of the tube formed by the rolled sheet is shorter, wherein those portions of the sports racquet or tennis racquet not formed by the shaped and molded tube or separately formed and attached to that portion of the sports racquet formed by the rolled and shaped tube.

[0313] Figure 33 is an exploded view of an example tennis racquet 1310. Tennis racquet 1310 is similar to tennis racquet 10 except that the tube formed from the rolled sheet that is used to form head portion 18 and throat portion 22 is not used to form handle portion 20. In such an implementation, the axial length of the tube formed from the rolled sheet is shorter, being of sufficient length to form head portion 18 and throat portion 22, wherein the yoke 350 is added during the molding step as described above. In such an implementation, handle portion 20 is separately formed and is secured to throat portion 22 by adhesive, welds, fasteners and the like.

[0314] Figure 34 is an exploded view of an example tennis racquet 1410. Tennis racquet 1410 is similar to tennis racquet 10 except that the tube formed from the rolled sheet that is used to form head portion 18 is not used to form throat portion 22 or handle portion 20. In such an implementation, the axial length of the tube formed from the rolled sheet is shorter, being of sufficient length to form head portion 18. In some implementations, the end portions of the tube formed from the rolled sheet come together to form a complete hoop, forming the complete string bed four tennis racquet 1410. In such an implementation, the additional yoke piece may be omitted. In other implementations, the end portion of the tube formed by the rolled sheet remain separated (having a generally U-shaped, wherein the racquet head interior or string bed is completed by the addition of a yoke piece, such as yoke 350 described above. In such an implementation, throat portion 22 and handle portion 20 is separately formed and is secured to the hoop or head portion 18 by adhesive, welds, fasteners and the like.

[0315] Although each of the above examples specifically illustrates a tennis racquet having the above-described constructions and formed by the above-described methods, each of the above-described constructions and methods may be equally employed to form other sports racquets. Figures 35and 36 illustrate an example racquet 1510 that has a different frame shape and that omits a string bed. Figure 36 is a sectional view of the racquet 1510 shown in Figure 35 taken along line 36-36. Racquet 1510 may be formed according to any of the above-described methods and have similar constructions as the tennis racquet 10 described above. In some implementations, racquet 1510 may be configured as a pickle ball racquet (sometimes also referred to as a pickle ball paddle). In some implementations, racquet 1510 may be configured as a padel racquet or a ping pong racquet. As shown by Figure 35, racquet 1510 comprises a head portion 1518, a handle portion 1520 and a throat portion 1522.

[0316] Head portion 1518 provides a hitting surface racquet 1510. Handle portion 1020 provides an extension configured to be gripped by a player's hand. Throat portion extends between and connect head portion 1518 to handle portion 1520. The head portion 1518, the portion 1520 is throat portion 1522 are each formed by a shape and molded fiber composite tube 1590 formed by rolling at least one sheet 304, 404, 704 about a centerline or mandrel pursuant to any of methods 200, 400 or 600 as described above with respect to Figures 6-28.

[0317] In the example illustrated, racquet 1510 additionally comprises the yoke 350 which may be formed pursuant to any of the above describe methods. In other implementations, the yoke piece may be omitted. As should be evident, the molded fiber composite tube 1590 (having a rolled fiber composite sheet and / or a rolled nine fiber composite sheet carrying fiber composite pieces) may be molded / fused with a different shape to form the racquet 1510 as compared to racquet 10. Although head portion 1518, handle portion 1520 and the throat portion 5022 are each at least partially formed from the fiber composite tube, in other implementations, smaller extents of racquet 1510 may be formed from the fiber composite to similar to the tennis racquets 1310 and 1410 shown in Figures 33 and 34. In some implementations, the fiber composite tube 1590 forms just the head portion 1518 and the throat portion 1522, wherein the handle portion 1520 is separately formed and attached. In some implementations, the fiber composite tube 1590 form just the head portion 1518, wherein the handle portion 1520 and the throat portion 1522 are separately formed and attached.

[0318] As shown by Figures35 and 36, the portion of tube 1590 forming head portion 1518 form a racquet head interior 1530. In contrast to tennis racquet 10 which comprises a string bed, racquet 1510 comprises a pair of covers, panels or faceplates 1532 extending across and spanning the racquet head opening 1530. Such faceplates 1532 and extend opposite to one another across tube 1590. In some implementations, faceplates 1532 are imperforate. In other implementations, faceplates 1532 are perforate. Such faceplates may be formed from a variety of different materials such as a polymer.

[0319] Figure 37 is a sectional taken along line 36-36 illustrating an alternative construction of racquet 1510. As shown by Figure 37, the racquet interior 1530 may be filled with a filler 1534. The filler may be in the form of one or more foam layers or one or more layers of different combinations of materials. In some implementations, the filler 1534 may comprise a honeycomb material. In some implementations, filler 1534 may comprise a solid material. In some implementations, filler 1534 is injected as a fluid into interior of racquet head opening 1530 before after the application faceplates 1532. In some implementations, filler 1534 comprises a solid panel (of one or more layers) that is secured within racquet head interior 1530 prior to the positioning of at least one of 15 plates 1532 across the racquet head opening 1530. In some implementations, one or both of faceplates 1532 may be omitted, wherein the filler 1534 provides a hitting surface within the racquet head opening.

[0320] Figure 38 illustrates another example sports racquet 1610 which may be formed pursuant to may be formed according to any of the above-described methods and have similar constructions as the tennis racquet 10 described above. In the example illustrated, racquet 1610 omits the yoke 350. Similar to racquet 1510, racquet 1610 is formed by the molded fiber composite tube 1590 (having a rolled fiber composite sheet and / or a rolled nine fiber composite sheet carrying fiber composite pieces) may be molded / fused with a different shape to form the racquet 1610 as compared to racquet 1510. Although head portion 1518, handle portion 1520 and the throat portion 5022 are each at least partially formed from the fiber composite tube, in other implementations, smaller extents of racquet 1610 may be formed from the fiber composite to similar to the tennis racquets 1310 and 1410 shown in Figures 33 and 34. In some implementations, the fiber composite tube 1590 forms just the head portion 1618 and the throat portion 1622, wherein the handle portion 1620 is separately formed and attached. In some implementations, the fiber composite tube 1690 form just the head portion 1618, wherein the handle portion 1620 and the throat portion 1622 are separately formed and attached. As with racquet 1510, the tube 1590 forms a racquet head opening 1630. In the example illustrated, the filler 1534 fills the racquet head opening 1630 and provides a hitting surface. In other implementations, the head portion 1618 of racquet 1610 may comprise faceplates 1532 extending across the racquet head opening 1630 without filler 1534 or faceplates 1532 extending across and covering racquet head opening 1630 with filler 1534 sandwiched therebetween as shown in Figures 36 and 37, wherein the faceplates provide hitting surface for the racquet 1610.

[0321] Although the claims of the present disclosure are generally directed to rolling of a sheet about a centerline to form portions of a fiber composite racquet, the present disclosure is additionally directed to the features set forth in the following clauses.

[0322] Although the present disclosure has been described with reference to example implementations, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the claimed subject matter. For example, although different example implementations may have been described as including features providing benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example implementations or in other alternative implementations. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example implementations and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. The terms "first", "second", "third" and so on in the claims merely distinguish different elements and, unless otherwise stated, are not to be specifically associated with a particular order or particular numbering of elements in the disclosure.

[0323] Additional features and aspects of the disclosure are also set out in the following numbered clauses.

[0324] CLAUSE 1: A fiber composite racquet comprising: a handle portion; and a head portion coupled to the handle portion and forming a loop, wherein at least the head portion comprises: a rolled fiber composite sheet wound about a centerline by at least 720 degrees.

[0325] CLAUSE 2: The fiber composite racquet of clause 1, wherein the handle portion and the head portion are each formed from the rolled fiber composite sheet.

[0326] CLAUSE 3: The fiber composite racquet of clause 1, wherein the rolled fiber composite sheet comprises completely surrounded apertures.

[0327] CLAUSE 4: The fiber composite racquet of clause 3 further comprising a throat portion between the head portion and the handle portion, wherein the completely surrounded apertures coincide with the throat portion.

[0328] CLAUSE 5: The fiber composite racquet of clause 1, wherein the rolled fiber composite sheet comprises inwardly extending perimeter notches.

[0329] CLAUSE 6: The fiber composite racquet of clause 1 further comprising a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0330] CLAUSE 7: The fiber composite racquet of clause 6, wherein the second fiber composite sheet is rolled and has overlapping portions extending at least 720° about the centerline.

[0331] CLAUSE 8: The fiber composite racquet of clause 7, wherein the second fiber composite sheet wraps about the rolled fiber composite sheet.

[0332] CLAUSE 9: The fiber composite racquet of clause 7, wherein the rolled fiber composite sheet wraps around the second fiber composite sheet.

[0333] CLAUSE 10: The fiber composite racquet of clause 1, wherein the rolled fiber composite sheet forms a tube having an interior.

[0334] CLAUSE 11: The fiber composite racquet of clause 10, wherein the interior is void.

[0335] CLAUSE 12: The fiber composite racquet of clause 10, wherein the interior is filled.

[0336] CLAUSE 13: The fiber composite racquet of clause 1 further comprising a layer captured between adjacent overlapping portions of the rolled fiber composite sheet.

[0337] CLAUSE 14: The fiber composite racquet of clause 13, wherein the layer is wound at least 720° about the centerline.

[0338] CLAUSE 15: The fiber composite racquet of clause 13, wherein the layer comprises a fiber composite layer.

[0339] CLAUSE 16: The fiber composite racquet of clause 13, wherein the layer omits fibers.

[0340] CLAUSE 17: The fiber composite racquet of clause 13, wherein the rolled fiber composite sheet has a first material characteristic and wherein the layer has a second material characteristic different than the first material characteristic.

[0341] CLAUSE 18: The fiber composite racquet of clause 17, wherein the first material characteristic is a first thickness and wherein the second material characteristic has a second thickness different than the first thickness.

[0342] CLAUSE 19: The fiber composite racquet of clause 17, wherein the first material characteristic is a first + / - fiber composite ply arrangement angle and wherein the second material characteristic is a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0343] CLAUSE 20: The fiber composite racquet of clause 18, wherein the first material characteristic is a first type of fiber material and wherein the second interior characteristic is a second type of fiber material different than the first type of fiber material.

[0344] CLAUSE 21: The fiber composite racquet of clause 13, wherein the rolled composite sheet and the layer have identical material characteristics.

[0345] CLAUSE 22: The fiber composite racquet of clause 13, wherein the layer is joined to the rolled fiber composite sheet along a fold.

[0346] CLAUSE 23: The fiber composite racquet of clause 13, wherein the layer comprises a fiber composite panel distinct from the rolled fiber composite sheet.

[0347] CLAUSE 24: The fiber composite racquet of clause 13 further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions.

[0348] CLAUSE 25: The fiber composite racquet of clause 24, wherein the second layer has a third material characteristic different than the first material characteristic and the second material characteristic.

[0349] CLAUSE 26: The fiber composite racquet of clause 25, wherein the first material characteristic is a first thickness and wherein the third material characteristic is a second thickness different than the first thickness.

[0350] CLAUSE 27: The fiber composite racquet of clause 25, wherein the first material characteristic is a first + / - fiber composite ply arrangement angle and wherein the third material characteristic is a second + / - fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0351] CLAUSE 28: The fiber composite racquet of clause 27, wherein the second material characteristic of the layer is a third + / - fiber composite ply arrangement angle different than the second + / -fiber composite ply arrangement angle.

[0352] CLAUSE 29: The fiber composite racquet of clause 25, wherein the first material characteristic is a first type of fiber material and wherein the third material characteristic is a second type of fiber material different than the first type of fiber material.

[0353] CLAUSE 30: The fiber composite racquet of clause 24, wherein the rolled composite sheet and the second layer have identical material characteristics.

[0354] CLAUSE 31: The fiber composite racquet of clause 24, wherein the second layer is joined to the rolled fiber composite sheet along a second fold.

[0355] CLAUSE 32: The fiber composite racquet of clause 24, wherein the second layer comprises a fiber composite panel distinct from the rolled fiber composite sheet.

[0356] CLAUSE 33: The fiber composite racquet of clause 13 further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions, wherein the layer is joined to the rolled fiber composite sheet folded along a first fold at a first angle and wherein the second layer is joined to the rolled fiber composite sheet folded at along a second fold at a second angle different than the first angle.

[0357] CLAUSE 34: The fiber composite racquet of clause 33, wherein the layer extends perpendicular to the centerline and wherein the second layer extends parallel to the centerline.

[0358] CLAUSE 35: The fiber composite racquet of clause 13 further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions, the layer forming a 9 o'clock region of the head portion and the second layer forming a 3 o'clock region of the head portion.

[0359] CLAUSE 36: The fiber composite racquet of clause 35, wherein the layer is joined to the rolled fiber composite sheet along a first fold to form the 9 o'clock region of the head portion and wherein the second layer is joined to the rolled fiber composite sheet along a second fold to form the 3 o'clock region of the head portion.

[0360] CLAUSE 37: The fiber composite racquet of clause 36 further comprising: a third layer joined to the rolled fiber composite sheet along a third fold to form a first side of the handle portion; and a fourth layer joined to the rolled fiber composite sheet along a fourth fold to form a second side of the handle portion.

[0361] CLAUSE 38: The fiber composite of clause 37, wherein the third fold and the fourth fold extend parallel.

[0362] CLAUSE 39: The fiber composite racquet of clause 37, wherein the first fold and the second fold are oblique to the third fold and the fourth fold.

[0363] CLAUSE 40: The fiber composite racquet of clause 3 further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions, wherein the layer form a first side and wherein the second layer form a second opposite side of the handle portion.

[0364] CLAUSE 41: The fiber composite racquet of clause 40, wherein the layer is joined to the rolled fiber composite sheet along a first fold and wherein the second layer is joined to the rolled fiber composite sheet along a second fold.

[0365] CLAUSE 42: The fiber composite racquet of clause 13 further comprising a second layer captured between second adjacent overlapping portions of the overlapping portions, wherein the layer is joined to the rolled fiber composite sheet along a first fold extending parallel to the and wherein the second layer is joined to the rolled fiber composite sheet along a second fold oblique to the centerline.

[0366] CLAUSE 43: The fiber composite racquet of clause 13, wherein the fiber composite sheet comprises a completely surround aperture and wherein the layer comprises a flap jointed to the fiber composite sheet by a fold along an edge of the completely surrounded aperture.

[0367] CLAUSE 44: The fiber composite racquet of clause 13, wherein the head portion, the throat portion, and the handle portion are formed from the rolled fiber composite sheet, wherein at least one of the head portion, the throat portion and the handle portion comprise the layer.

[0368] CLAUSE 45: The fiber composite racquet of clause 13 further comprising a second layer sandwiched between the layer and one of the overlapping portions.

[0369] CLAUSE 46: The fiber composite racquet of clause 42, wherein the second layer is joined to the first linear along a fold between the layer and the second layer.

[0370] CLAUSE 47: The fiber composite racquet of clause 1, wherein the rolled fiber composite sheet comprises completely surrounded apertures and a layer sandwiched between adjacent overlapping portions of the rolled fiber composite sheet.

[0371] CLAUSE 48: The fiber composite racquet of clause 1, wherein the head portion comprises a beam extending at least partially about and forming a racquet head opening, the beam being formed from the rolled fiber composite sheet.

[0372] CLAUSE 49: The fiber composite racquet of clause 48, wherein the racquet head opening comprises a string bed area, the beam comprising a series of frame openings through the beam for receiving strings to extend across the string bed area.

[0373] CLAUSE 50: The fiber composite racquet of clause 48 further comprising a panel coupled to the beam and extending across the racquet head opening.

[0374] CLAUSE 51: The fiber composite racquet of clause 50 further comprising a yoke portion forming the racquet head opening.

[0375] CLAUSE 52: The fiber composite racquet of Definition 51, wherein the yoke portion comprises a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a second centerline.

[0376] CLAUSE 53: The fiber composite racquet of clause 52 further comprising a throat portion extending between the handle portion and the head portion.

[0377] CLAUSE 54. The fiber composite racquet of clause 53, wherein the head portion and the throat portion are formed from the rolled fiber composite sheet.

[0378] CLAUSE 55: A method for forming a fiber composite racquet, the method comprising: rolling a fiber composite sheet about a mandrel; fusing the overlapping portions of the rolled fiber composite sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0379] CLAUSE 56: The method of clause 55 further comprising cutting an aperture in the fiber composite sheet prior to the rolling of the fiber composite sheet about the mandrel.

[0380] CLAUSE 57: The method of clause 56, wherein the fiber composite racquet comprises a head portion, a handle portion and a throat portion between the head portion and the handle portion, wherein the aperture has a location and size through the fiber composite sheet and a location along the mandrel corresponding to a location of the throat portion of the fiber composite racquet.

[0381] CLAUSE 58: The method of clause 55 further comprising removing the mandrel.

[0382] CLAUSE 59: The method of clause 58, wherein the mandrel has a linear centerline and wherein the rolled fiber composite sheet is shaped following removal of the mandrel.

[0383] CLAUSE 60: The method of clause 58 further comprising positioning the rolled fiber composite sheet within a mold, following removal of the mandrel, to shape the rolled fiber composite sheet into at least a portion of the fiber composite racquet.

[0384] CLAUSE 61: The method of clause 58 further comprising pressurizing an interior of the rolled fiber composite sheet while within the mold, the interior being formed by the removal of the mandrel.

[0385] CLAUSE 62: The method of clause 61, wherein the fiber composite sheet is rolled about an inflatable bladder positioned about the mandrel, wherein upon the removal of the mandrel and the positioning of the rolled fiber composite sheet within the mold, the rolled fiber composite sheet is heated within the mold and the interior of the rolled fiber composite sheet is pressurized while within the mold by pressurizing an interior of the inflatable bladder.

[0386] CLAUSE 63: The method of clause 55 further comprising pressurizing an interior of the rolled fiber composite sheet during the fusing of the overlapping portions.

[0387] CLAUSE 64: The method of clause 58, wherein the fiber composite sheet is rolled about an inflatable bladder positioned about the mandrel, wherein the mandrel is removed and wherein the interior of the rolled fiber composite sheet is pressurized during the fusing of the overlapping portions by pressurizing an interior of the inflatable bladder.

[0388] CLAUSE 65: The method of clause 55 further comprising heating the mandrel during rolling of the fiber composite sheet about the mandrel.

[0389] CLAUSE 66: The method of clause 55 further comprising: coupling an end portion of the fiber composite sheet to the mandrel so as to rotate with rotation of the mandrel; and rotating the mandrel with the coupled end portion of the fiber composite sheet to roll the fiber composite sheet about the mandrel.

[0390] CLAUSE 67: The method of clause 55, wherein the overlapping portions of the rolled fiber composite sheet are fused while shaped to form the head portion and a handle portion of the fiber composite racquet.

[0391] CLAUSE 68: The method of clause 55, wherein the loop forms first portion of a racquet head opening, the method further comprising forming a second portion of the racquet head opening comprising a yoke portion along the racquet head opening.

[0392] CLAUSE 69: The method of clause 68, wherein the yoke portion comprises a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a centerline.

[0393] CLAUSE 70: The method of clause 55, wherein the fiber composite racquet comprises a handle portion and a throat portion extending between the handle portion and the head portion.

[0394] CLAUSE 71: The method of clause 70, wherein the head portion and the throat portion are formed from the rolled fiber composite sheet.

[0395] CLAUSE 72: The method of clause 55, wherein the fiber composite racquet comprises a handle portion, the handle portion being formed from the rolled fiber composite sheet.

[0396] CLAUSE 73: The method of clause 55, wherein the head portion of the fiber composite racquet comprises racquet head opening having a string bed area and wherein the rolled fiber composite sheet forms a beam about the racquet head opening, the method further comprising forming a series of frame openings through the beam for receive strings that are to extend across the string bed area.

[0397] CLAUSE 74: The method of clause 55, wherein the head portion of the fiber composite racquet comprises racquet head opening and wherein the rolled fiber composite sheet forms a beam about the racquet head opening, the method further comprising securing a panel coupled to the beam and extending across the racquet head opening.

[0398] CLAUSE 75: The method of clause 55 further comprising rolling a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0399] CLAUSE 76: The method of clause 75, wherein the second fiber composite sheet is rolled and has overlapping portions extending at least 720° about a centerline.

[0400] CLAUSE 77: The method of clause 76, wherein the second fiber composite sheet wraps about the rolled fiber composite sheet.

[0401] CLAUSE 78: The method of clause 76, wherein the rolled fiber composite sheet wraps around the second fiber composite sheet.

[0402] CLAUSE 79: The method of clause 55, wherein the rolled fiber composite sheet forms a tube having an interior.

[0403] CLUASE 80: The method of clause 79, wherein the interior is void.

[0404] CLAUSE 81: The method of clause 79 further comprising filling the interior.

[0405] CLAUSE 82: The method of clause 55, wherein the fiber composite racquet comprises a head portion having a beam at least partially surrounding a racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising filling the racquet head opening with a fluid composition and solidifying the fluid composition.

[0406] CLAUSE 83: The method of clause 55, wherein the fiber composite racquet comprises a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising: securing a first plate to the beam to cover a first side of the racquet head opening; securing a second plate to the beam to cover a second side of the racquet head opening, the second plate being spaced from the first plate by a void; injecting a fluid composition into the void; and solidifying the fluid composition within the void.

[0407] CLAUSE 84: The method of clause 55, wherein the fiber composite racquet comprises a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising: securing first plate I'd the racquet opening; filling the racquet head opening with a fluid composition; securing a second plate to the beam to cover a second side of the racquet head opening; and solidifying the fluid composition.

[0408] CLAUSE 85: The method of clause 55 further comprising sandwiching a layer between overlapping portions of the rolled fiber composite sheet.

[0409] CLAUSE 86: The method of clause 85 further comprising forming a marking on the fiber composite sheet that indicates a designated positioning and orientation of the layer on fiber composite sheet.

[0410] CLAUSE 87: The method of clause 55, wherein the sandwiching of the layer between overlapping portions of the rolled fiber composite sheet comprises folding a portion of the fiber composite sheet prior to the rolling of the fiber composite sheet to form the layer.

[0411] CLAUSE 88: The method of clause 87 further comprising cutting a perimeter of the portion of the fiber composite sheet prior to the folding and prior to the rolling of the fiber composite sheet.

[0412] CLAUSE 89: The method of clause 88, wherein the cutting of the perimeter of the portion of the fiber composite sheet comprises forming a pair of cuts having offset ends such that the portion is folded along an angled fold such that the layer is angled.

[0413] CLAUSE 90: The method of clause 88 further comprising: cutting a perimeter of a second portion of the fiber composite sheet; and folding the second portion prior to the spiral rolling of the fiber composite sheet to form a second layer, wherein the second layer is sandwiched between overlapping portions of the rolled fiber composite sheet.

[0414] CLAUSE 91: The method of clause 90, wherein the second portion is folded along a fold such that the formed second layer is angled differently than the layer.

[0415] CLAUSE 92: The method of clause 90, wherein the layer has a first size and / or shape and wherein the second layer has a second size and / or shape different than the first size and / or shape.

[0416] CLAUSE 93: The method of clause 85 further comprising depositing a liquid second layer on fiber composite sheet and solidifying the second layer between the overlapping portions of the rolled fiber composite sheet.

[0417] CLAUSE 94: The method of clause 85, wherein the layer comprises a fiber composite layer.

[0418] CLAUSE 95: The method of clause 85, wherein the layer omits fibers.

[0419] CLAUSE 96: The method of clause 55, wherein the rolled fiber composite sheet has a first material characteristic and wherein the layer has a second material characteristic different than the first material characteristic.

[0420] CLAUSE 97: The method of clause 96, wherein the first material characteristic is a first thickness and wherein the second material characteristic has a second thickness different than the first thickness.

[0421] CLAUSE 98: The method of clause 96, wherein the first material characteristic is a first + / - fiber composite ply arrangement angle and wherein the second material characteristic is a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0422] CLAUSE 99: The method of clause 96, wherein the first material characteristic is a first type of fiber material and wherein the second interior characteristic is a second type of fiber material different than the first type of fiber material.

[0423] CLAUSE 100: The method of clause 85, wherein the rolled composite sheet and the layer have identical material characteristics.

[0424] CLAUSE 101: The method of clause 85 further comprising sandwiching a second layer between the overlapping portions, wherein the layer is joined to the rolled fiber composite sheet folded along a first fold at a first angle and wherein the second layer is joined to the rolled fiber composite sheet folded at along a second fold at a second angle different than the first angle.

[0425] CLAUSE 102: The method of clause 101, wherein the layer extends perpendicular to the centerline and wherein the second layer extends parallel to the centerline.

[0426] CLAUSE 103: The method of clause 85 further comprising sandwiching a second layer between the layer and one of the overlapping portions.

[0427] CLAUSE 104: The method of clause 103, wherein the second layer is joined to the first linear along a fold between the layer and the second layer.

[0428] CLAUSE 105: The method of clause 85 further comprising sandwiching a second layer between overlapping portions of the overlapping portions, the layer forming a 9 o'clock region of a head portion and the second layer forming a 3 o'clock region of the head portion.

[0429] CLAUSE 106: The method of clause 105, wherein the layer is joined to the rolled fiber composite sheet along a first fold to form the 9 o'clock region of the head portion and wherein the second layer is joined to the rolled fiber composite sheet along a second fold to form the 3 o'clock region of the head portion.

[0430] CLAUSE 107: The method of clause 106 further comprising: forming a third layer joined to the rolled fiber composite sheet along a third fold to form a first side of the handle portion; and forming a fourth layer joined to the rolled fiber composite sheet along a fourth fold to form a second side of the handle portion.

[0431] CLAUSE 108: The method of clause 106, wherein the third fold and the fourth fold extend parallel.

[0432] CLAUSE 109: The method of clause 108, wherein the first fold and the second fold are oblique to the third fold and the fourth fold.

[0433] CLAUSE 110: The method of clause 85 further comprising sandwiching a second layer between adjacent overlapping portions of the overlapping portions, wherein the layer forms a first side of a handle portion of the fiber composite racquet and wherein the second layer forms a second opposite side of the handle portion of the fiber composite racquet.

[0434] CLAUSE 111: The method of clause 110, wherein the layer is joined to the rolled fiber composite sheet along a first fold and wherein the second layer is joined to the rolled fiber composite sheet along a second fold.

[0435] CLAUSE 112: The method of clause 85 further comprising sandwiching a second layer between adjacent overlapping portions of the overlapping portions, wherein the layer is joined to the rolled fiber composite sheet along a first fold extending parallel to an axis and wherein the second layer is joined to the rolled fiber composite sheet along a second fold oblique to the axis.

[0436] CLAUSE 113: The method of clause 85, wherein the fiber composite racquet comprises a head portion that comprises a beam extending at least partially about and forming a racquet head opening, the beam being formed from the rolled fiber composite sheet.

[0437] CLAUSE 114. The method of clause 113 further comprising forming a yoke portion along the racquet head opening.

[0438] CLAUSE 115: The method of clause 114, wherein the yoke portion comprises a second rolled fiber composite sheet having overlapping portions extending at least 720 degrees about a centerline.

[0439] CLAUSE 116: The method of clause 85, wherein the fiber composite racquet comprises a throat portion extending from the head portion, wherein the head portion and the throat portion are formed from the rolled fiber composite sheet.

[0440] CLAUSE 117: The method of clause 85, wherein the fiber composite racquet comprises a handle portion and a throat portion between the head portion and the handle portion, the handle portion being formed from the rolled fiber composite sheet, wherein at least one of the head portion, the throat portion and the handle portion comprise the layer.

[0441] CLAUSE 118: The method of clause 85, wherein the head portion comprises a racquet head opening having a string bed area, the method further comprising forming a series of frame openings through the beam for receive strings that are to extend across the string bed area.

[0442] CLAUSE 119: The method of clause 85, wherein the head portion comprises a racquet head opening and wherein the rolled fiber composite sheet forms a beam at least partially about the racquet head opening, the method further comprising securing a panel coupled to the beam and extending across the racquet head opening.

[0443] CLAUSE 120: The method of clause 85 further comprising sandwiching a second layer between the layer and one of the overlapping portions.

[0444] CLAUSE 121: The method of clause 120, wherein the second layer is joined to the first linear along a fold between the layer and the second layer.

[0445] CLAUSE 122: The method of clause 85 further comprising rolling a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0446] CLAUSE 123: The method of clause 122, wherein the second fiber composite sheet is rolled and has overlapping portions extending at least 720° about a centerline.

[0447] CLAUSE 124: The method of clause 123, wherein the second fiber composite sheet wraps about the rolled fiber composite sheet.

[0448] CLAUSE 125: The method of clause 123, wherein the rolled fiber composite sheet wraps around the second fiber composite sheet.

[0449] CLAUSE 126: The method of clause 85, wherein the rolled fiber composite sheet forms a tube having an interior.

[0450] CLAUSE 127: The method of clause 126, wherein the interior is void.

[0451] CLAUSE 128. The method of clause 126 further comprising filling the interior.

[0452] CLAUSE 129: The method of clause 85, wherein the fiber composite racquet comprises a head portion having a beam at least partially surrounding a racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising filling the racquet head opening with a fluid composition and solidifying the fluid composition.

[0453] CLAUSE 130: The method of clause 85, wherein the fiber composite racquet comprises a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising: securing a first plate to the beam to cover a first side of the racquet head opening; securing a second plate to the beam to cover a second side of the racquet head opening, the second plate being spaced from the first plate by a void; injecting a fluid composition into the void; and solidifying the fluid composition within the void.

[0454] CLAUSE 131: The method of clause 85, wherein the fiber composite racquet comprises a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising: securing first plate I'd the racquet opening; filling the racquet head opening with a fluid composition; securing a second plate to the beam to cover a second side of the racquet head opening; and solidifying the fluid composition.

[0455] CLAUSE 132: The method of clause 85, wherein the fiber composite racquet comprises a head opening having a beam at least partially surrounded by racquet head opening, the beam being formed by the rolled fiber composite sheet, the method further comprising forming a non-string layer within the racquet head opening across the racquet head opening.

[0456] CLAUSE 133: A fiber composite racquet comprising: a handle portion; and a head portion extending from the handle portion, wherein at least the head portion comprises: a sheet wound about a centerline; and a fiber composite layer sandwiched between adjacent overlapping portions of the sheet.

[0457] CLAUSE 134: The fiber composite racquet of clause 133, wherein the handle portion and the head portion are each formed from portions of the rolled sheet and portions of the fiber composite layer.

[0458] CLAUSE 135: The fiber composite racquet of clause 133, wherein the sheet is wound at least 720° about the centerline.

[0459] CLAUSE 136: The fiber composite racquet of clause 133, wherein the layer is wound less than 720° about the centerline.

[0460] CLAUSE 137: The fiber composite racquet of clause 133, wherein the rolled sheet omits fibers.

[0461] CLAUSE 138: The fiber composite racquet of clause 137 further comprising a second fiber composite layer sandwiched between adjacent overlapping portions of the sheet.

[0462] CLAUSE 139: The fiber composite racquet of clause 138, wherein the fiber composite layer is part of a first piece and wherein the second fiber composite is part of a second piece discrete from the first piece.

[0463] CLAUSE 140: The fiber composite racquet of clause 139, wherein the first piece and the second do not radially overlap.

[0464] CLAUSE 141: The fiber composite racquet of clause 139, wherein the first piece and the second piece radially overlap.

[0465] CLAUSE 142: The fiber composite racquet of clause 139, wherein the fiber composite layer has a first material characteristic and wherein the second fiber composite layer has a second material characteristic different than the first material characteristic.

[0466] CLAUSE 143: The fiber composite racquet of clause 142, wherein the first material characteristic is a first thickness and wherein the second material characteristic has a second thickness different than the first thickness.

[0467] CLAUSE 144: The fiber composite racquet of clause 142, wherein the first material characteristic is a first + / - fiber composite ply arrangement angle and wherein the second material characteristic is a second + / -fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0468] CLAUSE 145: The fiber composite racquet of clause 142, wherein the first material characteristic is a first type of fiber material and wherein the second interior characteristic is a second type of fiber material different than the first type of fiber material.

[0469] CLAUSE 146: The fiber composite racquet of clause 139, wherein the layer and the second layer have identical material characteristics.

[0470] CLAUSE 147: The fiber composite racquet of clause 133 further comprising a second fiber composite layer sandwiched between adjacent overlapping portions of the sheet, wherein the sheet comprises a fiber composite sheet, wherein the first fiber composite layer is joined to the sheet along a fold and wherein the second fiber composite layer is part of a piece discrete from the sheet and the fiber composite layer.

[0471] CLAUSE 148: The fiber composite racquet of clause 147, wherein the fiber composite sheet and the fiber composite layer have a first material characteristic and wherein the second fiber composite layer has a second material characteristic different than the first material characteristic.

[0472] CLAUSE 149: The fiber composite racquet of clause 148, wherein the first material characteristic is a first thickness and wherein the second material characteristic is a second thickness different than the first thickness.

[0473] CLAUSE 150: The fiber composite racquet of clause 148, wherein the first material characteristic is a first + / - fiber composite ply arrangement angle and wherein the second material characteristic is a second + / - fiber composite ply arrangement angle different than the first + / - fiber composite ply arrangement angle.

[0474] CLAUSE 151: The fiber composite racquet of clause 148, wherein the first material characteristic is a first type of fiber material and wherein the second material characteristic is a second type of fiber material different than the first type of fiber material.

[0475] CLAUSE 152: The fiber composite racquet of clause 133 further comprising a marking on the sheet that indicates a designated positioning and orientation of the fiber composite layer on sheet.

[0476] CLAUSE 153: The fiber composite racquet of clause 133 further comprising a non-fiber composite piece sandwiched between adjacent overlapping portions of the sheet.

[0477] CLAUSE 154: The fiber composite racquet of clause 153, wherein the sheet comprises a fiber composite sheet, wherein the fiber composite layer is joined to the fiber composite sheet along a fold and wherein the non-fiber composite piece is discrete from the sheet and the fiber composite layer.

[0478] CLAUSE 155: A method for forming a fiber composite racquet, the method comprising: positioning at least one fiber composite piece on a sheet; rolling the sheet about a mandrel; and fusing the overlapping portions of the sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0479] CLAUSE 156: The method of clause 155, wherein the sheet comprises a fiber composite sheet.

[0480] CLAUSE 157: The method of clause 155, wherein the sheet is a non-fiber composite sheet or omits fibers.

[0481] CLAUSE 158: A method for forming a fiber composite racquet, the method comprising: folding a portion of fiber composite sheet to form a fiber composite layer; positioning a piece discrete from the fiber composite sheet and the fiber composite layer on the fiber composite sheet; rolling the sheet with a folded portion forming the fiber composite layer and with the piece about a mandrel; and fusing the overlapping portions of the rolled fiber composite sheet while shaped in a loop to form at least a head portion of the fiber composite racquet.

[0482] CLAUSE 159: The method of clause 158, wherein the piece comprises a second fiber composite layer.

[0483] CLAUSE 160: The method of clause 158, or the piece comprises a non-fiber composite material or omits fibers.

[0484] CLAUSE 161. A fiber composite racquet comprising: a handle portion; and a head portion coupled to the handle portion and forming a loop, wherein at least the head portion comprises: a rolled sheet wound about a centerline by at least 720 degrees, and wherein the head portion comprises a fiber composite material.

[0485] CLAUSE 162: The fiber composite racquet of clause 161, wherein the handle portion and the head portion are each formed from the rolled sheet.

[0486] CLAUSE 163: The fiber composite sheet of clause 161, wherein the fiber composite material forms the rolled sheet.

[0487] CLAUSE 164: The fiber composite racquet of clause 163, wherein the rolled sheet comprises completely surrounded apertures.

[0488] CLAUSE 165: The fiber composite racquet of clause 164 further comprising a throat portion between the head portion and the handle portion, wherein the completely surrounded apertures coincide with the throat portion.

[0489] CLAUSE 166: The fiber composite racquet of clause 161, wherein the rolled sheet is a fiber composite sheet comprising inwardly extending perimeter notches.

[0490] CLAUSE 167: The fiber composite racquet of clause 161 wherein the rolled sheet is a rolled fiber composite sheet and wherein the fiber composite racquet further comprises a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion and the handle portion.

[0491] CLAUSE 168: The fiber composite racquet of clause 167, wherein the second fiber composite sheet wraps about the rolled fiber composite sheet.

[0492] CLAUSE 169: The fiber composite racquet of clause 167, wherein the rolled fiber composite sheet wraps around the second fiber composite sheet.

[0493] CLAUSE 170: The fiber composite racquet of clause 161 further comprising a layer sandwiched between adjacent overlapping portions of the rolled sheet.

[0494] CLAUSE 171: The fiber composite racquet of clause 170, wherein the layer is wound at least 720° about the centerline.

[0495] CLAUSE 172: The fiber composite racquet of clause 170, wherein the layer comprises a fiber composite layer.

[0496] CLAUSE 173: The fiber composite racquet of clause 170, wherein the layer omits fibers.

[0497] CLAUSE 174: The fiber composite racquet of clause 170, wherein the rolled sheet is a rolled fiber composite sheet having a first material characteristic and wherein the layer has a second material characteristic different than the first material characteristic.

[0498] CLAUSE 175: The fiber composite racquet of clause 170, wherein the layer is joined to the rolled fiber composite sheet along a fold.

[0499] CLAUSE 176: The fiber composite racquet of clause 170, wherein the layer comprises a fiber composite piece distinct from the rolled fiber composite sheet.

[0500] CLAUSE 177: The fiber composite racquet of clause 170 further comprising a second layer captured between second adjacent overlapping portions of the rolled sheet.

[0501] CLAUSE 178: The fiber composite racquet of clause 177, wherein the rolled sheet is a rolled fiber composite sheet having a first material characteristic, wherein the layer has a second material characteristic different than the first material characteristic and wherein the second layer has a third material characteristic different than the first material characteristic and the second material characteristic.

[0502] CLAUSE 179: The fiber composite racquet of clause 170, wherein the rolled sheet comprises a rolled fiber composite sheet, the fiber composite racket further comprising a second layer captured between second adjacent overlapping portions of the rolled fiber composite sheet, wherein the layer is joined to the rolled fiber composite sheet along a first fold at a first angle and wherein the second layer is joined to the rolled fiber composite sheet at along a second fold at a second angle different than the first angle.

[0503] CLAUSE 180: The fiber composite racquet of clause 170, wherein the rolled sheet comprises a rolled fiber composite sheet, wherein the fiber composite sheet comprises a completely surround aperture and wherein the layer comprises a flap jointed to the rolled fiber composite sheet by a fold along an edge of the completely surrounded aperture.

Claims

1. A fiber composite racquet (10) comprising: a handle portion (20); and a head portion (18) coupled to the handle portion (20) and forming a loop, wherein the head portion (18) comprises a fiber composite material, and wherein at least the head portion (18) comprises: a rolled sheet (304) wound about a centerline (331) by at least 720 degrees; and at least one of: a layer (300) joined to the rolled sheet (304) along a fold and sandwiched between adjacent overlapping portions of the rolled sheet (304); and a completely surrounded aperture (307) in the rolled sheet (304).

2. The fiber composite racquet (10) of claim 1, wherein the handle portion (20) and the head portion (18) are each formed from the rolled sheet (304).

3. The fiber composite racquet (10) of claim 1, wherein the fiber composite material forms the rolled sheet (304), and the completely surrounded aperture (307); wherein optionally; the composite fiber racquet (10) further comprises a throat portion (22) between the head portion (18) and the handle portion (20), wherein the completely surrounded aperture (307) coincides with the throat portion (22).

4. The fiber composite racquet (10) of any preceding claim, wherein the rolled sheet (304) is a fiber composite sheet comprising inwardly extending perimeter notches (406).

5. The fiber composite racquet (10) of any preceding claim, wherein the rolled sheet (304) is a rolled fiber composite sheet and wherein the fiber composite racquet (10) further comprises a second fiber composite sheet extending about the centerline by at least 360°, the second fiber composite sheet forming at least one of the head portion (18) and the handle portion (20).

6. The fiber composite racquet (10) of claim 5, wherein the second fiber composite sheet wraps about the rolled fiber composite sheet (304), or wherein the rolled fiber composite sheet (304) wraps around the second fiber composite sheet.

7. The fiber composite racquet (10) of any preceding claim, comprising the layer (300) sandwiched between adjacent overlapping portions of the rolled sheet (304).

8. The fiber composite racquet of claim 7, wherein the layer (300) is wound at least 720° about the centerline (331).

9. The fiber composite racquet (10) of claims 7 or 8, wherein the layer (300) comprises a fiber composite layer.

10. The fiber composite racquet (10) of claims 7 or 8, wherein the layer (300) omits fibers.

11. The fiber composite racquet (10) of any one of claims 7 to 10, wherein the rolled sheet (304) is a rolled fiber composite sheet having a first material characteristic and wherein the layer (300) has a second material characteristic different than the first material characteristic.

12. The fiber composite racquet (10) of any one of claims 7 to 11, wherein the layer (300) is joined to the rolled fiber composite sheet (304) along a fold, or wherein the layer (300) comprises a fiber composite piece distinct from the rolled fiber composite sheet (304).

13. The fiber composite racquet (10) of any one of claims 7 to 12, further comprising a second layer captured between second adjacent overlapping portions of the rolled sheet (304), wherein optionally the rolled sheet (304) is a rolled fiber composite sheet having a first material characteristic, wherein the layer has a second material characteristic different than the first material characteristic and wherein the second layer has a third material characteristic different than the first material characteristic and the second material characteristic.

14. The fiber composite racquet (10) of claim any one of claims 7 to 13, wherein the rolled sheet (304) comprises a rolled fiber composite sheet, the fiber composite racket (10) further comprising a second layer captured between second adjacent overlapping portions of the rolled fiber composite sheet, wherein the layer (300) is joined to the rolled fiber composite sheet (304) along a first fold at a first angle and wherein the second layer is joined to the rolled fiber composite sheet (304) at along a second fold at a second angle different than the first angle.

15. The fiber composite racquet (10) of any one of claims 7 to 14, wherein the rolled sheet comprises (304) a rolled fiber composite sheet, wherein the fiber composite sheet comprises a completely surrounded aperture (307) and wherein the layer (300) comprises a flap jointed to the rolled fiber composite sheet (304) by a fold along an edge of the completely surrounded aperture (307).

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