Integrally Encapsulated Racket Molding for Stable Handle Attachment

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Solution Overview

Problem

Racket components, such as the wrapping surface and handle sleeve, tend to separate during use, leading to high wastage rates in traditional production methods.

Innovation Solution

An integrally encapsulated racket production process involving injection molding of a plastic adhesive tape and handle sleeve, with a honeycomb board as the substrate, ensuring the wrapping surface and handle are securely attached to the racket body, and a smooth cladding layer for protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual sticking and adhesive tape winding methods are used to attach the wrapping surface and handle sleeve, then the production process is simple and flexible, but the components are prone to separation during use, leading to high wastage rate

Engineering Contradiction:

Improveproduction process simplicityVSAvoidcomponent attachment stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the wrapping surface and handle sleeve attachment process into a single injection molding operation. The injection mold simultaneously forms both components, integrating multiple manufacturing steps into one automated process, which eliminates manual sticking and ensures consistent, reliable attachment without separation during use.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces manual mechanical operations (sticking, winding adhesive tape) with automated injection molding. This substitution eliminates human error and variability in attachment quality, ensuring uniform and reliable bonding of the wrapping surface and handle sleeve to the racket body.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If injection molding is used to integrally encapsulate the racket components, then the component attachment reliability is improved and wastage rate is reduced, but the device complexity and manufacturing process complexity increase

Engineering Contradiction:

Improvecomponent attachment stabilityVSAvoidinjection mold complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The injection mold is designed with separate, modular components for forming the wrapping surface and handle sleeve. This segmentation allows each component to be independently designed and positioned within the mold, simplifying the overall mold structure while maintaining the ability to integrally encapsulate multiple racket components in one operation.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If traditional manual production methods are used, then the production process is flexible and adaptable, but the production efficiency is low and labor intensity is high

Engineering Contradiction:

Improveproduction process flexibilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical operations with automated injection molding machinery. This substitution dramatically increases production efficiency by forming multiple components simultaneously in one automated cycle, eliminating repetitive manual labor while maintaining design flexibility through programmable mold configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances the durability and hand feel of the racket, reduces noise, prevents bulging, and increases production efficiency by securely integrating the racket components.

Implementation Method 1

placing the racket body with the edge sealed in S2 in an injection mold, wrapping, by the injection mold, the racket body with the edge of the racket body being exposed, and injecting the injection mold by an injection molding machine, so that a plastic covered edge is injection molded at the edge of the racket body

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

a plastic adhesive tape is disposed at a connecting part between the wrapping surface and the racket body, the plastic adhesive tape is attached to an edge of the racket body

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS20250387961A1Production process of integrally encapsulated racket

Publication Date: 2025.12.25 DONGGUAN RENCHANG INSULATING MATERIAL CO LTD

AI summary

The present invention discloses a production process of an integrally encapsulated racket. The integrally encapsulated racket is provided. The integrally encapsulated racket includes a racket body, the racket body is externally wrapped with a wrapping surface, a plastic adhesive tape is disposed at a connecting part between the wrapping surface and the racket body, the plastic adhesive tape is attached to an edge of the racket body, a top end of the wrapping surface is in a same horizontal plane as a racket surface of the racket body, a handle sleeve is injection molded at a bottom end of the racket body, and an inner side surface of the handle sleeve is closely attached to the wrapping surface.