SPORTS RACQUET AND MANUFACTURING METHOD

Abstract

A sports racquet includes a frame provided with a head portion and a handle portion, a central body couplable to a cavity provided in the head portion, and at least one impact plate couplable to an attachment region arranged in the head portion and/or couplable to the central body, preferably two impact plates couplable facing each other with respect to the head portion, wherein in the attachment region there are attachment means configured for coupling the impact plate. The method for manufacturing the central body and the impact plates, as well as the assembly of the racquet in the different modalities thereof are provided.

Claims

1. A sports racquet, comprising: a frame provided with a head portion and a handle portion, wherein the head portion has an arcuate shape wherein a cavity is disposed along the head portion; a central body couplable to the cavity of the head portion; and an impact plate couplable to an attachment region arranged in the head portion and/or couplable to the central body, wherein attachment means are arranged in the attachment region and configured for coupling the impact plate; wherein the central body comprises a first portion and a second portion couplable together, and the first portion has a ring-like arrangement enabled for inserting thereof in the cavity of the head portion.

2. The sports racquet according to claim 1, wherein the attachment means comprise an adhesive, wherein the adhesive is at least partially arranged in the attachment region and configured to permanently join the impact plate to the head portion.

3. The sports racquet according to claim 1, wherein the attachment means comprise an adhesive tape, wherein the adhesive tape is at least partially arranged in the attachment region and configured to semi-permanently join the impact plate to the head portion.

4. The sports racquet according to claim 1, wherein the attachment means comprise a releasable connection system, wherein the releasable connection system is at least partially arranged in the attachment region and configured to releasably join the impact plate to the head portion.

5. The sports racquet according to claim 4, wherein the releasable connection system comprises a plurality of inserts spacedly attached to the attachment region, and each of the plurality of inserts being is configured for the respective coupling of a fastener, such that the impact plate is configured to be coupled to the attachment region through combination of the plurality of inserts and fasteners.

6. The sports racquet according to claim 1, wherein the second portion of the central body in turn comprises a first part and a second part couplable together.

7. The sports racquet according to claim 6, wherein the impact plate comprises a first impact plate and a second impact plate, wherein the first impact plate is enabled to be coupled to the first part, and the second impact plate is enabled to be coupled to the second part.

8. The sports racquet according to claim 1, wherein the cavity has an essentially C transversal shape, wherein the attachment region is arranged at each of open ends of the cavity of the essentially C transversal shape.

9. The sports racquet according to claim 1, wherein the cavity has two flanges respectively arranged in the open ends, wherein the attachment region is disposed in each of the two flanges.

10. The sports racquet according to claim 1, wherein the frame is a one-piece monocoque structure, wherein the head portion and the handle portion are permanently coupled in the one-piece monocoque structure.

11. The sports racquet according to claim 1, further comprising detection means arranged in the frame and/or in the central body, wherein the detection means are configured to record data on use of the sports racquet, and transmit the data to an external terminal.

12. A method for manufacturing and assembling the sports racquet according to claim 1, comprising steps of: providing the frame; manufacturing the central body, wherein the step of manufacturing the central body comprises steps of machining a block of polymeric material; manufacturing the impact plate; and assembling the central body and two impact plates on the frame; wherein in the step of machining the block of polymeric material to form the central body, the central body is divided into two portions by machining: a first ring-shaped portion intended to be inserted into the cavity of the frame; and a second portion couplable to the first portion.

13. The method according to claim 12, wherein the step of manufacturing the impact plate comprises the-steps of: depositing layers of patterned fabric made of composite material making an impact plate preform of a preset thickness in a mold; heating the mold to a preset curing temperature and applying a preset curing vacuum pressure, monitoring and controlling start, hold and end of a curing temperature and a curing vacuum pressure; demolding a shaped impact plate from a tool; and machining the impact plate for final shaping.

14. The method according to claim 12, wherein the step of depositing the layers of patterned fabric made of composite material making the impact plate preform of the preset thickness in a mold comprises depositing the layers of patterned fabric made of composite material to form a ring on a periphery of the impact plate preform, this ring being thicker than a predetermined thickness of the impact plate preform.

15. The method according to claim 12, wherein in the step of machining the block of polymeric material to form the central body, the second portion is divided into two parts couplable together in a form of a first part and a second part, wherein the first part and the second part are allowed to be coupled to the first portion.

16. The sports racquet according to claim 2, wherein the second portion of the central body in turn comprises a first part and a second part couplable together.

17. The sports racquet according to claim 3, wherein the second portion of the central body in turn comprises a first part and a second part couplable together.

18. The sports racquet according to claim 4, wherein the second portion of the central body in turn comprises a first part and a second part couplable together.

19. The sports racquet according to claim 5, wherein the second portion of the central body in turn comprises a first part and a second part couplable together.

20. The sports racquet according to claim 2, wherein the cavity has an essentially C transversal shape, wherein the attachment region is arranged at each of open ends of the cavity of the essentially C transversal shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The foregoing and other advantages and features will be more fully understood from the following detailed description of exemplary embodiments with reference to the accompanying drawings, which should be considered by way of illustration and not limitation, wherein:

[0049] FIG. 1 is a perspective view of the sports racquet of the invention in an assembled and disassembled state.

[0050] FIG. 2A is a perspective view of the frame in a disassembled state, wherein the head portion and the handle portion are seen separately.

[0051] FIG. 2B is a schematic cross-sectional transverse view wherein the cavity of the head portion is observed.

[0052] FIGS. 3A-3C represent a series of perspective views of the central body in the different embodiments thereof.

[0053] FIGS. 4A-4B are a perspective view of the frame and a cross-sectional view wherein a modality of the attachment means in the form of a permanent joining is shown.

[0054] FIGS. 5A-5C are a perspective view of the frame and a cross-sectional view wherein a modality of the attachment means in the form of a detachable joining is shown.

[0055] FIGS. 6A-6B and FIGS. 7A-7B are a perspective view of the frame and a cross-sectional view wherein a modality of the attachment means in the form of a semi-permanent joining is shown.

[0056] FIG. 8 is a schematic view of the method for manufacturing the central body.

[0057] FIG. 9 is a schematic view of the method for manufacturing the impact plates.

[0058] FIG. 10 is a schematic view of the method for assembling the sports racquet in the detachable modality thereof.

[0059] FIG. 11 is a schematic view of the method for assembling the sports racquet in the permanent modality thereof.

[0060] FIG. 12 is a schematic view of the method for assembling the sports racquet in the semi-permanent modality thereof.

[0061] FIG. 13 is a schematic view of the method for assembling the sports racquet in an alternative detachable modality.

[0062] FIG. 14 is a schematic view of the electronic system of the racquet present in any of the modalities thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0063] In the following detailed description, numerous specific details are set forth in the form of examples to provide a thorough understanding of the relevant teachings. However, it will be apparent to those skilled in the art that the present teachings can be implemented without such details.

[0064] As seen in FIG. 1, the present invention provides a sports racquet (1), hereinafter racquet (1), including a frame (2) having a head portion (2.2) and a handle portion (2.1), a central body (3) couplable to the head portion of the frame (2.2), and at least one impact plate (4) couplable to an attachment region (9) provided in the head portion of the frame (2.2) and/or couplable to the central body (3). Preferably, two impact plates (4) can be coupled opposite to and facing each other in respective attachment regions (9) of the head portion (2.2).

[0065] Alternatively, as seen in FIG. 2A, the handle portion (2.1) can be coupled and uncoupled from the head portion (2.2), therefore resulting in a frame (2) that is also detachable between these two portions for all the following preferred embodiments and their alternatives. However, in the preferred embodiment, the frame (2) is a single piece (monocoque), so that the head portion (2.2) and the handle portion (2.1) are permanently joined.

[0066] As can be seen from the foregoing, the racquet (1) provided is designed to be assembled/detachable, the frame (2), the central body (3) and the impact plates (4) being able to be manufactured in independent processes, wherein depending on the manner in which these elements are joined, and as will be detailed later, the racquet (1) may belong to the permanent joining (5) (FIG. 11), semi-detachable joining (6) (FIG. 12), or completely detachable joining (7) (FIGS. 10 and 13) type.

[0067] As can be seen in FIG. 3A, in one embodiment the central body (3) is a single piece including a perimeter portion intended to be coupled to the head portion of the frame (2.2). To achieve this coupling, the head portion (2.2) has a cavity (8), preferably a C transversal shape, the sports racquet being seen in an AA profile cross-section, so that the perimeter portion of the central body (3) is configured to be inserted into this cavity of the head portion (2.2). In this sense, as seen in FIG. 2B, in order to attach the impact plates (4) to the head portion (2.2), the attachment region (9) takes the form of flanges (9) defined by the C transversal shaped cavity (8), such that the impact plate (4) is coupled to one of said flanges (9). The person skilled in the art will see that, in order to have the racquet (1), two impact plates (4) are arranged to be coupled in these flanges (9) of the head portion (2.2) facing each other on sides or faces opposite to the central body (3).

[0068] As seen in FIGS. 4A-4B, when the impact plates (4) are permanently joined to the frame (2) and/or to the central body (3), the latter being coupled by the perimeter portion in the cavity of the head, by means of an adhesive means applied to the flanges (9), such as epoxy structural adhesive (10a), or through a welding process, or some other analogous technique, the sports racquet with permanent joining (5) (FIG. 3A) is obtained. Although the sports racquet (1) is permanently assembled, it is possible to choose both the frame (2), the central body (3) (foam material, density, volume distribution, etc.) and the materials of the impact plates (4), such that the sports racquet (1) has unique features, although the elements are permanently joined.

[0069] In another preferred embodiment, illustrated in FIGS. 7A-7B, when the impact plates (4) are semi-permanently joined to the frame (2) by means of a high-strength double-sided adhesive tape applied on the flanges (9), such as an acrylic foamed adhesive tape (12a) so that the impact plates (4) can be semi-permanently attached to the frame (2), and the impact plates (4) are further joined to the central body (3) by means of a double-sided adhesive tape, the latter being coupled by the perimeter portion in the cavity of the head (2.2), the sports racquet with semi-permanent joining (6) is obtained.

[0070] Alternatively, as seen in FIGS. 6A-6B, the impact plates (4) are semi-permanently joined to the frame (2) by a hook and loop fastener (22). In this way we have another sports racquet (7b) (FIG. 5A) with a completely detachable joining.

[0071] In another preferred embodiment, as shown in FIGS. 5A-5C, the flanges (9) of the frame (2) further incorporate holes suitable for coupling, using a type of high-strength double-sided adhesive such as an acrylic foamed adhesive tape (12b), star-shaped inserts (13) with a hole each, such as a 4-pointed star, on which other self-locking female threaded inserts (14) are assembled. The star shaped insert (13) is ideal for withstanding the tightening torque of a threaded fastener (15) on a self-locking female threaded insert (14) when the impact plate (4) is coupled without moving in relation to the flange (9). In this way the impact plates (4) can be detachably attached to the frame by means of a common threaded fastener such as a screw (15a). The racquet (7) (FIG. 4A) with a detachable attachment is thus obtained.

[0072] In this sense, the attachment regions (9) (flanges) include a plurality of insert assemblies (12b, 13, 14) spacedly fixed therein, each of said insert assemblies being configured for the coupling of a threaded fastener (15). Therefore, the impact plates (4) are configured to be coupled to the attachment region by the combination of assembly inserts (12b, 13, 14) and fasteners (15).

[0073] Alternatively, as a more simplified assembly, the flanges (9) of the frame (2) are further machined with holes suitable for the coupling of self-locking female threaded inserts (14), so that the impact plates (4) can be detachably attached to the frame (2) by means of threaded fasteners.

[0074] Moreover, in other alternative embodiments of the central body (3), as illustrated in FIG. 3B, it is formed (and can be divided into a greater number of portions) from a first portion or ring (16) and a second portion or core (17) couplable together, wherein the first portion (16) is configured to be coupled to the C transversal shaped cavity (8) of the head of the frame (2.2). The first portion (16) of the central body (3) has an essentially ring shape, wherein the attachment portion for attaching to the head cavity (2.2) is arranged in this ring, at least one poka-yoke portion remaining or not outside said cavity for the coupling of the second portion (17). This shape of the central body (3) from (and not exclusively) two parts or portions, allows for example to have a first portion (16) with one density and a second portion with another density to vary the balance of the sports racquet (1) or allows for only one of the portions of the central body (3) to be replaced if required.

[0075] In another preferred embodiment, illustrated in FIG. 3C, the second portion (17) of the central body (3) is shaped by a first part (19) and a second part (20) couplable together, wherein the first part (19) has protrusions and the second part (20) has recesses, the protrusions and recesses being arranged and positioned for the complementary tongue-and-groove insertion thereof.

[0076] In this embodiment, the impact plates (4) are each suitably attached, by means of, for example, a high-strength double-sided adhesive, such as an acrylic adhesive tape, respectively on the first part (19) and on the second part (20). In addition, the impact plates (4) are glued around the perimeter thereof by means of a high-strength double-sided adhesive, such as an acrylic adhesive tape, a shock-absorbing gasket, such as neoprene, which will function as a separator between the flange (9) (head portion of the frame) and the attachment portion of the impact plate (4).

[0077] In this way there is a detachable racquet (7), since, with the first portion (16) of the central body (3) coupled to the cavity of the head portion (2.2), the first part (19) and the second part (20) are coupled together so that the impact plates (4) each rest on the flanges (9) (attachment portion) of the head portion (2.2) of the frame (2), being able to be attached to the latter by means of releasable joinings, such as a threaded fastener or screw (15a). Alternatively, the shock-absorbing gasket (21a) can be anchored to the flanges (9) of the frame (2) to fulfil the same function.

[0078] As seen in FIGS. 10-13, all possible configurations of the racquet (1) are compatible with a series of common accessories such as: a grip (35), a protector (34) of the head of the frame (2.2), a strap (29) and a plug with housing (36) for a counterweight (37) or an electronic system (25).

[0079] Alternatively, the strap (29) can be presented as a single component or divided into two portions (not exclusively). A first portion (29a) coupled to the handle portion (2.1) and a second portion (29b) corresponding to the portion that is attached to the wrist of the player. The joining game between both portions is possible through a coupler (29c).

[0080] As can be seen in FIG. 14, the racquet (1), in any of its modalities, includes detection means (not illustrated) arranged in the frame (2) and/or in the central body (3) and/or in the impact plate (4), configured to record data on the use of the sports racquet (1), and also configured to transmit said data to an external terminal (24). In particular, such detection means can be arranged in a recess in the handle portion (2.2), which can take the form of an electronic system (25) including, for example, battery, wireless transmitter and receiver, gyroscopes, accelerometers or the like to record and transmit vibrations, accelerations, orientation of the paddle, etc., in order to provide data that can be used by the user to analyze their way of playing and improve their performance, wherein such data can be transmitted to an external terminal for the subsequent processing thereof.

[0081] It is important to note that, although the frame (2) can be made such that the head portion (2.2) and the handle portion (2.1) can be coupled together, in the preferred embodiment, the frame (2) is monocoque or single piece, such that the head portion (2.2) and the handle portion (2.1) are formed in the same body. The fact that the frame (2) is a single piece is advantageous in terms of the stability of the racquet (1) and the durability thereof, as well as to facilitate the coupling of the central body (3) and the impact plates (4).

[0082] The materials from which the frame (2) or the impact plates (4) are made cover a wide range of thermosetting and/or thermoplastic matrices reinforced with reinforcing fibers of glass, carbon, aramid, Kevlar, among others, or combinations of the same (23). Likewise, the central body (3) can be made of a suitable foamed cross-linked polymeric material, for example, foam rubber, with different densities depending on the customization or the functionalities that are to be given to the sports racquet (1).

[0083] In addition to the above, and as shown in FIGS. 8 and 9, the invention provides a method for manufacturing the central body (3) and the impact plates (4) of the sports racquet (1) as described until now, wherein, due to the nature of said racquet (1), which is assembled from three independent elements, it includes a step of providing a frame (2), a step of manufacturing a central body (3) and a step of manufacturing impact plates (4).

[0084] The manufacture of the frame (2) is previously carried out under methods for handling and shaping structures that are based on composite materials, for example, carbon fiber, glass, Kevlar, among others, which enable a monocoque frame to be obtained wherein the handle (2.1) and the head portion (2.2) can be coupled together, or the frame (2) is a single piece with handle (2.1) and head portion permanently attached. Additionally, depending on the type of racquet, once the frame is provided, it is machined for final shaping. The machining can be carried out on a CNC machine (31) that enables the final shaping of the frame (2) according to the type of racquet (1) to be assembled, i.e., depending on whether it is detachable, permanent or semi-permanent. An auxiliary referencing and positioning attachment system can be used as a support.

[0085] In addition, when the racquet (1) has a detachable arrangement, when machining the frame (2) for final shaping, holes are further machined that enable the direct coupling of the self-locking threaded inserts (14) or star-shaped inserts (13) in which the previous self-locking threaded inserts (14) are housed; thus obtaining the frame (2b), detachable racquet (7).

[0086] Alternatively, the star-shaped inserts (13) can be offered in different geometric configurations, as long as their design preserves the anti-rotation functionality thereof.

[0087] Moreover, the step of manufacturing the central body (3), as seen in FIG. 8, includes machining a block (32) of polymeric material by means of a CNC machine. Alternatively, the manufacture of the central body (3) is carried out by means of an injection process of polymeric materials.

[0088] In the embodiment of the racquet with permanent attachment (5) or semi-permanent attachment (6), this manufacturing step results in a central body (3) made up of a single piece of polymeric material, as shown in FIG. 3A.

[0089] Alternatively, in the manufacture of the central body (3), the same is divided into two or three components: [0090] A first ring-shaped part (16); and [0091] A second part (17) couplable to the first part. At the same time, the second part (17) is divided into two parts couplable together, in the form of: [0092] A first impact portion (19); and [0093] A second impact portion (20).

[0094] Moreover, as seen in FIG. 9, the step of manufacturing the impact plates (4) includes: [0095] providing a composite material (carbon fibers, glass, Kevlar or any combination, or similar materials) in prepreg format, wherein this prepreg material (23) (in sheet or fabric format) is formed according to patterns or shapes and orientations (e.g., 90 or 45) obtaining patterned sheets; [0096] depositing at least one layer of patterned sheet (33b) making an impact plate preform of a preset thickness in a mold (26c); [0097] performing a curing cycle, heating the mold (26c) with the impact plate preform to a preset curing temperature and applying a preset curing vacuum pressure, monitoring and controlling the start, hold and end of the curing temperature and curing vacuum pressure; [0098] demolding the shaped impact plate (4) from the mold (26c); and [0099] machining (with a CNC machine (31)) the impact plate (4) for final shaping.

[0100] Alternatively, in the method for manufacturing a racquet with detachable joining (7), in the manufacture of the impact plates (4), a patterned sheet is further deposited forming an outer ring to provide an added thickness suitable for drilling holes. Likewise, during the machining, a countersinking or counterboring of said holes is carried out; which allows the fastener (15) to be positioned flush with the impact plate (4) itself. The machining of the collection of central holes will also be carried out, resulting in the impact plate (4b), as illustrated at the end of the schematic method in FIG. 9.

[0101] In the method of manufacturing a racquet with permanent attachment (5) or a racquet with semi-permanent attachment (6), in the manufacture of the impact plates (4); machining with a CNC machine (31) will be carried out to either finish profiling the outer perimeter of the impact plate, or to obtain the shape if, for example, the cured plate does not have a shape essentially identical to the one that is expected to be obtained from the impact plate (4).

[0102] However, after the manufacture of the frame (2), the manufacture of the central body (3) and the manufacture of the impact plates (4), the final assembly of the different parts is carried out depending on the functionality of the target racquet.

[0103] Therefore, for the manufacture and, especially, the assembly of a racquet with permanent joining (5), as illustrated in FIG. 11, the central body (3) is incorporated into the frame (2a) without drilling (3a) formed by a single piece, on which the unperforated impact plates (4a) are positioned with adhesive means. These, in turn, are solidly joined to the frame (2a) by means of a structural adhesive means, such as epoxy (10a) or similar features. Next, the unperforated racquet with permanent joining (5a) is ready for machining, for example, on a CNC machine, wherein the corresponding central holes of the impact plate(s) (4) and of the central body (3) will be machined.

[0104] Furthermore, as can be seen in FIG. 12, for the manufacture and assembly of a racquet with permanent joining (6), the unperforated central body (3a), formed by a single piece, is incorporated into the frame (2a), on which the unperforated impact plates (4a) are adhesively positioned. These, in turn, are solidly joined to the frame (2a) by means of a double-sided acrylic foam adhesive tape (12a) or with similar features. Next, the unperforated sports racquet with semi-permanent joining (6a) is arranged for machining, for example, on a CNC machine, wherein the corresponding central holes of the impact plate(s) (4) and of the central body (3) will be machined.

[0105] Now, for manufacturing and assembling a detachable racquet (7), illustrated in FIG. 10, a certain number of previously described insert assemblies are incorporated into the frame (2b), which will enable the coupling of threaded fasteners (15a). Subsequently to the frame (2bb), of FIG. 5A, the first portion (16) of the central body (3) in the shape of a ring is incorporated therein. In parallel, each of the portions (18) (19) of the second portion (17) of the central body (3) are assembled to the respective impact plates (4). The first portion (19) and the second portion (20) are permanently attached to the respective perforated impact plates (4) thereof and with a reinforcement ring (4b), FIG. 5C, the shock-absorbing tape or gasket (21a) is further incorporated. The impact plates (4b) with gasket and first portion (19) and second portion (20) can then be joined to the frame (2bb) by means of the threaded fasteners (15a) giving rise to the paddle with detachable joining (7).

[0106] Alternatively, for the manufacture and assembly of a racquet (7b) with detachable joining and hook and loop mechanism, as illustrated in FIG. 13, the final racquet assembly process is analogous to that described above with two exceptions: The shock-absorbing gasket (21a) is replaced by portion one of the hook and loop fastener (22a); and the frame (2a) that is devoid of insert assemblies receives portion two of the hook and loop fastener (22b) on the flange (9).

[0107] Due to the present invention, a racquet (1) optimized in terms of weight and functionalities is achieved, allowing the consumer to choose and/or personalize it, adapting it to their tastes and style of play, as well as the possibility of maintaining and updating it. Currently there is no racquet on the market that offers the possibility of replacing broken, worn or obsolete components.

[0108] Due to the demands in weight, stiffness, wear, resistance to impact and corrosion, composite materials are the ideal material for manufacturing the racquet of the invention in any of the modalities thereof. The frame (2) is the main structure the innovative design of which enables it to be laminated in an easily accessible open mold, wherein the combination and positioning of different reinforcement materials are possible.

[0109] The cavity (8) seen in a C-shaped cross section (8) of the head portion (2.2) and the attachment region (9) in the form of flanges that act as an interface with the impact plate (4), are the differentiating design features of the sports racquet (1) of the invention.