FIELD OF INVENTION

This invention relates to a table tennis bat. More particularly, this invention relates to a table tennis bat with a plurality of transverse members extending through a blade core.

BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion does not relate to what is commonly or well known by the person skilled in the art, but assists in the understanding of the inventive step of the present invention of which the identification of pertinent prior art proposals is but one part.

Table tennis bats have been described in which a plurality of holes aligned transverse to a plane of a blade are provided. The holes may be left as through-holes for weight reduction, air-flow and pressure-at-face reduction. The holes may be filled in material such as wooden plugs or pegs for improved weight distribution, rebound or strengthening. There has been an enormous improvement in bat technology and development activity in the industry, and interest in obtaining improvements in performance are a constant source of research and development. However, in the construction of competition table tennis bats, there is typically involve a trade off between rigidity and speed on the one hand, and the control and maximisation of the sweet spot on the other.

An object of the present invention is to ameliorate the aforementioned disadvantages of the prior art or to at least provide a useful alternative thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects is as defined in the independent claims. Some optional and/or preferred features of the invention are defined in the dependent claims.

Accordingly, in one aspect of the invention there is provided:

A central portion of a table tennis bat including the following elements:

(a) a continuous inner plate that forms a core made of cellulosic material; and

(b) a first layer on a first side of the core made of a first high strength material adapted to form thin sheets and elongate rigid rods, wherein:

(i) the core includes a plurality of transversely aligned elongate members each made of a second material capable of high tensile strength and adapted to be compatible in being joinable with the first material, each of the members having a first end extending through the core from at or adjacent a first outer surface of the core; and

(ii) the first end of each of the members is joined to a first facing surface of the first layer whereby to form a rigid matrix comprising the first layer and the plurality of members that is anchored by the first layer on a first side of the core and extending through the core by means of the plurality of lengths.

Preferably, the central portion includes a second layer on a second side of the core. The second layer is preferably made of the first material and/or the second material. The first and second materials may be the same type of material. The first and second materials may be different but compatible in being adapted to be meldable with each other to form a bond. The first and second materials may include one or a combination of the following examples: carbon fibre, Arylate (supplied by Butterfly), basalt fibre, Curran and Vectran (both supplied by Curran), aramids (such as Kevlar, Technora, Twaron and Heracron), Innegra S, Nylon, and Ultra-high MW polyethylene. Preferably the first and second layers are made from sheets of carbon fibre. The members preferably comprise a plurality of lengths of rigid carbon, each length being made of substantially rigid carbon material.

Each member may include a second end. The second end may extend from at or adjacent a second outer surface of the core. The second end of each of the members may be joined to a second facing surface of the second layer.

Accordingly, in another aspect, the invention provides:

A central portion of a table tennis bat including the following elements:

(a) a continuous inner plate that forms a core made of cellulosic material; and

(b) a first layer on a first side of the core and a second layer on a second side of the core, the first and second layers made of carbon fibre, wherein:

(i) the core includes a plurality of transversely aligned members being lengths of rigid carbon, each member being made of substantially rigid carbon material and having a first end and a second end, the first end extending from at or adjacent a first outer surface of the core and the second end extending from at or adjacent a second outer surface of the core; and

(ii) the first end of each of the members is joined to a first facing surface of the first layer and the second end of each of the members is joined to a second facing surface of the second layer.

In still another aspect, the invention provides:

A method for manufacturing a central portion of a table tennis bat including the following steps:

(a) providing a core in the form of a continuous inner plate made of cellulosic material;

(b) inserting a plurality of transversely aligned members being lengths of rigid carbon through the core, each member extending from a first outer surface to a second outer surface of the core;

(c) providing first and second layers made of carbon fibre either side of the core; and

(d) joining the first end of each member of carbon to a first facing surface of the first layer and joining the second end of each member to a second facing surface of the second layer.

Advantageously, the method further includes:

(e) extending the plurality of rods fully through the corresponding plurality of bores being through-bores formed in the core; and

(f) joining the second end of each of the rods to the second facing surface of the second layer.

With regard to step (e), each of the rods may extend from the first outer surface through the core and may terminate at the second outer surface.

Step (f) may be used to form the matrix comprising of a single piece of material made up of the first and second layers and the rods.

CENTRAL PORTION

The central portion herein refers to the central layer or layers that extends coplanar with the general plane of a table tennis blade. In competition table tennis bats, the central portion predominantly forms the required wood-derived portion of the bat.

CORE

Competition table tennis bats under current international rules must constitute at least 85% of the thickness of the blade (measured in the direction normal to the plane of the blade). The core may be predominantly made of balsa wood, a light wood-derived material that provides good shock-absorption and dampening properties. The core preferably comprises cellulosic material. The core may be made of cellulosic materials, such as Paulownia tomentosa (Paulownia, Kiri), Havea brasiliensis (Rubber Fig), or Ochroma pyramidale (Balsa). The core may include and/or multiple layers of cellulosic material. The wood product used for the core is generally lightweight, low-density and relatively soft wood product.

The core is typically 3 - 8mm in thickness and co-extensive with the blade of which it forms a part. The blade in face view is generally round and has a width that is typically 130 - 170mm, and preferably about 150mm, and a length that is between 130mm and 200mm, and preferably about 150mm - 160mm. The length of the blade is measured from the edge opposed to a handle or gripping area of the bat, to a zone at which an external portion of the handle meets the blade. The portions of the gripping area and the blade area may overlap.

The first and second outer surfaces of the core may be planar and traditionally form a bearing surface for adhesively attaching further outer layers to the blade, such as smooth rubber layers or dimpled rubber, whether externally facing or inverted with or without foam backing

FIRST AND SECOND LAYERS

The first and second layers may be made from a variety of suitable materials adapted to melt and reform strong bonds at low temperatures. For example, the first and second layers may be made of woven carbon fibre sheets. The first and second layers are preferably adapted to soften in temperatures less than 100°C and preferably between 55°C and 70°C. Preferably, at such temperatures, the first and second layers may be meldable and adapted to form polymeric bonds with the first and/or second ends of the members.

The first layer preferably includes a first facing surface adapted to face a first direction of the core. Similarly, the second facing surface is preferably adapted to face the core from a second direction opposed to the first direction.

TRANSVERSE MEMBERS

The members may be made of any one or more of metals, polymers, reinforced polymers, composites, alloys, and suitable materials including, most preferably, carbon fibre. The members may be in the form of solid rods, tubular lengths, flexible woven or twined lengths, and may be adapted to extend linearly through the transverse hole. The transverse holes may be inclined to a direction normal to the blade plane, or are preferably aligned normal to the blade plane, the members forming a 3 dimensional matrix structure with at least the first layer. Preferably, the second end of each of the members is joined to the second layer and collectively form a strong tensile connection between the first and second layers. Preferably, the members are strategically spaced across the first facing surface of the first layer whereby the collective tensile connection of the members to the first layer is distributed and adapted to disperse localised forces applied thereto by the impact of an object (i.e. the table tennis ball). The holes and the corresponding members may be evenly distributed across the first facing surface or may be concentrated in high-probability hitting zones of the blade’ s face, typically concentrated toward the centre of the blade’s face and spaced from the gripping zone and the peripheral zones of the blade in a rounded crescent shape.

The members may each be of consistent cross-section along their lengths. The first and second ends may be formed by cutting long lengths of the second material into short lengths corresponding to the thickness of the core. A margin of error is preferable in that the members are preferably cut into lengths slightly longer (5 - 10%) than the thickness of the core.

JOINED

Joining of the members to the first and/or the second layer is preferably by melding the respective first and second materials at relatively low melting temperatures in a die and allowing the first ends to meld with the first facing surface, then left to cure at room temperature. The core may comprise transversely aligned holes that are preformed, such as by drilling or moulding with inserts, so that the core during manufacture forms part of the die for the melding process.

Alternatively, the first and/or second end may be glued, welded (including ultrasonically) or otherwise attached in a moulding process to the respective first ends.

HANDLE

The handle may include an extension of the core to form a central portion of the handle. The handle may be formed in a moulding process including the steps of applying a permanent foam mould to at least one side of the handle central portion and then over-moulding an outer surface layer over or around the central portion and the foam mould. The outer surface layer is preferably made of carbon fibre sheeting.

Handle die surface material and finish The die used to form a half shell of the handle is preferably finished with polished metal to provide an extremely smooth die cast mould. A polished metal surface may be advantageous because, for mass production, the mould is preferably durable so that it has a long service life. The long service life of a polished metal- surfaced die may be compared to a die with a fibreglass gelcoat finish. The latter tend to break down over time. Moreover, there may be release issues (the moulded material increasingly tending to stick to the die surface). The fibreglass gelcoat finish may have a comparatively limited polishing service life and may not perform well in high temperatures in an autoclave environment. Therefore, preferable die surfaces are long term polished aluminium, shock chromed surfaces, or other durable die metals which allow for a sustainable high polished surface and tends to cope well with repeat polishing to achieve a shining up of the mould.

Handle external surface in the finished product

The quality of the finish on the handle’s external surface relies on the epoxy resin shine generated within the opposing mould surface.

Curing Speed

By applying heat in an autoclave, the handle components may be cured faster compared to curing at room temperature, for example. If curing occurs at higher temperatures and under pressure, production speeds can be increased.

The moulding process for the handle may include the following steps:

STEP 1. One or two carbon fibre cloth layers are laid in a two-piece mould, which is sealed tightly overall with an inlet and outlet or a combination of single and multiple inlets and outlets, optionally including an array of tubes to supply epoxy flow to the mould. The inlet and the outlet provide an epoxy infusion to form an outer shell of the handle. A two-piece mould defining a gap is therefore provided in readiness for infusion to form a hard shell comprising a carbon fibre layer. The space between the moulds corresponding to the gap may be between 0.8mm and 1.4mm. The moulded shell formed in the gap may be in a half egg shell form (comprising preferably carbon cloth and resin) that is removed from the mould; and STEP 2. The handle material forming the components may be trimmed off at a later stage to remove flashes, excess and dags; and

STEP 3. Once trimmed flush the, handle portion, comprising the outer half shell is ready to be adhered to an outer handle surface of the core; OR

STEP 4. The handle shell may then be filled with a liquid foam which cures within the cavity between the shell and the outer surface of the handle portion of the core. A light foam filler, more preferably an ultra-lightweight foam or synthetic filler, may be inserted or injected to fill the cavity defined by the outer moulded handle shell component, made of carbon fibre and epoxy (egg shell), and the outer surface of the handle portion of the core.

Steps 3 and 4 above may be reversed in order. The advantage of ordering step 3 before step 4 is a potentially stronger adherence of the flat foam surface to the handle portion of the core surface using an epoxy or other strong adhesive, rather than relying on the small surface-surface contact of the half edge to the handle portion of the core surface.

It will noted that in Step 3, the outer half shell may be first filled with foam, as in Step 4, before the half shell is attached to the handle portion of the core. This preferably involves a process of filling the half shell cavity with foam, preferably synthetic liquid foam. The foam filling step may be carried out separately before the half shell is attached to the handle portion of the core outer surface. The foam may expand and then dry. The excess foam may then be cut off where it sits beyond plane in which the half shell edge lies. The excess foam may be cut off with a blade, linishing or sanding device, thereby providing an external flat foam surface. The half shell edge and flat foam surface may then be glued or otherwise attached to the handle portion of the core outer surface in accordance with Step 3.

The advantage of this preferred process is that no penetrations or notable holes are required to fill the cavity with foam after the half shell has been adhered to the handle portion of the core outer surface, as may be the case when step 3 precedes step 4.

It will be appreciated that any of the features described herein can be used in any combination, and that the invention as described in respect of the second aspect may have the specific features referred to above in respect of the invention as described in respect of the first aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

Figure 1 is a front elevation view of a core of a table tennis bat according to a first embodiment of the invention;

Figure 2 is a side elevatory view of the core shown in Fig. 1, to which first and second layers of woven sheet are applied on either side to form a central portion of the bat;

Figure 3 is a side view of a combination of the core shown in Fig. 1, first and second layers of woven sheet shown in Fig. 2, and mouldings either side of a handle portion of the bat;

Figure 4 is a lower end elevatory view of the combination shown in Fig. 3;

Figure 5 is a upper end elevatory view of the central portion shown in Fig. 2;

Figure 6 is an exploded upper end view of the central core and first and second layers of woven sheet, including an outer veneer or a combination of laminated timber veneers;

Figure 7 is an upper end elevatory view of the central portion with the first and second layers of woven sheet applied to the core prior to melding, including outer veneer or a combination of laminated timber veneers; and

Figure 8 is an upper end elevatory view of the central portion with the first and second layers of woven sheet applied to the core after melding, and showing optional veneer, foam and outer rubber layers in ghosted outline.

DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention, except as may be recited in the claims accompanying this specification.

As shown in Figs. 1 - 5, the preferred embodiment provides a central portion 110 of a table tennis bat 100. The central portion includes: (a) a continuous or single piece inner plate that forms a core 120 made of cellulosic material; and (b) a first layer 132 on a first side 123 of the core 120 made of a first high strength material having a melting point in the range of 50 - 200°C, and preferably 60 - 70°C. In the preferred embodiment, the central portion 110 includes a corresponding second layer 134 also made of the first material on a second side 125 of the core 120.

With reference to Figs. 6 - 8, the first high strength material is carbon fibre and is suitable for forming thin woven fibre sheets 130 and also suitable for forming elongate rigid rods 140. The first layer 132 when applied to the core 120 extends in a first plane Pi that is parallel to a general plane P of the core 120. More particularly with regard to the preferred embodiment, the sheets 130 are adapted to each extend in one plane of a pair of spaced planes Pi 2 that are each substantially parallel to and positioned either side and parallel planar of and with the general plane P of the core 120. The core 121 includes a plurality of transversely aligned elongate members in the form of the rigid rods 140, each made of a second material. The second material has a melting point int the range of 50 - 200°C, and preferably 60 - 70°C. The second material in the preferred embodiment is also carbon fibre. The second material has high tensile strength and is adapted to be compatible with the first material in being meldable and joinable with the second material such that the rods 140 in a core 120 completed according to the invention extend normal to the plane Pi of the first layer 132 to form an integral and unitary piece connected at rod-layer joins 141. The rods 140 are adapted to extend transversely relative to the plane P and normal to the planes Pi _, 2. The rods 140 are sized to extend substantially into corresponding holes 126 extending from the first outer surface 121 of the core 120 on the first side 123. The rods 140 are sized, even more particularly, to extend the full length of the holes 126. The holes 126 may terminate intermediate the width of the core 120, or may extend fully through the core 120 as through- bores 126, as will be described later.

In the preferred embodiment, the holes 126 are a plurality of bores 126 formed in the core 120 from at or adjacent a first outer surface 121 on the first side 123 of the core 120. Indeed, in the preferred form, the bores 126 extend fully through from the first outer surface 121 of the core 120 on the first side 123 to a second surface 122 of the core 120 on the second side 125. Therefore, in the preferred form, the bores 126 are through bores.

The rods 140 are in the form of a plurality of lengths of rigid carbon, each length being made of substantially rigid carbon material. Each of the rods 140 has a first end 142 adapted to be a leading end that can be inserted into and can be extended through the bores 122.The first end 142 of each of the rods 140 is joined to a first facing surface 135 of the first layer 132 whereby to form a rigid matrix 150 comprising the first layer 132 and the plurality of rods 140 that is joined to and anchored by the first layer 132 on the first side 123 of the core 120 and extends through the core 120 in the form of the plurality of rods 140.

The central portion 110 includes the second layer 134 on the second side 125 of the central portion 110. The second layer 134 is made of the first material. In the preferred form of the invention, the first and second materials are the same type of material, namely carbon fibre. The first and second layers 130 are made from sheets of carbon fibre. The first and second layers 132,134 are advantageously made of sheets of woven carbon fibre.

The first and second materials are meldable with each other to form a bond at each of the joins 141. The matrix 150 is formed by the effect of the bonds 141 that connect the first layer 132 and/or the second layer 134 to the rods 140 for a continuous, single piece and integrally formed structure that is embedded in and around the core 120. The core bores 126 therefore act as permanent dies within which the melded rods 140 form part of the matrix 150. The first outer surface 121 also forms one face of a mould for a first inward facing surface 135 of the first layer 132. The second outer surface 122 also forms another face of a mould for a second inward facing surface of the second layer 136.

Each of the rods 140 include a second end 144. The second end 144 extends from at or adjacent the second outer surface 125 of the core 120. The second end 144 of each of the rods 140 is joined to the second inward facing surface 136 of the second layer 134. The first and second inward facing surfaces 135,136 are coextensive with each other in plan and opposed to each other.

Accordingly, in the preferred form, the central portion 110 of the table tennis bat 110 includes:

(a) the continuous inner plate 120 that forms the core 120 made of cellulosic material; and (b) the first layer 132 on the first side 123 of the core 120 and a second layer 134 on the second side 125 of the core 120. The first and second layers 132,134 are made of carbon fibre. The core 120 includes the plurality of transversely aligned rods 140 being lengths of rigid carbon fibre. Each of the rods 140 is made of substantially rigid carbon fibre material. The first and second ends 142,144 of the rods 140 are arranged such that the first end 142 extends from at or adjacent the first outer surface 123 of the core 121 and the second end 144 extends from at or adjacent the second outer surface 125 of the core 121. The first end 142 of each of the rods 140 is joined to the first facing surface 135 of the first layer 132 and the second end 144 of each of the rods 140 is joined to the second facing surface 136 of the second layer 134.

A method for manufacturing the central portion 110 of the table tennis bat 100 includes the following steps:

(a) providing the core 120 in continuous form using cellulosic material to make the core in the form of an inner plate 120;

(b) inserting in transverse alignment the plurality of rods 140 being lengths of rigid carbon extending through the core 120, each of the rods 140 extending from the first outer surface 121 into the core 120; and

(c) providing the first layer 132 made of carbon fibre such that it is positioned on the first side 123 of the core 120; and

(d) joining a first end 142 of each of the rods 140 to the first facing surface 135 of the first layer 132, including joining the material of the first layer 132 and the first end 142 to form the matrix 150 comprising of a single piece of material made up of the first layer 132 and the rods 140.

Advantageously, the method further includes:

(e) extending the plurality of rods 140 fully through the corresponding plurality of bores 126 being through-bores formed in the core 120, each of the rods 140 extending from the first outer surface 121 through the core 120 and terminating at the second outer surface 122; and

(f) joining a second end 144 of each of the rods 140 to the second facing surface 136 of the second layer 134 whereby 142 to form the matrix 150 comprising of a single piece of material made up of the first and second layers 132,134 and the rods 140.

CENTRAL PORTION

Core

The core 120 is made of a wood-based material. The core 120 material is preferably made from balsa wood.

In terms of thickness, the core 120 is preferably of constant thickness throughout its length and breadth, being between 3 - 5mm in thickness. An outer periphery 124 of the core 120, excluding a portion through which a handle portion 160 is connected, is co-extensive with a blade portion 102 being the paddle or striking portion of the bat 100. The blade portion 102 in face view (see Fig. 1) is generally a rounded square shape in keeping with typical table tennis bat shapes currently on the market and has a width that is typically 150 - 160mm, and a length that is between 165mm and 175mm, with a tapered upper section 162 of the handle portion 160 overlapping or extending into a lower area 104 of the blade portion 102, representing a transition between the handle portion 160 and the blade portion 102. The length of the blade portion 102 is measured from the edge opposed to a handle or gripping area 164 of the bat, to transition zone 104 at which the tapered upper portion 162 of the handle 160 meets the blade portion 102. The tapered upper portion 162 and the transition zone 104 of the blade 102 overlap.

The first and second outer surfaces 121,122 of the core 120 are planar and can form a bearing surface for adhesively attaching further outer layers to the blade portion 102, such as smooth rubber layers or dimpled rubber, whether externally facing or inverted with or without foam backing. First And Second Layers

The first and second layers 132,134 are made from woven carbon fibre sheets. The first and second layers 132,134 can be softened in a die subjecting the material to temperatures less than 100°C and preferably between 55°C and 70°C. At such temperatures, the first and second layers 132,134 are meldable with the rods 140 whereby to form polymeric bonds with the first and/or second ends 142,144 of the rods 140 thus forming the matrix 150.

Transverse Rods

The rods 140 is made of carbon fibre. The rods 140 are in the form of solid or hollow rods, formed in cylindrical or tubular lengths, respectively approximately 2mm to 8mm, and in diameter. The rods 140 form a 3-dimensional matrix structure 150 with at least the first layer 132.

In the preferred form, the second end 144 of each of the rods 140 is joined to the second inward facing surface 136 of the second layer 134 and collectively form a strong tensile connection between the first and second layers 132,134.

The rods 140 are each of consistent cross-section along their lengths. The first and second ends 142,144 are formed by cutting longer lengths of the tubular or cylindrical second material normally supplied on a reel, noting that the second material is very stiff and cannot be subject to sharp bends without damaging the integrity of the fibre. The longer lengths of the second material are cut into short lengths corresponding to the thickness of the core 120. The rod 140 length is then adapted to extend through the bore 126 and for each respective end 142,144 to term in ate flush with the respective surfaces 121,122.

A margin of error is incorporated in calculations of rod 140 length in that the rods 140 are preferably cut into lengths slightly longer (5 - 10%) than the thickness of the core 120 thereby supplying a small weld pool of second material at the location of each end 142,144 to provide the strong joins 141.

Joins

Joining of the rods 140 to the first and/or the second layer 132,134 is achieved, according to the preferred method, by melding the respective first and second materials at relatively low melting temperatures in a die 170 and allowing the first ends 142 to meld with the first facing surface 135, then left to cure at room temperature. The transversely aligned bores 126 are preformed, such as by drilling, stamping, punching, laser or moulding with inserts (not shown), so that the core 120 during manufacture functions as a part of a die complex for the melding process.

TRANSVERSE BORES

The transverse bores 126 are aligned in a direction perpendicular to the blade 102 plane P.

The bores 126 in the core 120, and consequently the rods 140, are strategically and generally evenly spaced in an array according to the array 127 depicted in Fig. 1. It is noted that the array 127 may be a grid pattern, or other geometric arrangement (triangular or hexagonal) that evenly spaces the bores 126 across a two-dimensional surface in the manner shown in relation to the core first surface 121. Accordingly, the corresponding array 127 pattern can be formed across the first facing surface 135 of the first layer 132. It is understood that the collective tensile connection of the rods 140 to the first layer 132 enables the dispersal and redistribution of localised forces applied to the core surface 121 by the impact of an object (i.e. a table tennis ball). The bores 126 and the corresponding rods 140 may alternatively be distributed across the first facing surface 135 in concentrated and high-probability hitting zones of the blade’s 102 face. The high concentration zones can be located in the centre of the blade’s 102 face. The one or more high concentration hitting zones can be spaced from the handle portion 160 and the peripheral edge 124 of the blade 102, for example in a rounded crescent shape. However, preferably the bores 126 are evenly distributed across the surface 121.

ADEHESIVE

As with prior art table tennis bat manufacture, the opposing surfaces of components to be adhered, including the core 120, first and second layers 132,134 and further outer layers, such as veneers, foam layers and outer rubbers, can be adhered using commercial adhesives, such as epoxy resin.

LAYERS

With reference to Figs. 2 and 6 - 8, added to the layers 130, including the first and second layers of woven sheet 132,134 that may be attached by epoxy to the central core 120, a finished bat 100 includes one or more timber veneer layers 145,146 or a combination of laminated timber veneers. The core 130 can be a saleable commodity in its own right, to which timber veneer (or veneer made from other wood-based layering material, foam and rubber layers may be added either side of the core 120 of the blade 102. Each of the first and second timber veneer layers 145,146 has an inner face 137,138 that is adhered to an outer surface 139a-b of the first and second layers 132,134 to complete a blade portion of a bat 100 that may be commercially described as a “core” (as distinct from the core 120 of the invention).

HANDLE

The handle may include an extension of the core 120 to form a central portion of the handle 160. The handle core 166 is a unitary coplanar structure extending from the blade 102 portion of the core 120.

Gripping portions 164 of the handle 160 are formed in a moulding process including the steps of:

(a) providing the die with one or more cavities 171 adapted to determine the external shape of one half of a handle grip 168.

(b) applying a layer of woven carbon fibre material 173 against the cavity 171 internal walls(c) applying another layer of woven carbon fibre material or similar for handle construction, including several combination options, depending on the colour and availability of cloth, with examples shown below. lx layer of BLACK 12k (12,000 fibres per strand). Stands alone and is sufficiently strong for the handle application; lx layer of 3k (3,000 fibres per strand) and 1 x layer of 225 GSM fibreglass layer of chop strand matt. This material is optional and can provide additional strength, although the material is less desirable because it has been found not to sand as well as carbon fibre material when cleaning flash off after the moulded material has cured; or

2x layers of 3k (3,000 fibres per strand) woven carbon fibre material that has been found to increase the strength of the moulded carbon fibre layers shell considerably. The outer layer presents a shiny surface appearance with sparkling wire thread and is considered an upmarket cloth capable of providing a striking visual appearance.

(d) inserting a solid handle grip mould insert 167 adapted to compress and form the woven carbon fibre material 173 into the ultimate external shape of the handle grip 168. And

(e) applying a heated press evenly to an upper flat surface 169 of the handle grip mould 167 whereby to wrap the woven fibre layer 173 around, in skin-tight adherence, the handle grip mould 167 as an over-moulded outer surface layer over or around the handle core 166 and the handle grip mould 167. The gripping portion 164 so formed therefore includes as a permanent core the handle grip mould 167. The handle grip mould 167 is preferably comprised of a high or medium density foam for light weight and has some capacity for resilient deformation for a good tactile feel for a player. The substantially one half of a handle grip 168 consisting of the is adapted to be gripping portion 164 is then adhered to one side of the handle core 166. Thus, the completed gripping portion 164 is adhered to one side of the handle core 166. The outer surface layer is formed from the carbon fibre sheeting of the layer 173.

The die 170 is preferably formed from polished aluminium, polished shock chromed steel, polished fibreglass, a high melting polymer, such as polypropylene, whereby to present the cavity 171 with a smooth internal surface for a good external finish that does not require polishing or other surface treatment or work to the outer surface layer.

Below is a table of references of features shown in the drawings for reference only. Note that the disclosure in the detailed description and drawings takes precedence if there is any discrepancy with those and the table of references.

Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word “comprise” and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

In the present specification, terms such as “apparatus”, “means”, “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an “apparatus”, “means”, “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an “apparatus”, “assembly”, “means”, “device” or “member” is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise. In the present specification, the phrase “and/or” refers to severally or any combination of the features. For example, the phrase “feature 1, feature 2 and/or feature 3” includes within its scope any one of the following combinations: Feature 1 or feature 2 or feature 3; feature 1 and feature 2 or feature 3; feature 1 or feature 2 and feature 3; feature 1 and feature 3 or feature 2; feature 1 and feature 2 and feature 3.

The meaning of descriptive, precise or absolute terms such as “flexed”, “normal”, “parallel”, “horizontal”, “vertical” or “fully” includes the preceding qualifier “substantially or almost”, unless the context or contrary is expressly indicated.

Qualifying relative terms, such as “relatively”, “sufficiently”, “near”, “almost” or “substantially”, may be taken to indicate a variation in an absolute value of between 0° and 10° or between 0% and 10%, relative to the absolute value. For example, “near horizontal” may be taken to mean any orientation between 0° and 10° relative to the horizontal.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, which will usually be apparent from the context.

In the present specification, the term “integral” means formed of one body in a single process. In particular, the term “integrally formed” means formed of the one body without post-forming attachment of separately formed component parts. That is, “integrally formed” and the similar term “unitarily formed” mean formed in a single forming process and do not include post forming attachment of component parts by means of fastener or other component fixing substances or methods.

The articles "a" and "an" are used herein to refer to one or to more than one (i.e. to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention. The features and components of each of the embodiments of the invention described in the detailed description and/or depicted in the accompanying drawings may be interchangeable as required, with regard to functional equivalency and compatibility. A feature or component described with reference to one but not all embodiments, if functionally and dimensionally compatible as an addition with another embodiment herein described, or substitutable with a corresponding feature or component of that other embodiment in relation to which it has not been expressly described, should be read as a potential addition or substitution to that other embodiment and as being within the scope of the invention. Furthermore, in considering a feature or component that is described in relation a particular embodiment but may be omitted from the embodiment without losing the functionality characterising the invention and without departing from the scope of the invention, unless the context and expressions used in describing the embodiment imputes that the feature or component is essential to the invention as broadly described, the omittable feature or component may be read as not being included in the embodiment.