Patent ID: 7811500

Claim:
A method for manufacturing at least a frame portion of a sports racquet frame having at least a string port hole formed therein, said frame having a string bed plane, along which said string port hole extends, wherein said method comprises the following manufacturing steps: a) providing a moldable tube structure, which comprises a first tube region containing a first inflatable bladder, a second tube region containing a second inflatable bladder and an intermediate tube region that is located between said first tube region and said second tube region, said tube structure comprising at least a cross channel, which passes through said tube structure at said intermediate tube region; b) placing said tube structure inside a mold which, when closed, forms a mold cavity of the desired shape of said frame portion, at least a mold member being inserted into said cross channel, said mold member having an outer surface, which faces an inner surface of said cross channel, said mold member having position and orientation that correspond to the position and orientation of said string port hole, along said string bed plane; c) pressurizing said first and second bladders, so that said tube structure conforms to the shape of the mold and heating said mold, such that said tube structure cures; and d) removing said cured tube structure from said mold cavity and removing said mold member from said cross channel, said cured tube structure thereby forming said frame portion, said cross channel thereby forming said string port hole; and wherein said step a), of providing said moldable tube structure, further comprises the following manufacturing steps: a.1) providing a chuck member, which comprises a first chuck element that is inserted into said first inflatable bladder, a second chuck element that is inserted into said second inflatable bladder, and an intermediate chuck element between said first chuck element and said second chuck element; a.2) disposing said chuck member within a prepreg tube, so as to be completely surrounded by said prepreg tube; a.3) removing predefined portions of said prepreg tube, at said first opposite sides of said intermediate chuck element, so as to form at least a couple of opposite holes on the opposite surfaces of said prepreg tube, which cover said first opposite sides of said intermediate chuck element; a.4) removing said intermediate chuck element from said prepreg tube; a.5) inserting at least a tube support element through said couple of opposite holes of said prepreg tube; and a.6) removing said first and second chuck elements respectively from said first and second inflatable bladders and from said prepreg tube.