Method of forming a sporting implement
A method of forming a sporting implement includes placing a plurality of fibers in a cavity formed in a first portion of a mold, the mold having an inlet and an outlet. A second portion of the mold is positioned in contact with the first portion such that the cavity cooperates with the second portion of the mold to define a chamber. A first material is mixed with a second material to form a thermoplastic resin. The thermoplastic resin is injected into the chamber through the inlet. The inlet and outlet are closed, and the thermoplastic resin completely polymerizes so as to form a fiber reinforced sporting element in the chamber, and the sporting element is removed from the chamber.
1. A method of forming a sporting implement comprising:
coating a plurality of fibers with one of an epoxy, polyurethane, and an aerosol adhesive;
placing the plurality of fibers in an empty cavity formed in a first portion of a mold, the mold having an inlet and an outlet, the fibers being randomly dispersed in the cavity;
positioning a second portion of the mold in contact with the first portion such that the cavity cooperates with the second portion of the mold to define a chamber, wherein a vacuum pump is operably connected to the chamber, and a gas reservoir is operably connected to the chamber;
creating a vacuum in the chamber with the vacuum pump;
flushing the chamber with gas from the gas reservoir;
mixing a first material with a second material to form a thermoplastic resin;
injecting the thermoplastic resin into the chamber through the inlet, the resin being injected into the chamber at a temperature of between approximately 20° C. and approximately 60° C.;
closing the inlet and the outlet;
waiting until the thermoplastic resin has completely polymerized so as to form a fiber reinforced sporting element in the chamber; and
removing the sporting element from the chamber.
2. The method of claim 1 , further comprising creating a vacuum within the cavity in the first portion of the mold through the outlet.
3. The method of claim 1 , further comprising directing nitrogen gas into the cavity in the first portion of the mold through the inlet.
4. The method of claim 1 , wherein the resin is injected into the chamber at a temperature of below approximately 50° C.
5. The method of claim 1 , wherein the first mold portion and second mold portion include registration elements.
6. The method of claim 1 , wherein the first mold portion includes a pair of projections and the second mold portion includes a pair of apertures, each aperture configured to receive one of the projections.
7. The method of claim 1 , wherein the fibers are coated with an epoxy.
8. The method of claim 1 , wherein the fibers are coated with polyurethane.
9. The method of claim 1 , wherein the fibers are coated with an aerosol adhesive.