AU2022275406B2

AU2022275406B2 - Sporting Equipment and a Method of Manufacturing Same

Info

Publication number: AU2022275406B2
Application number: AU2022275406A
Authority: AU
Inventors: Craig Leach
Original assignee: RAPTOR SPORTS Pty Ltd
Current assignee: RAPTOR SPORTS Pty Ltd
Priority date: 2022-02-28
Filing date: 2022-11-21
Publication date: 2023-12-21
Anticipated expiration: 2042-11-21
Also published as: AU2022275406A1

Abstract

A method of manufacturing an item of sporting equipment including: impregnating a material comprising a plurality of boron nitride nanotubes with a matrix material to form a composite material; moulding the composite material; and curing the composite material, wherein the item of sporting equipment is at least partially fabricated from the composite material. 1/3 DRAWINGS Impregnating a material comprising a 10 plurality of BNNT with a matrix material Moulding the impregnated material 20 Curing the moulded impregnated 30 material to form the sporting equipment FIG 1

Description

1/3

DRAWINGS

Impregnating a material comprising a 10 plurality of BNNT with a matrix material

Moulding the impregnated material 20

Curing the moulded impregnated 30 material to form the sporting equipment

FIG 1

SPORTING EQUIPMENT AND A METHOD OF MANUFACTURING SAME TECHNICAL FIELD

[0001] The present invention relates to sporting equipment and a method of manufacturing same. In particular, the present invention relates to sporting equipment fabricated from boron nitride nanotubes and a method of manufacturing same.

BACKGROUND

[0002] Almost all sporting product manufacturers have a shared goal to make equipment lighter, stronger and faster. Advances in material technology such as use of composite materials and fibre reinforced materials have improved modern sporting equipment such as racquets, golf clubs, sticks, bats, and fishing rods. Composite materials have also been used to improve safety in sporting equipment, such as in cockpit construction in racing cars. In particular, modern sporting equipment is often fabricated from graphite, carbon fibre, fibreglass, or a composite mix including boron, graphite, or a ceramic additive.

[0003] Inclusion of novel materials, such as graphite, fibreglass, and carbon fibre, in fishing rods have assisted in improving the strength and reducing the weight of the rod while providing sensitivity to feel the biting fish. While fishing rods comprising graphite are lighter, more flexible and have better sensitivity, they are prone to being stiff and/or brittle, causing the rod to snap under load.

[0004] Sporting equipment may also be fabricated from hybrid or multilayer materials, composite materials, and the like. For example, racquets may be fabricated from fibre-reinforced composite materials such as fibreglass, carbon fibre and aramid which have been moulded into shape. While manufacturing racquets from composite materials provides sporting equipment manufacturers with improved freedom of design, mass distribution and stiffness, the higher stiffness of the racquets may increase risk of injury to the player due to repetitive strain-like injuries.

[0005] Several crystalline forms of boron nitride are versatile synthetic materials. For example, hexagonal boron nitride has been used as a lubricant in paints, cosmetics, pencil lead and cement while cubic boron nitride has been used as a cutting or abrasive tool. Cubic boron nitride has also been applied to the surface layers of golf club heads to increase the hardness and strength of the head and has a benefit of being relatively wear-resistant. However, other crystalline forms of boron nitride, such as nanotubes, are considered to be both difficult and expensive to produce (particularly in comparison to more commonly used materials) and their properties, performance and cost-effectiveness in commercial applications such as sporting equipment are untested and unknown.

[0006] Thus, there would be an advantage if it were possible to provide sporting equipment that maintained the relatively light, flexible constructions of existing composite materials, while also improving the strength and/or ductility of the sporting equipment and reducing the risk of injury to users.

[0007] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[0008] Embodiments of the present invention provide sporting equipment at least partially fabricated from a composite material, the composite material comprising a plurality of boron nitride nanotubes within a matrix material, and a method of manufacturing sporting equipment at least partially fabricated from a material comprising a plurality of boron nitride nanotubes which may at least partially address one or more of the problems or deficiencies mentioned above or which may provide the public with a useful or commercial choice.

[0009] The term "sporting equipment" as used herein is broadly defined as an object that may be used during a particular sporting, recreational or fitness activity. Exemplary sporting equipment may include golf clubs, sticks (such as, but not limited to, hockey sticks), bats (such as, but not limited to, cricket bats, baseball bats and the like), paddles, racquets, vaulting poles, fishing rods, and the like, or parts thereof.

[0010] The terms "boron nitride nanotubes" and "BNNT" as used herein is intended to refer to structures that consist of a single layer or multiple layers of boron nitride which are generally tubular and coaxial. The terms "boron nitride nanotubes" and "BNNT" as used herein and, unless otherwise qualified, is intended to encompass any type of nanotube material formed from boron nitride.

[0011] According to a first aspect of the present invention, the invention resides broadly in an item of sporting equipment at least partially fabricated from a composite material, the composite material comprising a plurality of boron nitride nanotubes within a matrix material.

[0012] In some embodiments, the item of sporting equipment may be at least partially fabricated from the composite material comprising a plurality of boron nitride nanotubes within a matrix material and at least partially fabricated from other materials. For instance, the frame of a racquet may be fabricated from the composite material while the strings and a grip portion of the handle may be fabricated from other materials. Similarly, a portion of the head of a golf club (such as, but not limited to the club face) may comprise a composite material and remaining portions of the head maybe fabricated from other materials. In some embodiments, substantially the entire head of the golf club could be fabricated from the composite material.

[0013] In some embodiments, the item of sporting equipment may be at least partially fabricated from two or more different types of composite material comprising a plurality of boron nitride nanotubes within a matrix material. In use, it is envisaged that fabricating the item of sporting equipment from two or more different types of composite material may provide the item of sporting equipment with regions having different properties. For instance, the regions may have different stiffness values, impact resistance, dampening, strength-to-weight ratio, or the like. For instance, the head of the golf club may be fabricated from a first composite material and the shaft of the golf club may be fabricated from a second composite material. The first and second composite materials may differ in any suitable manner. For instance, the first and second composite materials may make use of a different matrix material, or a different concentration of boron nitride nanotubes within the matrix. In other embodiments, the composite materials may include different additives therein, the additives being configured to provide the composite materials with particular physical properties. For instance, it may be desired that the composite material be resiliently deformable. Alternatively, it may be desired that the composite material be substantially rigid.

[0014] Any suitable portion of the sporting equipment may be at least partially fabricated from the composite material. Generally, the portion may be a portion of the item of sporting equipment which may benefit from one or more of improved strength, reduced weight, improved flexibility, improved damping, increased durability, and the like. For instance, the portion of the sporting equipment may comprise a contact portion such as a head of a golf club or hockey stick, a frame of a racquet, a bat trunk of a baseball bat, a blade of a cricket bat, or the like. Further, the portion of the sporting equipment may be a grip portion or a portion which enables a user to manipulate the sporting equipment such as a shaft, bat, handle, rod, a vaulting pole, or the like of the sporting equipment. Still further, the portion of the sporting equipment may be a portion which in use may be under high load such as the shaft of a fishing rod, the shaft of a golf club, or the shaft of a vaulting pole.

[0015] In some embodiments, substantially all of the item of sporting equipment may be fabricated from the composite material.

[0016] The composite material may be of any suitable type. Generally, however, the composite material may be suitable for shaping. Any suitable shaping process may be used, such as, but no limited to, casting, moulding, extrusion, sheet or filament forming, machining, printing, laser cutting or the like, or any suitable combination thereof. For instance, the composite material may comprise a composite material (or a nanocomposite material) comprising boron nitride nanotubes dispersed within a polymer, metal and/or ceramic matrix, an assembly of boron nitride nanotubes impregnated with a polymer, metal and/or ceramic material, a material at least partially coated with boron nitride nanotubes such that a multi-layered structure is formed, or the like.

[0017] It will be understood that the shaping process that is used to form the item of sporting equipment from the composite material will depend on the nature of the item of sporting equipment. For instance, in embodiments of the invention in which the item of sporting equipment comprises an elongate member (such as a fishing rod, golf club shaft or the like), the composite material may be moulded about a mandrel to form the item of sporting equipment. In other embodiments, such as when the item of sporting equipment comprises the club face of a golf club, the composite material may be cast to form the item of sporting equipment.

[0018] As previously indicated, the composite material comprises a plurality of boron nitride nanotubes within a matrix material. In some embodiments, a material comprising a plurality of boron nitride nanotubes may be impregnated with a matrix material to form a composite material. It will be understood that the material comprising a plurality of boron nitride nanotubes may comprise a material of which the plurality of boron nitride nanotubes form a portion. For instance, the boron nitride nanotubes may be contained within a material. This material may be retained within the matrix or may be removed or destroyed when the matrix material is added thereto. Alternatively, the material may comprise a plurality of boron nitride nanotubes as well as other components, such as, but not limited to, a plurality of carbon nanotubes.

[0019] In other embodiments, the term "the material comprising a plurality of boron nitride nanotubes" may simply refer to a plurality of boron nitride nanotubes.

[0020] Any suitable matrix material may be used. For instance, the matrix material may be a polymer, a metal and/or a ceramic matrix material. Preferably, the matrix material may comprise a polymer.

[0021] In some embodiments, the polymer may at least partially coat the material, may substantially encase the material, may impregnate the material such that the polymer at least partially fills any openings in and or around the boron nitride nanotubes, or any suitable combination thereof. Generally, however, the polymer may bond to the material such that the material and the polymer may not separate from one another.

[0022] In a preferred embodiment of the invention, the polymer material may be provided in liquid form, and may be allowed to flow around and/or into the material to at least partially penetrate and/or encapsulate the boron nitride nanotubes. Preferably, the polymer may be allowed to at least partially set to form a solid composite material.

[0023] Any suitable polymer may be used. For instance, the polymer may be polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyether sulphones, acrylonitrile butadiene styrene, polyether polyols, polyester polyols, polyacetal or polyoxymethylene (acetal, POM), polycarbonates, elastomers, thermoplastic elastomers, thermoplastic polyester, thermoplastic polyurethane, polyketones (such as but not limited to polyaryletherketone (PAEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK) or the like), acrylate polymers, poly(methyl methacrylate) (PMMA), polyphenylene sulfide (PPS), polyamides, polyphthalamide (PPA, performance Nylon), fluoropolymers (such as, but not limited to, polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), polyvinylidene fluoride or polyvinylidene difluoride (PVDF), polychlorotrifluoroethylene (PCTFE), perfluoroalkoxy alkane (PFA), or the like), high density polyethylene (HDPE), ultra-high molecular weight polyethylene (UHMWPE), epoxy resins, phenolic resins, and the like, their monomers thereof, or any suitable combination thereof. In a preferred embodiment of the invention, the polymer may be a thermosetting polymer.

[0024] In some embodiments, the polymer may be an epoxy resin. Any suitable type of epoxy resin may be used, such as a bisphenol epoxy resins, an aliphatic epoxy resins, a novolac epoxy resin, a halogenated epoxy resin, an epoxy resin diluent, and/or a glycidylamine epoxy resin.

[0025] In some embodiments, the matrix material may comprise two or more polymers. The two or more polymers may be the same type of polymer or may be of different types.

[0026] The composite material may comprise any suitable weight percent boron nitride nanotubes in the matrix material. For instance, the composite material may comprise between about 0.05 wt% and about 60 wt% boron nitride nanotubes. More preferably, the composite material may comprise between about 0.1 wt% and about 55 wt% boron nitride nanotubes. Still more preferably, the composite material may comprise between about 0.5 wt% and about wt% boron nitride nanotubes. Yet more preferably, the composite material may comprise between about 0.5 wt% and about 30 wt% boron nitride nanotubes. Even more preferably, the composite material may comprise between about 0.5 wt% and about 20 wt% boron nitride nanotubes. Still more preferably the composite material may comprise between about 0.5 wt% and about 10 wt% boron nitride nanotubes.

[0027] In some embodiments, the composite material may further comprise a metal. Any suitable metal may be used, such as titanium or alloys thereof, zirconium or alloys thereof, aluminium or alloys thereof, copper or alloys thereof, or the like. In some embodiments, the composite material may comprise a metal-boron nitride nanotube layered structure wherein a metal material may be at least partially coated with boron nitride nanotubes, a plurality of metal particles dispersed within a material comprising a plurality of boron nitride nanotubes, a plurality of boron nitride nanotubes dispersed within a metal-based structure, or the like.

[0028] In some embodiments, the composite material may further comprise a fibre such as aramid fibre, carbon fibre, carbon nanotubes, a glass fibre, a polymer fibre, or the like.

[0029] In embodiments of the invention in which the composite material further comprises carbon nanotubes, the carbon nanotubes may be present in any suitable concentration. For instance, the composite material may comprise between about 0.05 wt% and about 60 wt% carbon nanotubes. More preferably, the composite material may comprise between about 0.1 wt% and about 55 wt% carbon nitride nanotubes. Still more preferably, the composite material may comprise between about 0.5 wt% and about 50 wt% carbon nanotubes. Yet more preferably, the composite material may comprise between about 0.5 wt% and about 300 wt% carbon nanotubes. Even more preferably, the composite material may comprise between about 0.5 wt% and about 20 wt% carbon nanotubes. Still more preferably the composite material may comprise between about 0.5 wt% and about 10 wt% carbon nanotubes.

[0030] The composite material may be provided in any suitable form. In a preferred embodiment of the invention, however, the composite material may be provided in the form of a tape, sheet, film or the like.

[0031] The applicant has discovered that boron nitride nanotubes may have a tendency to agglomerate or clump in certain circumstances and at certain concentrations within the composite material. This agglomeration of boron nitride nanotubes may result in a non homogenous distribution of boron nitride nanotubes within the composite material, which in turn reduces the advantageous mechanical and physical properties of the composite material.

[0032] Thus, in some embodiments of the invention, the composite material may further comprise a dispersant. Any suitable dispersant may be used, although it will be understood that the purpose of the dispersant may be to ensure that the boron nitride nanotubes are substantially homogenously distributed within the composite material.

[0033] The dispersant may be of any suitable form. For instance, the dispersant may comprise an inorganic solvent, such as, but not limited to, N, N-dimethylformamide, N-methyl 2-pyrrolidone, hexamethylphosphoramide, N-methylcaprolactam, dimethyl sulfoxide, N-acetyl 2-pyrrolidone, N, N-dimethyl. Acetamide, water, monohydric alcohols such as methanol, ethanol, propanol, isopropanol and butanol, dihydric alcohols such as ethylene glycol and propylene glycol, trihydric alcohols such as glycerin, ketones such as acetone, cyclic ethers such as tetrahydrofuran, halogenated aromatic hydrocarbons such as 1,2-dichlorobenzene, haloalkanes such as chloroform, 1-methylnaphthalene, and so on. In some embodimenmts of the invention, the dispersant may comprise sodium dodecylbenzene sulfonate.

[0034] In some embodiments of the invention, the dispersant may comprise a surfactant. The surfactant may be of any suitable form, although in a preferred embodiment of the invention the surfactant may comprise a non-ionic surfactant, and particularly a hydrophilic non-ionic surfactant. In some embodiments of the invention, the dispersant may comprise a poloxamer. In some embodiments, the dispersant may comprise a triblock copolymer.

[0035] In some embodiments, a grip portion or a portion which enables a user to manipulate the sporting equipment may be at least partially fabricated from a material comprising a plurality of boron nitride nanotubes within a matrix material. For instance, the grip portion may be a shaft, bat, handle, rod, vaulting pole, or the like.

[0036] In other embodiments, a contact portion of the sporting equipment may be at least partially fabricated from a composite material comprising a plurality of boron nitride nanotubes within a matrix material. The term "contact portion" as used herein is intended to refer to the portion of the sporting equipment configured to contact or impact an object when participating in a sport. For instance, the contact portion may be a club face of a golf club or hockey stick, a frame of a racquet, a bat trunk of a baseball bat, a blade of a cricket bat, or the like.

[0037] In preferred embodiments, the item of sporting equipment may be a golf club or a fishing rod.

[0038] According to a second aspect of the present invention, there is provided a method of manufacturing an item of sporting equipment, the method including:

impregnating a material comprising a plurality of boron nitride nanotubes with a matrix material to form a composite material;

moulding the composite material; and

curing the composite material to form the item of sporting equipment, wherein the item of sporting equipment is at least partially fabricated from the composite material.

[0039] Preferably, the matrix material of the first aspect is the matrix material of the second aspect.

[0040] The material comprising a plurality of boron nitride nanotubes may be of any suitable form. For instance, the material may comprise an assembly of boron nitride nanotubes such as fibrils, yarns, films, tapes, sheets, buckypaper, or the like. For instance, the material may comprise an injectable composition. However, it will be appreciated by a person skilled in the art that the form of the material may vary depending on a number of factors such as the moulding manufacturing process and the application of the sporting equipment.

[0041] In some embodiments, the material may be relatively dry. In this instance, it will be understood that the material may comprise a plurality of boron nitride nanotubes that are substantially free of a polymer before being impregnated with a matrix material.

[0042] Preferably, the matrix material may comprise a polymer. Any suitable polymer may be used. For instance, the polymer may be polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyether sulphones, acrylonitrile butadiene styrene, polyether polyols, polyester polyols, polyacetal or polyoxymethylene (acetal, POM), polycarbonates, elastomers, thermoplastic elastomers, thermoplastic polyester, thermoplastic polyurethane, polyketones (such as but not limited to polyaryletherketone (PAEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK) or the like), acrylate polymers, poly(methyl methacrylate) (PMMA), polyphenylene sulfide (PPS), polyamides, polyphthalamide (PPA, performance Nylon), fluoropolymers (such as, but not limited to, polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), polyvinylidene fluoride or polyvinylidene difluoride (PVDF), polychlorotrifluoroethylene (PCTFE), perfluoroalkoxy alkane (PFA), or the like), high density polyethylene (HDPE), ultra-high molecular weight polyethylene (UHMWPE), epoxy resins, phenolic resins, and the like, their monomers thereof, or any suitable combination thereof

[0043] In other embodiments, the material may be pre-impregnated with an amount of a polymer. In this instance, the polymer used to provide a pre-composite material may be the same type of polymer or a different type of polymer used to impregnate the material.

[0044] In some embodiments, the polymer may be an epoxy resin. Any suitable type of epoxy resin may be used, such as a bisphenol epoxy resins, an aliphatic epoxy resins, a novolac epoxy resin, a halogenated epoxy resin, an epoxy resin diluent, and/or a glycidylamine epoxy resin.

[0045] In some embodiments, the polymer may comprise a hardener. In this instance, it is envisaged that the hardener may assist in the curing of the composite material. The hardener may be of any suitable form, such as, but not limited to one or more aliphatic and aromatic amines, anhydrides or polyamides, or any suitable combination thereof. In embodiments of the invention in which the hardener comprises an anhydride, the anhydride may comprise phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, pyromellitic dianhydride, 3, 3, 4, 4-tetracarboxybenzophenonedianhy-dride, chlorendic anhydride, methylnadic anhydride and/or trimellitic anhydride.

[0046] The material comprising a plurality of boron nitride nanotubes may be impregnated with a polymer using any suitable technique known in the art. For instance, the material may be impregnated by applying a polymer to the surface of the material until the required thickness is achieved (such as by coating, by deposition, by spraying, etc.), the polymer may be absorbed into the material, the polymer may be injected into a mould cavity comprising the material during an injection moulding process, the polymer may be pressed into the material during a vacuum moulding process, or the like. In some embodiments of the invention, the polymer may be provided in liquid form and allowed to at least partially set after being introduced to the boron nitride nanotubes in order to form the composite material.

[0047] As previously stated, the composite material may be shaped using any suitable process known in the art, and the shaping process used may be determined by the nature of the item of sporting equipment to be formed. In some embodiments of the invention, the composite material may be moulded to form the item of sporting equipment. In this embodiment, the composite material may be moulded using spray-forming, filament winding, liquid forming, resin transfer moulding, compression moulding, injection moulding, vacuum autoclave, vacuum induction, induction heating, high temperature moulding, lamination moulding, pultrusion moulding, bladder moulding, mandrel moulding or the like.

[0048] The composite material may be cured using any suitable process known in the art. In this instance, it will be understood that curing is a chemical process which initiates cross linking of polymer chains causing the polymer to harden or toughen. However, a person skilled in the art will appreciate that the curing process may vary depending on a number of factors such as the type of polymer, the form of the material, the desired properties of the composite material and the moulding manufacturing process. For instance, the composite material may be cured using an additive, radiation, temperature and/or pressure.

[0049] In some embodiments, the composite material may comprise one or more layers of material. In embodiments of the invention in which the composite material comprises two or more layers of material, the two or more layers of material may be laminated together to form a laminated composite material (for instance, about a mandrel, by applying pressure and/or an adhesive etc.) and cured using a hardener and/or by applying pressure and/or temperature to form the sporting equipment. In embodiments of the invention in which the composite material comprises two or more layers, at least one layer of the laminated composite material may comprise a material other than the composite material. Any other suitable material may be used, and it is envisaged that the other material may be used to impart the laminated composite material with particular properties (such as mechanical properties, electrical properties or the like, or any suitable combination thereof).

[0050] According to a third aspect of the present invention, there is provided an item of sporting equipment or a portion thereof when manufactured according to the method of the second aspect.

[0051] Advantageously, the item of sporting equipment of the present invention provides improved strength to weight compared to sporting equipment using existing reinforced fibre compositions. Further, the sporting equipment of the present invention has a reduced failure rate due to the improved binding of the boron nitride nanotube and polymers in the composite material.

[0052] It is envisaged that, advantageously, sporting equipment manufactured from the composite material may have improved ductility over existing reinforced fibre compositions. This improved ductility may reduce damage to, or breakage of, the sporting equipment in high load situations. The composite material may be opaque or at least semi-transparent. Preferably, the composite material provides the item of sporting equipment with a relatively high strength to weight ratio, and relatively high durability.

[0053] It is anticipated that a composite material comprising boron nitride nanotubes would offer improved strength to weight ratio without compromising flexibility over other crystalline forms of boron nitride currently in use. In addition, it is anticipated that a composite material comprising boron nitride nanotubes would offer improved thermal stability over other crystalline forms of boron nitride currently in use.

[0054] In another aspect, the invention resides broadly in a screen for a computing device, the screen comprising a one or more layers, wherein at least one of the one or more layers includes a material comprising a plurality of boron nitride nanotubes.

[0055] The screen may comprise any suitable number of layers. However, in a preferred embodiment of the invention, the screen may comprise a plurality of layers. In a specific embodiment, the screen may comprise at least three layers. In this embodiment, the four layers may comprise a transparent layer, such as a layer fabricated from glass, polymer (such as, but not limited to, a polycarbonate) or the like (wherein the transparent layer is preferably coated with a metallic-conductive coating on an upper surface thereof), a spacer layer and an outer coated layer, and specifically an outer polyester-coated layer (preferably with a metallic-conductive coating on a lower surface thereof). In this embodiment of the invention the polyester-coated layer may include the material comprising a plurality of boron nitride nanotubes. Preferably, the polyester coated layer comprises an outer layer of the screen, while the transparent layer comprises an inner layer of the screen. The outer coated layer may be fabricated from any suitable material, such as glass, polymer (such as, but not limited to, polycarbonate) and the like. The boron nitride nanotubes may be embedded or impregnated within the outer coated layer. Alternatively, the outer coated layer may comprise a mixture of glass or polymer and the composite material according to the other aspects of the invention.

[0056] In an alternative embodiment of the invention, the screen may comprise at least four layers. In this embodiment, the five layers may comprise a transparent layer, such as a layer fabricated from glass, polymer (such as, but not limited to, a polycarbonate) or the like (wherein the transparent layer is preferably coated with a metallic-conductive coating on an upper surface thereof), a spacer layer, a coated layer, and specifically a polyester-coated layer (preferably with a metallic-conductive coating on a lower surface thereof), and a layer of material comprising a plurality of boron nitride nanotubes. In this embodiment of the invention, the layer of material comprising a plurality of boron nitride nanotubes may comprise an outer layer of the screen. The coated layer may be fabricated from any suitable material, such as glass, polymer (such as, but not limited to, polycarbonate) and the like.

[0057] The layer of material comprising a plurality of boron nitride nanotubes may comprise the composite material according to the other aspects of the invention.

[0058] It will be understood that the term "inner layer" is intended to refer to the layer of the screen that is located adjacent to the display (such as an LCD display) of the computing device, while the term "outer layer"refers to the layer of the screen that forms at least part of the external surface of the computing device.

[0059] Preferably, the spacer layer includes a plurality of sensors configured to sense touching of the screen (whether by a user's finger, or an object such as a stylus).

[0060] In other embodiments of the invention, it is envisaged that two or more layers within the screen may include, or be fabricated from, the material comprising a plurality of boron nitride nanotubes.

[0061] Preferably, the material comprising a plurality of boron nitride nanotubes is the same material as described in respect to the other aspects of the invention.

[0062] In a preferred embodiment of the invention, the screen may comprise a touchscreen. The touchscreen may comprise a capacitive touchscreen, a resistive touchscreen, or any other suitable type of touchscreen.

[0063] In a preferred embodiment of the invention, the computing device may comprise a mobile telephone, computing tablet, laptop computer, smart watch or the like, or any suitable combination thereof. It is envisaged that, by introducing a material comprising a plurality of boron nitride nanotubes into the screen, the strength and durability (and the resistance to cracking or shattering) of the screen may be improved.

[0064] The layers including boron nitride nanotubes may comprise any suitable weight percent boron nitride nanotubes in the matrix material. For instance, the layers may comprise between about 0.05 wt% and about 60 wt% boron nitride nanotubes. More preferably, the layers may comprise between about 0.1 wt% and about 55 wt% boron nitride nanotubes. Still more preferably, the layers may comprise between about 0.5 wt% and about 50 wt% boron nitride nanotubes. Yet more preferably, the layers may comprise between about 0.5 wt% and about 30 wt% boron nitride nanotubes. Even more preferably, the layers may comprise between about 0.5 wt% and about 20 wt% boron nitride nanotubes. Still more preferably the layers may comprise between about 0.5 wt% and about 10 wt% boron nitride nanotubes.

[0065] It has surprisingly been found that the addition of boron nitride nanotubes to the screen not only improves the properties of the screen (such as the mechanical strength, durability, elastic deformability, crack resistance and so on) but also does not have a detrimental effect on the responsiveness of the screen to a user's touch.

[0066] In another aspect of the invention, the present invention resides broadly in a component for a watch, the component including a material comprising a plurality of boron nitride nanotubes.

[0067] The component may be of any suitable type. For instance, the component may comprise a watch crystal, a watch band, a watch casing or the like.

[0068] In embodiments of the invention in which the component comprises a watch crystal, the watch crystal may be fabricated from a transparent glass or polymer material that is impregnated with the material comprising a plurality of boron nitride nanotubes. Alternatively, the watch crystal may be of conventional design and may be provided with one or more layers of the material comprising a plurality of boron nitride nanotubes. The one or more layers of the material comprising a plurality of boron nitride nanotubes may be provided on an inner surface of the watch crystal, an outer surface of the watch crystal, or a combination of the two.

[0069] In some embodiments, the watch crystal may be of conventional composition with the addition of boron nitride nanotubes embedded or impregnated therewithin. Preferably, the material comprising a plurality of boron nitride nanotubes is the composite material as described in respect to the other aspects of the invention.

[0070] The watch crystal and/or the composite material may comprise any suitable weight percent boron nitride nanotubes in the matrix material. For instance, the watch crystal and/or the composite material may comprise between about 0.05 wt% and about 60 wt% boron nitride nanotubes. More preferably, the watch crystal and/or the composite material may comprise between about 0.1 wt% and about 55 wt% boron nitride nanotubes. Still more preferably, the watch crystal and/or the composite material may comprise between about 0.5 wt% and about wt% boron nitride nanotubes. Yet more preferably, the watch crystal and/or the composite material may comprise between about 0.5 wt% and about 30 wt% boron nitride nanotubes. Even more preferably, the watch crystal and/or the composite material may comprise between about 0.5 wt% and about 20 wt% boron nitride nanotubes. Still more preferably the watch crystal and/or the composite material may comprise between about 0.5 wt% and about 10 wt% boron nitride nanotubes.

[0071] It is envisaged that a watch fabricated from the component (or a plurality of components) of the present invention may be relatively lightweight, durable and have relatively high impact resistance. Thus, it is envisaged that a watch fabricated from the component (or a plurality of components) of the present invention may be a sports watch. The sports watch may be broadly described as an item of sporting equipment.

[0072] Those skilled in the art would immediately understand that the performance and properties of boron nitride nanotubes in sporting equipment, screens and watch crystals as described herein is both previously unknown and previously untested. While some relatively obscure studies of the general properties of boron nitride nanotubes may have occurred, no previous efforts to determine the suitability of boron nitride nanotubes in the specific applications of the present invention have been made. Given the varied environments in which the sporting equipment, screens and watch crystals of the present invention are used, and the different forces experienced during the use of these objects, a skilled addressee could not predict the suitability of boron nitride nanotubes in these specific applications based on studies of the general properties of this material.

[0073] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0074] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0075] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0076] Figure 1 illustrates a method of manufacturing an item of sporting equipment according to an embodiment of the present invention.

[0077] Figure 2 illustrates a fishing rod fabricated using a method according to an embodiment of the present invention.

[0078] Figure 3 illustrates a golf club fabricated using a method according to an embodiment of the present invention.

[0079] Figure 4 illustrates a portion of a golf club fabricated using a method according to an embodiment of the present invention.

[0080] Figure 5 illustrates a screen for a computing device fabricated using a method according to an embodiment of the present invention.

DETAILED DESCRIPTION

[0081] Figure 1 illustrates a method (100) of manufacturing an item of sporting equipment according to an embodiment of the present invention.

[0082] At step 10, a material comprising a plurality of boron nitride nanotubes may be impregnated with a matrix material. The material comprising a plurality of boron nitride nanotubes may in the form of a tape or a sheet.

[0083] In some embodiments, the material comprising a plurality of boron nitride nanotubes may be impregnated with a polymer. The material may be impregnated in any suitable manner. However, in the embodiment of the invention illustrated in Figure 1, the material is impregnated by allowing liquid polymer to flow around and into the material in order to encapsulate and/or penetrate the boron nitride nanotubes. The polymer bonds to the material such that the material and the polymer will not separate from one another. In Figure 1, the material comprising a plurality of boron nitride nanotubes is simply a plurality of boron nitride nanotubes.

[0084] In the embodiment of the invention illustrated in Figure 1, the polymer comprises an epoxy resin, and in particular a bisphenol epoxy resin.

[0085] At step 20, the composite material may be moulded. It will be understood that the moulding of the composite material is performed in order to provide the desired shape of the item of sporting equipment. For instance, the composite material may be cast to form the item of sporting equipment, or may be moulded by wrapping the composite material around a mandrel to form an elongate member.

[0086] Once the item of sporting equipment has been formed in the desired shape through the moulding process 20, the composite material may be cured 30 to form the sporting equipment. The composite material is cured through the addition of a hardener in the form of phthalic anhydride to the composite material. Curing of the composite material may also (or in addition to) be achieved by applying a source of heat to the composite material to harden the polymer and/or accelerate the curing process.

[0087] Figure 2 illustrates a fishing rod 40 fabricated using a method according to an embodiment of the present invention. The fishing rod 40 of Figure 2 has been fabricated using the method described in Figure 1, and the shaft 41 of the rod 40 has been fabricated by rolling one or more sheets of composite material about a mandrel to form the elongate shaft 41 of the rod.

[0088] In addition, the grip portion, or handle 42, of the rod 40 has been fabricated in the same manner.

[0089] By fabricating the shaft 41 and the handle 42 of the fishing rod 40 according to the method of present invention, the fishing rod 40 has been provided with improved mechanical strength, improved durability and improved elastic deformability.

[0090] Figure 3 illustrates a golf club 43 fabricated using a method according to an embodiment of the present invention. The golf club 43 of Figure 3 has been fabricated using the method described in Figure 1, and the shaft 44 of the golf club 43 has been fabricated by rolling one or more sheets of composite material about a mandrel to form the elongate shaft 44 of the rod.

[0091] In addition, the grip portion, or handle 45, of the golf club 43 has been fabricated in the same manner.

[0092] By fabricating the shaft 44 and the handle 45 of the golf club 43 according to the method of present invention, the golf club 43 has been provided with improved mechanical strength, improved durability and improved elastic deformability.

[0093] Figure 4 illustrates a portion of a golf club 43 fabricated using a method according to an embodiment of the invention. Specifically, Figure 4 illustrates the head 46 of the golf club 43.

[0094] The head 46 of the golf club 43 includes a club face 47 fabricated according to the method of the present invention. The club face 47 is fabricated in much the same way as described in relation to Figure 1, with the exception that the club face 47 is shaped from the composite material by bladder moulding, casting or the like.

[0095] Figure 5 illustrates a screen 48 for a computing device fabricated using a method according to an embodiment of the present invention. In particular, the screen 48 comprises a touchscreen for use with a computing device, such as a mobile telephone, laptop computer, smart watch, computing tablet or the like.

[0096] The screen 48 comprises a plurality of layers configured to be located over the LCD display 49 of the computing device. A transparent inner layer 50 of the screen 48 comprises a glass layer that is configured for adhesion to the LCD display 49. The transparent inner layer is located between the LCD display and a spacer layer 51 of the screen 48. The spacer layer 51 comprises a plurality of sensors 52 configured to sense touching of the screen 48 (whether by a user's finger, or an object such as a stylus) and react accordingly.

[0097] The screen further comprises an outer coated layer 53. Preferably, the outer coated layer 53 is a polyester-coated layer, and is configured to be the layer a user contacts with their finer or an object (such as a stylus) to operate the touchscreen 48. The outer coated layer 53 may be fabricated from a substantially transparent material, such as glass or a polymer (and particularly a polycarbonate). In the embodiment of the invention illustrated in Figure 5, the outer coated layer 53 is at least partially fabricated from a material comprising a plurality of boron nitride nanotubes. The boron nitride nanotubes may be embedded or impregnated within the material from which the outer coated layer 53 is formed.

[0098] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises'and 'comprise'includeeach of the stated integers but does not exclude the inclusion of one or more further integers.

[0099] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[00100] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A method of manufacturing an item of sporting equipment including:

impregnating a material comprising a plurality of boron nitride nanotubes with a polymer to form a composite material;

moulding the composite material; and

curing the composite material,

wherein the item of sporting equipment is at least partially fabricated from the composite material, and

wherein the item of sporting equipment comprises a shaft of a golf club, golf club head, a shaft of a fishing rod or a shaft of a vaulting pole.

2. A method according to claim 1 wherein the composite material comprises between about 0.5 wt% and about 50 wt% boron nitride nanotubes.

3. A method according to claim 1 and claim 2, wherein the composite material further comprises a plurality of carbon nanotubes.

4. A method according to claim 3 wherein the composite material comprises between about 0.5 wt% and about 50 wt% carbon nanotubes.

5. A method according to any one of the preceding claims wherein the polymer comprises an epoxy resin.

6. A method according to any one of the preceding claims, wherein the item of sporting equipment is formed from a laminated composite material comprising a plurality of layers of the composite material are laminated together.

7. A method according to any one of the preceding claims, wherein the composite material is cured using a hardener and/or by applying pressure and/or temperature thereto to form the item of sporting equipment.

8. A method according to any one of the preceding claims, wherein the composite material is moulded using bladder moulding.

9. A method according to any one of the preceding claims wherein the composite material further comprises a metal.

10. A method according to claim 9 wherein the metal is provided in the form of a metal boron nitride nanotube layered structure wherein the metal is at least partially coated with boron nitride nanotubes, a plurality of metal particles dispersed within the composite material or a plurality of boron nitride nanotubes dispersed within a metal based structure.

11. A method according to claim 9 or claim 10 wherein the metal comprises titanium, a titanium alloy, aluminium or an aluminium alloy.

12. A method according to any one of the preceding claims wherein the composite material further comprises a dispersant.

13. An item of sporting equipment or portion thereof manufactured according to the method of any one of claims 1 to 11.