U.S. patent application number 10/290052 was filed with the patent office on 2003-06-26 for hockey stick.
This patent application is currently assigned to EASTON, JAS D.. Invention is credited to DeLap, Christopher K., Goldsmith, Edward M..
Application Number | 20030119612 10/290052 |
Document ID | / |
Family ID | 24662511 |
Filed Date | 2003-06-26 |
United States Patent
Application |
20030119612 |
Kind Code |
A1 |
Goldsmith, Edward M. ; et
al. |
June 26, 2003 |
Hockey stick
Abstract
A hockey stick having a composite blade and a shaft is
disclosed. The composite blade includes a heel section that is
recessed relative to the front and back faces of the blade. The
recessed heel section is configured to be received by a hockey
stick shaft or an adapter member configured to connect the blade to
the shaft. The composite blade preferably comprise a foam inner
core overlaid preferably with substantially continuous fibers
disposed in a matrix material and may include an internal bridge
structure extending from one side of the blade to the other. The
blade may also be preferably comprised of a core comprising
non-continuous fibers disposed within a matrix material. In another
aspect, processes for manufacturing the previously described hockey
stick blade(s) are described.
Inventors: |
Goldsmith, Edward M.;
(Studio City, CA) ; DeLap, Christopher K.; (San
Diego, CA) |
Correspondence
Address: |
JONES DAY
555 WEST FIFTH STREET, SUITE 4600
LOS ANGELES
CA
90013-1025
US
|
Assignee: |
EASTON, JAS D.
Suite 200 7855 Haskell Avenue
|
Family ID: |
24662511 |
Appl. No.: |
10/290052 |
Filed: |
November 6, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10290052 |
Nov 6, 2002 |
|
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09663598 |
Sep 15, 2000 |
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Current U.S.
Class: |
473/560 |
Current CPC
Class: |
B29C 70/44 20130101;
B29L 2031/5227 20130101; B29C 70/865 20130101; A63B 59/70 20151001;
A63B 2102/24 20151001; A63B 2209/02 20130101; A63B 60/52 20151001;
B29C 70/46 20130101; B29C 70/345 20130101 |
Class at
Publication: |
473/560 |
International
Class: |
A63B 059/14 |
Claims
What is claimed is:
1. A hockey stick comprising: a shaft; a blade connected with the
shaft, the blade including an elongated member extending from a tip
section to a heel section and having a front face and a back face;
the heel section comprising front-side and back-side facing
surfaces that are recessed relative to adjacent portions of the
front and back faces; and the elongated member further comprising
an inner foam core and one or more plies overlaying the inner foam
core, wherein the one or more plies comprise substantially
continuous fibers disposed within a matrix material.
2. The hockey stick of claim 1, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
3. The hockey stick of claim 1, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
4. The hockey stick of claim 1, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
5. The hockey stick of claim 1, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber and
aramid.
6. The hockey stick of claim 1, wherein at least part of one of the
fibers comprises carbon fiber.
7. The hockey stick of claim 1, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of the shaft.
8. The hockey stick of claim 1, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received into a slot disposed within the shaft.
9. The hockey stick of claim 1, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of an adapter member that connects the
blade with the shaft.
10. The hockey stick of claim 1, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received into a slot disposed within a mating portion of an
adapter member that connects the blade with the shaft.
11. The hockey stick of claim 1, wherein the shaft further includes
a forward facing surface, a rearward facing surface, a front facing
surface, a back facing surface, and a lower end section, the lower
end section includes an open-ended slot that extends from the
forward facing surface of shaft and is disposed between the front
and back facing surfaces of the shaft, wherein the recessed
front-side and back-side facing surfaces of the heel section are
disposed within the slot.
12. The hockey stick of claim 11, wherein the slot extends from the
forward facing surface through the rearward facing surface of the
shaft.
14. The hockey stick of claim 12, wherein the lower end section of
the shaft further includes an end surface generally perpendicular
to the forward facing surface and wherein the slot extends from the
forward facing surface through the end surface of the shaft.
14. The hockey stick of claim 11, wherein the shaft is constructed
at least in part of wood.
15. The hockey stick of claim 1 further comprising an adapter
member that connects the shaft with the blade, the adapter member
includes a first end section, a second end section forward facing
surface, a rearward facing surface, a front facing surface, and a
back facing surface, the first end section includes an open-ended
slot that extends from the forward facing surface of the adapter
member and is disposed between the front and back facing surfaces
of the adapter member, wherein the recessed front-side and
back-side facing surfaces of the heel section are disposed within
the slot.
16. The hockey stick of claim 15, wherein the slot extends from the
forward facing surface through the rearward facing surface of the
adapter member.
17. The hockey stick of claim 15, wherein the first end section of
the adapter member further includes an end surface generally
perpendicular to the forward facing surface and wherein the slot
extends from the forward facing surface through the end surface of
the adapter member.
18. The hockey stick of claim 15, wherein the adapter member is
constructed at least in part of wood.
19. The hockey stick of claim 15, wherein the second end section of
the adapter member is connected to the shaft.
20. The hockey stick of claim 15, wherein the shaft includes a
lower end section that includes a cavity and wherein the second end
section of the adapter member is disposed within the cavity of the
shaft.
21. The hockey stick of claim 1 further comprising one or more
internal bridge structures disposed within the foam core and
extending between the front and back faces of the blade.
22. The hockey stick of claim 21, wherein at least one of the one
or more internal bridge structures comprises one or more plies of
substantially continuous fibers disposed within a matrix
material.
23. The hockey stick of claim 21, wherein at least one of the one
or more internal bridge structure comprises non-continuous fibers
disposed within a matrix material.
24. The hockey stick of claim 1 further comprising one or more
internal bridge structures disposed within the foam core and
extending between the recessed front-side and back-side facing
surfaces of the heel section.
25. The hockey stick of claim 1 further comprising one or more
internal bridge structures disposed within the foam core and
extending between the front and back faces of the blade and between
the recessed front-side and back-side facing surfaces of the heel
section.
26. The hockey stick of claim 1, wherein the foam core further
comprises a top edge and a bottom edge extending between the front
face and back face of the blade, wherein at least part of the
bottom edge or the top edge of the foam is overlaid with a durable
edging material.
27. The hockey stick of claim 26, wherein at least part of both the
top edge and bottom edge of the foam is overlaid with the durable
edging material.
28. The hockey stick of claim 26, wherein the durable edging
material is selected from the group of materials consisting of
thermoplastic resins, thermosetting resins, substantially
continuous fibers disposed within either thermoplastic or
thermosetting resins, and non-continuous fibers disposed within
either thermoplastic or thermosetting resins.
29. The hockey stick of claim 1, wherein the foam core comprises at
least one material selected from the group consisting of
polyurethane, PVC, and epoxy.
30. A blade for a hockey stick comprising: an elongated member
extending from a tip section to a heel section and having a front
face and a back face; the heel section comprising front-side and
back-side facing surfaces that are recessed relative to adjacent
portions of the front and back faces; and the elongated member
further comprising an inner foam core and one or more plies
overlaying the inner foam core, wherein the one or more plies
comprise substantially continuous fibers disposed within a matrix
material.
31. The blade of claim 30, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
32. The blade of claim 30, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
33. The blade of claim 30, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
34. The blade of claim 30, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber and
aramid.
35. The blade of claim 30, wherein at least part of one of the
fibers comprises carbon fiber.
36. The blade of claim 30, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of a shaft.
37. The blade of claim 30, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received within a slot disposed within a shaft.
38. The blade of claim 30, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of an adapter member configured to
connect the blade with a shaft.
39. The blade of claim 30, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received within a slot disposed within a mating portion of an
adapter member configured to connect the blade with a shaft.
40. The blade of claim 30 further comprising one or more internal
bridge structures disposed within the foam core and extending
between the front and back faces.
42. The blade of claim 41, wherein at least one of the one or more
internal bridge structures comprises one or more plies of
substantially continuous fibers disposed within a matrix
material.
43. The blade of claim 41, wherein at least one of the one or more
internal bridge structure comprises non-continuous fibers disposed
within a matrix material.
44. The blade of claim 30 further comprising one or more internal
bridge structures disposed within the foam core and extending
between the recessed front-side and back-side facing surfaces of
the heel section.
45. The blade of claim 30 further comprising one or more internal
bridge structures disposed within the foam core and extending
between the front and back faces of the blade and between the
recessed front-side and back-side facing surfaces of the heel
section.
46. The blade of claim 30, wherein the foam core further comprises
a top edge and a bottom edge extending between the front face and
back face of the blade, wherein at least part of the bottom edge or
the top edge of the foam is overlaid with a durable edging
material.
47. The blade of claim 46, wherein at least part of both the top
edge and bottom edge of the foam is overlaid with the durable
edging material.
48. The blade of claim 46, wherein the durable edging material is
selected from the group of materials consisting of thermoplastic
resins, thermosetting resins, substantially continuous fibers
disposed within either thermoplastic or thermosetting resins, and
non-continuous fibers disposed within either thermoplastic or
thermosetting resins.
49. The blade of claim 30, wherein the foam core comprises at least
one material selected from the group consisting of polyurethane,
PVC, and epoxy.
50. A hockey stick comprising: a shaft; a blade connected with the
shaft, the blade including an elongated member extending from a tip
section to a heel section and having a front face and a back face;
the heel section comprising front-side and back-side facing
surfaces that are recessed relative to adjacent portions of the
front and back faces; and the elongated member further comprising a
core of non-continuos random fibers disposed within a matrix
material.
51. The hockey stick of claim 50, wherein at least part of one of
the fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
52. The hockey stick of claim 50, wherein at least part of one of
the fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
53. The hockey stick of claim 50, wherein at least part of one of
the fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
54. The hockey stick of claim 50, wherein at least part of one of
the fibers is selected from the group consisting of carbon fiber
and aramid.
55. The hockey stick of claim 50, wherein at least part of one of
the fibers comprises carbon fiber.
56. The hockey stick of claim 50, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received in a mating portion of the shaft.
57. The hockey stick of claim 50, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received into a slot disposed within the shaft.
58. The hockey stick of claim 50, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received in a mating portion of an adapter member that connects
the blade with the shaft.
59. The hockey stick of claim 50, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received into a slot disposed within a mating portion of an
adapter member that connects the blade with the shaft.
60. The hockey stick of claim 50, wherein the shaft further
includes a forward facing surface, a rearward facing surface, a
front facing surface, a back facing surface, and a lower end
section, the lower end section includes an open-ended slot that
extends from the forward facing surface of shaft and is disposed
between the front and back facing surfaces of the shaft, wherein
the recessed front-side and back-side facing surfaces of the heel
section are disposed within the slot.
61. The hockey stick of claim 60, wherein the slot extends from the
forward facing surface through the rearward facing surface of the
shaft.
62. The hockey stick of claim 60, wherein the lower end section of
the shaft further includes an end surface generally perpendicular
to the forward facing surface and wherein the slot extends from the
forward facing surface through the end surface of the shaft.
63. The hockey stick of claim 50, wherein the shaft is constructed
at least in part of wood.
64. The hockey stick of claim 50 further comprising an adapter
member that connects the shaft with the blade, the adapter member
includes a first end section, a second end sections forward facing
surface, a rearward facing surface, a front facing surface, and a
back facing surface, the first end section includes an open-ended
slot that extends from the forward facing surface of the adapter
member and is disposed between the front and back facing surfaces
of the adapter member, wherein the recessed front-side and
back-side facing surfaces of the heel section are disposed within
the slot.
65. The hockey stick of claim 64, wherein the slot extends from the
forward facing surface through the rearward facing surface of the
adapter member.
66. The hockey stick of claim 64, wherein the first end section of
the adapter member further includes an end surface generally
perpendicular to the forward facing surface and wherein the slot
extends from the forward facing surface through the end surface of
the adapter member.
67. The hockey stick of claim 64, wherein the adapter member is
constructed at least in part of wood.
68. The hockey stick of claim 64, wherein the second end section of
the adapter member is connected to the shaft.
69. The hockey stick of claim 64, wherein the shaft includes a
lower end section that includes a cavity and wherein the second end
section of the adapter member is disposed within the cavity of the
shaft.
70. A blade for hockey stick comprising: an elongated member
extending from a tip section to a heel section and having a front
face and a back face; the heel section comprising front-side and
back-side facing surfaces that are recessed relative to adjacent
portions of the front and back faces; and the elongated member
further comprising a core of non-continuos random fibers disposed
within a matrix material.
71. The blade of claim 70, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
72. The blade of claim 70, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
73. The blade of claim 70, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
74. The blade of claim 70, wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber and
aramid.
75. The blade of claim 70, wherein at least part of one of the
fibers comprises carbon fiber.
76. The blade of claim 70, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of a shaft.
77. The blade of claim 70, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received within a slot disposed within a shaft.
78. The blade of claim 70, wherein the recessed front-side and
back-side facing surfaces of the heel section are configured to be
received in a mating portion of an adapter member configured to
connect the blade with a shaft.
79. The hockey stick of claim 70, wherein the recessed front-side
and back-side facing surfaces of the heel section are configured to
be received within a slot disposed within a mating portion of an
adapter member configured to connect the blade with a shaft.
80. A hockey stick adapter member for connecting a hockey stick
shaft to a hockey stick blade comprising: a member extending from a
first end section to a second end section and having a forward
facing surface, a rearward facing surface, and an end surface; the
first end section comprising a slot extending from the forward
facing surface toward the rearward facing surface; the second end
section being configured to mate with a hockey stick shaft.
81. The hockey stick adapter member of claim 80, wherein the slot
extends through the rearward facing surface.
82. The hockey stick adapter member of claim 80, wherein the slot
extends through the end surface.
83. The hockey stick adapter member of claim 80, wherein the second
end section is configured to mate within a tubular hockey stick
shaft.
84. The hockey stick adapter member of claim 80, wherein the second
end section comprises a mating section that is dimensioned to be
received within a tubular hockey stick shaft.
85. The hockey stick adapter member of claim 80, wherein the second
end section comprises a rectangular mating section dimensioned to
be received within a tubular hockey stick shaft.
86. The hockey stick adapter member of claim 80, wherein the second
end section comprises a mating section dimensioned to be slidably
received within a tubular hockey stick shaft.
87. The hockey stick adapter member of claim 80, wherein the second
end section comprises a mating section dimensioned to be slidably
and snugly received within a tubular hockey stick shaft.
88. The hockey stick adapter member of claim 80, wherein the
adapter member is constructed at least in part of wood.
89. The hockey stick adapter member of claim 80, wherein the
adapter member comprises a core overlaid with substantially
continuous fibers disposed within a matrix material.
90. The hockey stick adapter member of claim 20, wherein the
adapter member comprises a core of fibers disposed within a matrix
material.
91. A method for manufacturing a composite hockey stick blade
comprising the following steps: (a) providing a foam core having
the general shape of a hockey stick blade; (b) forming an uncured
blade assembly by wrapping the foam core with one or more plies
comprising substantially continuous fibers pre-impregnated with a
curable matrix material; (c) providing a mold having the desired
exterior shape of the blade; (d) loading the mold with the uncured
blade assembly; (e) applying heat to the mold to cure the blade
assembly; and (f) removing the cured blade assembly from the
mold.
92. The method of claim 91 for manufacturing a composite hockey
stick blade wherein-the mold is configured to impart a recessed
surface at the heel of the blade.
93. The method of claim 91 wherein in forming the uncured blade
assembly a durable edging material is laid about at least a portion
of the circumference of the foam core.
94. The method of claim 91 wherein the mold includes a convex
surface configured to impart a cavity into the blade.
95. The method of claim 91 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
96. The method of claim 91 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
97. The method of claim 91 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
98. The method of claim 91 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber and
aramid.
99. The method of claim 91 wherein at least part of one of the
fibers comprises carbon fiber.
100. A method for manufacturing a composite hockey stick blade
comprising the following steps: (a) providing a mold having the
desired exterior shape of the blade; (b) loading the mold with a
mixture of non-continuous fibers disposed in a curable matrix
material; (c) applying heat to the mold to cure; and (d) removing
the cured blade from the mold.
101. The method of claim 100 for manufacturing a composite hockey
stick blade wherein the mold is configured to impart a recessed
surface at the heel of the blade.
102. The method of claim 100 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, ceramic, boron, quartz, and
polyester.
103. The method of claim 100 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, glass, polyethylene, and ceramic.
104. The method of claim 100 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber,
aramid, and glass.
105. The method of claim 100 wherein at least part of one of the
fibers is selected from the group consisting of carbon fiber and
aramid.
106. The method of claim 100 wherein at least part of one of the
fibers comprises carbon fiber.
107. A hockey blade for attachment with a hockey stick shaft
comprising: an elongated member; the elongated member extending
from a tip section to a heel section; the elongated member having a
front face and a back face; the elongated member comprising a core
of non-continuos random fibers disposed within a matrix material.
Description
FIELD OF THE INVENTION
[0001] The field of the present invention generally relates to
hockey sticks.
BACKGROUND OF THE INVENTION
[0002] Generally, hockey sticks are comprised of a blade portion
and an elongated shaft portion.
[0003] Traditionally, each portion was constructed of wood (e.g.,
solid wood, wood laminates) and attached together at a permanent
joint. The joint generally comprised a slot formed by two opposing
sides of the lower end section of the shaft with the slot opening
on the forward facing surface of the shaft. As used in this
application "forward facing surface of the shaft" means the surface
of the shaft that faces generally toward the tip of the blade and
is generally perpendicular to the longitudinal length of the blade
at the point of attachment. The heel of the blade comprised a
recessed portion dimensioned to be receivable within the slot. Upon
insertion of the blade into the slot, the opposing sides of the
shaft that form the slot overlap the recessed portion of the blade
at the heel. The joint was made permanent by application of a
suitable bonding material or glue between the shaft and the blade.
In addition, the joint was oftentimes further strengthened by an
overlay of fiberglass material.
[0004] Traditional wood hockey stick constructions, however, are
expensive to manufacture due to the cost of suitable wood and the
manufacturing processes employed. In addition, due to the wood
construction, the weight may be considerable. Moreover, wood sticks
lacked durability, often due to fractures in the blade, thus
requiring frequent replacement. Furthermore, due to the variables
relating to wood construction and manufacturing techniques, wood
sticks were often difficult to manufacture to consistent
tolerances. For example, the curve and flex of the blade often
varied even within the same model and brand of stick. Consequently,
a player after becoming accustomed to a particular wood stick was
often without a comfortably seamless replacement when the stick was
no longer in a useable condition.
[0005] Notwithstanding, the "feel" of traditional wood-constructed
hockey sticks was found desirable by many players. The "feel" of a
hockey stick can vary depending on a myriad of factors including
the type of materials employed in construction, the structure of
the components, the dimensions of the components, the rigidity or
bending stiffness of the shaft and blade, the weight and balance of
the shaft and blade, the rigidity and strength of the joint(s)
connecting the shaft to the blade, the curvature of the blade, etc.
Experienced players and the public are often inclined to use hockey
sticks that have a "feel" that is comfortable yet provides the
desired performance. Moreover, the subjective nature inherent in
this decision often results in one hockey player preferring a
certain "feel" of a particular hockey stick while another hockey
player preferring the "feel" of another hockey stick.
[0006] Perhaps due to the concerns relating to traditional wood
hockey stick constructions, contemporary hockey stick design veered
away from the traditional permanently attached blade configuration
toward a replaceable blade and shaft configuration. The blade
portion of these contemporary designs employ a blade connection
member that is generally comprised of an upward extension of the
blade from the heel often referred to as a "tennon", "shank" or
"hosel." The shafts of these contemporary designs generally employ
a four-sided tubular member having a connection portion comprising
a socket (e.g., the hollow at the end of the tubular shaft). The
socket is configured and dimensioned so that it may slidably and
snugly receive the connection member of the blade. Thus, the joint
generally is comprised of a four-plane lap joint. In order to
facilitate the detachable connection between the blade and the
shaft and to further strengthen the integrity of the joint, a
suitable bonding material or glue is typically employed. Notable in
these contemporary replaceable blade and shaft configuration design
is that the point of attachment between the blade and the shaft is
substantially elevated relative to the heel attachment employed in
traditional wood type constructions.
[0007] Contemporary replaceable blades, of the type discussed
above, are constructed of various materials including wood, wood
laminates, wood laminate overlaid with fiberglass, and what is
often referred to in the industry as "composite" constructions.
Composite constructions generally comprised a core overlaid with
plies of woven and substantially continuous fibers, such as carbon,
graphite or Kevlar.TM. disposed within a matrix material.
Contemporary replaceable blades, employing such composite
constructions, are typically manufactured by employment of a resin
transfer molding (RTM) process, generally involving the following
steps. First, a plurality of inner core elements composed of
compressed foam, such as polyurethane, are individually and
together inserted into one or more woven-fiber sleeves to form an
uncured blade assembly. The uncured blade assembly including the
hosel or connection member is then inserted into a mold having the
desired exterior shape of the blade. After the mold is sealed, a
suitable matrix material or resin is injected into the mold to
impregnate the woven-fiber sleeves. Thus, the resin is transferred
into the mold after the blade assembly is fitted in the mold and
the mold is sealed. The blade assembly is then cured for the
requisite time, removed from the mold and finished. Experience has
shown that the employment of the woven-fiber sleeve material
together with the step of impregnating the fiber sleeves in the
mold involves considerable expense due to the cure time involved
and the costs of the woven sleeve materials employed.
[0008] Composite blades, nonetheless, are thought to have certain
advantages over wood blades. For example, composite blades may be
more readily manufactured to consistent tolerances and are
generally more durable than wood blades. Moreover, due to the
strength that may be achieved via the employment of composite
construction, the blades may be made thinner and lighter than wood
blades of similar strength and flexibility.
[0009] Despite the advent of the contemporary replaceable blade and
shaft hockey stick configuration, traditional wood constructed
hockey sticks are still preferred by many players notwithstanding
the drawbacks noted above.
SUMMARY OF THE INVENTION
[0010] The present invention relates in one aspect to hockey stick
blades suitable for use in the sport of hockey and the like.
[0011] According to one aspect as described herein, a blade for a
hockey stick comprises an elongated member extending from a tip
section to a heel section and having a front face and a back face.
The heel section comprises front-side and back-side facing surfaces
that are recessed relative to adjacent portions of the front and
back faces. The elongated member further comprises an inner foam
core and one or more plies overlaying the inner foam core, wherein
the one or more plies comprise substantially continuous fibers
disposed within a matrix material.
[0012] According to another aspect, a blade for hockey stick
comprises an elongated member extending from a tip section to a
heel section and having a front face and a back face. The heel
section comprises front-side and back-side facing surfaces that are
recessed relative to adjacent portions of the front and back faces.
The elongated member further comprises a core of non-continuos
random fibers disposed within a matrix material.
[0013] According to another aspect, a hockey blade for attachment
with a hockey stick shaft comprises an elongated member. The
elongated member extends from a tip section to a heel section. The
elongated member has a front face and a back face. The elongated
member comprises a core of non-continuos random fibers disposed
within a matrix material.
[0014] The present invention relates in another aspect to hockey
sticks suitable for use in the sport of hockey and the like.
[0015] According to one aspect as described herein a hockey stick
comprises a shaft and a blade connected with the shaft. The blade
includes an elongated member extending from a tip section to a heel
section and having a front face and a back face. The heel section
comprises front-side and back-side facing surfaces that are
recessed relative to adjacent portions of the front and back faces.
The elongated member further comprises an inner foam core and one
or more plies overlaying the inner foam core, wherein the one or
more plies comprise substantially continuous fibers disposed within
a matrix material.
[0016] According to another aspect, the hockey stick comprises a
shaft and a blade connected with the shaft. The blade includes an
elongated member extending from a tip section to a heel section and
having a front face and a back face. The heel section comprises
front-side and backside facing surfaces that are recessed relative
to adjacent portions of the front and back faces. The elongated
member further comprises a core of non-continuos random fibers
disposed within a matrix material.
[0017] The present invention relates in another aspect to a hockey
stick adapter member for connecting a hockey stick shaft to a
hockey stick blade.
[0018] According to one aspect as described herein, a hockey stick
adapter member for connecting a hockey stick shaft to a hockey
stick blade comprises a member extending from a first end section
to a second end section and having a forward facing surface, a
rearward facing surface, and an end surface. The first end section
comprises a slot extending from the forward facing surface toward
the rearward facing surface. The second end section is configured
to mate with a hockey stick shaft.
[0019] The present invention relates in another aspect to methods
for manufacturing composite hockey stick blades.
[0020] According to one aspect as described herein, a method for
manufacturing a composite hockey stick blade comprises the steps
of: (a) providing a foam core having the general shape of a hockey
stick blade; (b) forming an uncured blade assembly by wrapping the
foam core with one or more plies comprising substantially
continuous fibers pre-impregnated with a curable matrix material;
(c) providing a mold having the desired exterior shape of the
blade; (d) loading the mold with the uncured blade assembly; (e)
applying heat to the mold to cure the blade assembly; and (f)
removing the cured blade assembly from the mold.
[0021] According to one aspect as described herein, a method for
manufacturing a composite hockey stick blade comprises the steps
of: (a) providing a mold having the desired exterior shape of the
blade; (b) loading the mold with a mixture of non-continuous fibers
disposed in a curable matrix material; (c) applying heat to the
mold to cure; and (d) removing the cured blade from the mold.
[0022] Additional implementations, features, variations and
advantageous of the invention will be set forth in the description
that follows, and will be further evident from the illustrations
set forth in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings illustrate presently preferred
embodiments of the invention and, together with the description,
serve to explain various principles of the invention.
[0024] FIG. 1 is a diagram illustrating a hockey stick in
accordance with a first preferred embodiment.
[0025] FIG. 2 is a rear view of the hockey stick illustrated in
FIG. 1.
[0026] FIG. 3 is a back face view of the hockey stick blade
illustrated in FIG. 1 detached from the hockey stick shaft.
[0027] FIG. 4 is a rear end view of the hockey stick blade
illustrated in FIG. 3.
[0028] FIG. 5 is a diagram illustrating a hockey stick in
accordance with a second preferred embodiment.
[0029] FIG. 6 is a rear view of the hockey stick illustrated in,
FIG. 5.
[0030] FIG. 7 is a back face view of the hockey stick blade
illustrated in FIG. 5 detached from the hockey stick shaft.
[0031] FIG. 8 is a rear end view of the hockey stick blade
illustrated in FIG. 7.
[0032] FIG. 9 is a bottom end view of the hockey stick shaft
illustrated in FIGS. 1 and 5 detached from the blade.
[0033] FIG. 10 is a diagram illustrating a hockey stick in
accordance with a third preferred embodiment.
[0034] FIG. 11 is a bottom end view of the hockey stick shaft
illustrated in FIGS. 10 and 12 detached from the blade.
[0035] FIG. 12 is a rear view of the hockey stick illustrated in
FIG. 10.
[0036] FIG. 13 is a back face view of the hockey stick blade
illustrated in FIG. 10 detached from the hockey stick shaft.
[0037] FIG. 14A is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7, and 13 illustrating a first preferred construction of
the hockey stick blade.
[0038] FIG. 14B is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7, and 13 illustrating a second preferred construction of
the hockey stick blade.
[0039] FIG. 14C is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7 and 13 illustrating a third preferred construction of
the hockey stick blade.
[0040] FIG. 14D is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7 and 13 illustrating a fourth preferred construction of
the hockey stick blade.
[0041] FIG. 14E is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7 and 13 illustrating a fifth preferred construction of
the hockey stick blade.
[0042] FIG. 14F is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7 and 13 illustrating a sixth preferred construction of
the hockey stick blade.
[0043] FIG. 14G is a cross-sectional view taken along line 14-14 of
FIGS. 3, 7 and 13 illustrating a seventh preferred construction of
the hockey stick blade.
[0044] FIG. 15A is a flow chart detailing preferred steps for
manufacturing the hockey stick blade illustrated in FIGS. 14A
through 14F.
[0045] FIG. 15B is a flow chart detailing preferred steps for
manufacturing the hockey stick blade illustrated in FIG. 14G.
[0046] FIGS. 16A-C is a flow chart of exemplary graphical
representations detailing preferred steps for manufacturing the
hockey stick blade illustrated in FIG. 14E.
[0047] FIG. 17A is a side view of an adapter member configured to
be joined with the hockey stick blade of the type illustrated in
FIGS. 3 and 7 and the shaft illustrated in FIGS. 10-12.
[0048] FIG. 17B is a perspective view of the adapter member
illustrated in FIG. 17A.
[0049] FIG. 17C is a cross-sectional view of the adapter member
illustrated in FIG. 17B.
[0050] FIG. 17D is a diagram illustrating a hockey stick having the
adapter member illustrated in FIGS. 17A-17C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] The preferred embodiments will now be described with
reference to the drawings. To facilitate description, any reference
numeral designating an element in one figure will designate the
same element if used in any other figure. The following description
of the preferred embodiments is only exemplary. The present
invention is not limited to these embodiments, but may be realized
by other implementations. Furthermore, in describing preferred
embodiments, specific terminology is resorted to for the sake of
clarity. However, the invention is not intended to be limited to
the specific terms so selected, and it is to be understood that
each specific term includes all equivalents.
[0052] FIGS. 1-13 and 17 are diagrams illustrating preferred
embodiments of a hockey stick 10.
[0053] Commonly shown in FIGS. 1-13 and 17 is a hockey stick 10
comprised of a shaft 20 and a blade 30. The blade 30 comprises a
lower section 70, an upper section 80, a front face 90, a back face
100, a bottom edge 110, a top edge 120, a tip section 130, and a
heel section 140. In the preferred embodiment, the heel section 140
generally resides between the plane defined by the top edge 120 and
the plane defined by the bottom edge 110 of the blade 30. The shaft
20 comprises an upper section 40, a mid-section 50, and a lower
section 60 that is adapted to be joined to the blade 30 or, with
respect to the embodiment illustrated in FIG. 17, the adapter
member 1000.
[0054] The shaft 20 is preferably rectangular in cross-section with
two wide opposed walls 150 and 160 and two narrow opposed walls 170
and 180. Narrow wall 170 includes a forward-facing surface 190 and
narrow wall 180 includes a rearward-facing surface 200. The
forward-facing surface 190 faces generally toward the tip section
130 of the blade 30 and is generally perpendicular to the
longitudinal length (i.e., the length between the heel section 140
and the tip section 130) of the blade 30. The rearward-facing
surface 200 faces generally away from the tip section 130 of the
blade 30 and is also generally perpendicular to the longitudinal
length of the blade 30. Wide wall 150 includes a front-facing
surface 210 and wide wall 160 includes a back-facing surface 220.
The front-facing surface 210 faces generally in the same direction
as the front face 90 of the blade 30 and the back-facing surface
220 faces generally in the same direction as the back face 100 of
the blade 30.
[0055] In the first and second preferred embodiments as illustrated
in FIGS. 1-9, the shaft 20 includes a tapered section 330 having a
reduced shaft width. The "shaft width" is defined for the purposes
of this application as the dimension between the front and back
facing surfaces 210 and 220. The tapered section 330 is preferably
dimensioned so that when the shaft 20 is joined to the blade 30 the
front and back facing surfaces 210, 220 of the shaft 20 are
generally flush with the adjacent portions of the front and back
faces 90 and 100 of the blade 30. The lower section 60 of the shaft
20 includes an open-ended slot 230 (best illustrated in FIG. 9)
that extends from the forward-facing surface 190 of narrow wall 170
preferably through the rearward-facing surface 200 of narrow wall
180. As best illustrated in FIG. 9, the slot 230 also extends
through the end surface 350 of the shaft 20. The slot 230 is
dimensioned to receive, preferably slidably, a recessed or tongue
portion 260 located at the heel section 140 of the blade 30.
[0056] As best illustrated in FIGS. 3-4 and 7-8, the transition
between the tongue portion 260 and an adjacent portion of the blade
30 extending toward the tip section 130 forms a front-side shoulder
280 and a back-side shoulder 290, each of which generally face away
from the tip section 130 of the blade 30. When the tongue portion
260 is joined to the shaft 20 via the slot 230 the forward facing
surface 190 of the shaft 20 on either side of the slot 230 opposes
and preferably abuts with shoulders 280 and 290. Thus, the joint
formed is similar to an open slot mortise and tongue joint. The
joint may be made permanent by use of adhesive such as epoxy,
polyester, methacrolates (e.g., Plexus.TM.) or any other suitable
material. Applicants have found that Plexus.TM. is suitable for
this application. In addition, as in the traditional wood
construction, the joint may be additionally strengthened after the
blade and shaft are joined by an overlay of fiberglass or other
suitable material over the shaft and blade.
[0057] As illustrated in FIGS. 14 and 9 of the first preferred
embodiment, the tongue portion 260 comprises an upper edge 300, a
lower edge 310, and a rearward-facing edge 320. The blade 30
preferably includes an upper shoulder 270 that extends from the
upper edge 300 of the tongue portion 260 upwardly away from the
heel section 140. When the tongue portion 260 is joined within the
slot 230, the forward-facing surface 190 of the shaft 200 located
directly above the top of the slot 230 opposes and preferably abuts
with the upper shoulder 270 of the blade 30; the rearward-facing
edge 320 of the tongue 260 is preferably flush with the
rearward-facing surface 200 of the shaft 20 on either side of the
slot 230; the lower edge 310 of the tongue 260 is preferably flush
with the end surface 350 of the shaft 20; the upper edge 300 of the
tongue 260 opposes and preferably abuts with the top surface 360 of
the slot 230; and the front and back side surfaces 370, 380 of the
tongue 260 oppose and preferably abut with the inner sides 430, 440
of the wide opposed walls 150, 160 that define the slot 230.
[0058] As illustrated in FIGS. 5-9 of the second preferred
embodiment, the tongue portion 260 extends upwardly from the heel
section 140 beyond the top edge 120 of the blade 30 and is
comprised of an upper edge 300, a rearward-facing edge 320, and a
forward-facing edge 340. The blade 30 includes a second set of
front and back-side shoulders 240 and 250 that border the bottom of
the tongue 260 and preferably face generally upward away from the
bottom edge 110 of the blade 30. When the tongue portion 260 is
received within the slot 230, the end surface 350 of the shaft 20
on either side of the slot opposes and preferably abuts with
shoulders 240 and 250; the rearward-facing edge 320 of the tongue
260 is preferably flush with the rearward-facing surface 200 of the
shaft 20 on either side of the slot 230; the forward-facing edge
340 of the tongue 260 is preferably flush with the forward-facing
surface 190 of the shaft 20 on either side of the slot 230; the
upper edge 300 of the tongue 260 opposes and preferably abuts with
the top surface 360 of the slot 230; and the front and back side
surfaces 370, 380 of the tongue 260 oppose and preferably abut with
the inner sides 430, 440 of the wide opposed walls 150, 160 that
define the slot 230.
[0059] Illustrated in FIGS. 10-13 is a third preferred embodiment
of a hockey stick 10. As best shown in FIG. 11 the shaft 20 is
preferably comprised of a hollow tubular member preferably having a
rectangular cross-sectional area throughout the longitudinal length
of the shaft 20. The blade 30 includes an extended member or hosel
portion 450 preferably comprised of two sets of opposed walls 390,
400 and 410, 420 and a mating section 460. The mating section 460
in a preferred embodiment is comprised of a rectangular cross
section (also having two sets of opposed walls 390a, 400a, and
410a, 420a) that is adapted to mate with the lower section 60 of
the shaft 20 in a four-plane lap joint along the inside of walls
150, 160, 170, and 180. The outside diameter of the rectangular
cross-sectional area of the mating section 460 is preferably
dimensioned to make a sliding fit inside the hollow center of the
lower section 60 of the shaft 20. It is also preferable that the
mating section 460 is dimensioned to make a sliding and snug fit
inside the hollow center of the lower section 60 of the shaft 20.
Preferably, the blade 30 and shaft 20 are bonded together at the
four-plane lap joint using an adhesive capable of removably
cementing the blade 30 to shaft 20. Such adhesives are commonly
known and employed in the industry and include Z-Waxx.TM.
manufactured by Easton Sports and hot melt glues.
[0060] FIGS. 14A through 14G are cross-sectional views taken along
line 14-14 of FIGS. 3, 7, and 13 illustrating preferred
constructions of the hockey stick blade 30. FIGS. 14A through 14F
illustrate constructions that employ an inner foam core 500
overlaid with one or more layers 510 comprising one or more plies
520 of substantially continuous fibers disposed in a matrix or
resin based material.
[0061] The foam core 500 may be constructed of formulations of
expanding syntactic or non-syntactic foam such as polyurethane,
PVC, epoxy, or any other suitable material capable of providing the
needed pressure (i.e., expansion during heating) in the mold while
having a suitable or desired weight or density. Applicants have
found that polyurethane foam, manufactured by Burton Corporation of
San Diego, Calif. is suitable for such applications.
[0062] The fibers employed in plies 520 may be comprised of carbon
fiber, aramid (such as Kevlar.TM. manufactured by Dupont
Corporation), glass, polyethylene (such as Spectra.TM. manufactured
by Allied Signal Corporation), ceramic (such as Nextel.TM.
manufactured by 3 m Corporation), boron, quartz, polyester or any
other fiber that may provide the desired strength. Preferably, at
least part of one of the fibers is selected from the group
consisting of carbon fiber, aramid, glass, polyethylene, ceramic,
boron, quartz, and polyester; even more preferably from the group
consisting of carbon fiber, aramid, glass, polyethylene, ceramic,
boron, and quartz; yet even more preferably from the group
consisting of carbon fiber, aramid, glass, polyethylene, ceramic,
and boron; yet even more preferably from the group consisting of
carbon fiber, aramid, glass, polyethylene, and ceramic; yet even
more preferably from the group consisting of carbon fiber, aramid,
glass, and polyethylene; yet even more preferably from the group
consisting of carbon fiber, aramid, and glass; yet even more
preferably from the group consisting of carbon fiber and aramid;
and most preferably comprises carbon fiber.
[0063] The matrix or resin based material is selected from a group
of resin based materials, including thermoplastics such as
polyetherether-ketone, polyphenylene sulfide, polyethylene,
polypropylene urethanes (thermoplastic), and Nylon-6 and thermosets
such as urethanes (thermosetting), epoxy, vinylester, polycyanate,
and polyester. In order to avoid manufacturing expenses relating to
transferring the resin into the mold after the foam-fiber layers
are inserted into the mold, the matrix material employed is
preferably pre-impregnated into the plies 520 prior to the uncured
blade assembly being inserted into the mold and the mold being
sealed. In addition, in order to avoid costs associated with the
woven sleeve materials employed in contemporary composite blade
constructs, it is preferable that the layers be comprised of one or
more plies 520 of non-woven uni-directional fibers.
[0064] As used herein the term "ply" shall mean "a group of fibers
which all run in a single direction, largely parallel to one
another, and which may or may not be interwoven with or stitched to
one or more other groups of fibers each of which may be or may not
be disposed in a different direction." A "layer" shall mean one or
more plies that are laid down together.
[0065] Applicants have found that a suitable material includes
unidirectional carbon fiber tape pre-impregnated with epoxy,
manufactured by Hexcel Corporation of Salt Lake City, Utah, and
also S & P Systems of San Diego, Calif. Another suitable
material includes uni-directional glass fiber tape pre-impregnated
with epoxy, also manufactured by Hexcel Corporation. Yet another
suitable material includes uni-directional Kevlar.TM. fiber tape
pre-impregnated with epoxy, also manufactured by Hexcel
Corporation.
[0066] With reference to FIG. 15A, the blade 30 constructions
illustrated in FIGS. 14A through 14F are generally constructed in
accordance with the following preferred steps. First, one or more
plies 520 of pre-impregnated substantially continuous fibers are
wrapped over a foam core 500 that is generally in the shape of the
blade 30 illustrated in FIGS. 3, 7, or 13 (step 600) to create an
un-cured blade assembly. It has been found preferable that each
uni-directional fiber ply be oriented so that the fibers run in a
different and preferably a perpendicular direction from the
underlying unidirectional ply. In the preferred embodiments each
ply is oriented so that the fibers run at preferably between +/-30
to 80 degrees relative to the longitudinal length of the blade 30
(i.e., the length from the heel section 140 to the tip section
130), and more preferably between +/-40 to 60 degrees, yet more
preferably between +/-40 to 50 degrees, even more preferably
between 42.5 and 47.5 degrees, and most preferably at substantially
+/-45 degrees. Other ply orientations may also be included, for
example it has been found preferable that an intermediate zero
degree oriented ply be included between one or more of the plies
520 to provide additional longitudinal stiffness to the blade 30 or
for example a woven outer ply (made of e.g., Kevlar.TM., glass, or
graphite) might be included to provide additional strength or to
provide desired aesthetics. Furthermore, it is to be understood
that additional plies may be placed at discrete locations on the
blade 30 to provide additional-strength or rigidity thereto. For
example, it is contemplated that additional plies be placed at or
around the general area where the puck typically contacts the blade
30 during high impact shots such as a slap shot.
[0067] Once the uncured blade assembly is prepared the uncured
composite structure is inserted into a mold that is configured to
impart the desired exterior shape of the blade 30 and the mold is
sealed (step 610 of FIG. 15A). Heat is then applied to the mold to
cure the blade assembly (step 620 of FIG. 15A). The blade 30 is
then removed from the mold and finished to the desired appearance
(step 630 of FIG. 15A). The finishing process may include aesthetic
aspects such as paint or polishing and also may include structural
modifications such as deburring. Once the blade 30 is finished, the
blade 30 is then ready for attachment to the shaft 20.
[0068] As shown in preferred embodiment FIG. 14A, a three-piece
foam core 500a, 500b and 500c is employed. Overlaying the centrally
positioned foam core element 500b are two plies 520a and 520b. In
application, plies 520a and 520b may be wrapped around core element
500b as a single layer 510. Once plies 520a and 520b are wrapped
around the foam core element 500b, plies 520c, 520d, and 520e are
wrapped over plies 520a and 520b and around core elements 500a and
500c as illustrated in FIG. 14A. The uncured blade assembly is then
inserted into a suitable mold configured to impart the desired
exterior shape of the blade 30 as previously discussed in relation
to step 610 of FIG. 15A. Once cured, plies 520a and 520b create
internal bridge structures 530 that extend from one side of the
blade 30 to the other (i.e., from the inner facing surface of ply
520c to the other side inner facing surface of ply 520c on the
other side of the blade 30) and thereby may provide additional
internal strength or impact resistance to the blade 30.
[0069] The internal bridge structure 530 previously referenced in
relation to FIG. 14A and also illustrated and discussed in relation
to FIGS. 14B through 14F may only extend along a desired discrete
portion of the longitudinal length (i.e., the length from the heel
to the tip section) of the blade 30. However, it is preferable that
the internal bridge structure(s) extend into the recessed or tongue
portion 260 of the heel 140 of the blade 30 so additional strength
may be imparted at the joint between the blade 30 and the shaft 20.
Moreover, by extending the internal bridge structure(s) into the
tongue 260 of the blade 30 a potentially more desirable blade 30
flex may be achieved.
[0070] Shown in FIGS. 14B and 14C are second and third preferred
constructions of the blade 30, each of which also comprises a
plurality of inner core elements 500a', 500b' and 500a", 500b",
500c", respectively. Three plies 520a', 520b', and 520c' overlay
the foam core elements. The positions of the interface or close
proximity of the plies 520 on opposite sides of the blade 30 (i.e.,
positions where opposed sides of ply 520a', 520b', and 520c' are
positioned in close proximity towards one another so that
preferably opposed sides of ply 520a' are touching one another)
form internal bridge structure(s) 530' interposed between the core
elements. The function and preferred position of the internal
bridge structure(s) 530' are as previously noted with respect to
the bridge structure 530 discussed in relation to FIG. 14A.
[0071] In application, the bridge structure(s) 530' illustrated in
FIGS. 14B and 14C can be implemented by the following process.
First, a single foam core 500, having generally the shape of the
blade 30, is provided and wrapped with plies 520a', 520b', and
520c' to create an uncured blade assembly (step 600 of FIG. 15A).
The blade assembly is then inserted into a mold having a convex
surfaces configured to impart the desired bridge structure 530'
into the blade 30 (step 610 of FIG. 15A). The convex surfaces force
the foam core structure out of the defined bridge structure region
and create a bias that urges the internal sides of the plies
towards one another at that defined region. The convex surface(s)
may be integral with the mold or may be created by insertion of a
suitable material, such as expanding silicone, into the mold at the
desired location(s).
[0072] Thus, in a preferred application a single foam core 500 is
partitioned during the molding process to create the discrete foam
core elements. Such a manufacturing process reduces the costs and
expenditures related with the manufacturing of a multi-piece foam
core structure as well as the time associated with wrapping the
plies about such a foam structure as was described in relation to
the foam core element 500b of FIG. 14A. In order to create a more
desirable blade surface configuration after the blade assembly is
cured, the cavities 540 formed by this process may be filled by a
suitable filler material 570 such as fiberglass, urethane, epoxy,
ABS, styrene, polystyrene, resin or any other suitable material to
effectuate the desired outer surface and performance results.
Filling the cavities 540 with urethane for example may assist in
gripping the puck.
[0073] Shown in FIG. 14D is a fourth preferred construction of the
blade 30 which also comprises a plurality of inner core elements
500a'" and 500b'" overlaid with three plies 520a'", 520b'", and
520c'". Extending between the inner core elements 500'" and 500b'"
is bead 590 of preferably pre-impregnated fiber material, such as
carbon or glass fiber. A preferred construction process includes
the following steps. First, foam core element 500 generally having
the shape of blade 30 is provided and a cavity is imparted,
preferably by mechanical means, within the foam core element 500
along a portion of its longitudinal length (i.e., generally from
the heel section to the toe section) so as to define core elements
500a'" and 500b'". Alternatively, the foam core element 500 may be
molded to include the cavity, thus avoiding the costs associated
with mechanical formation of the cavity into the form core element
500. As previously noted in relation to internal bridge structure
530 of FIG. 14A, the bead 590 preferably extends longitudinally
into the tongue 260 of the blade 30 so that it may provide
additional strength at the joint between the shaft 20 and the blade
30. The cavity is filled with a bead of preferably pre-impregnated
fibers. The fiber bead may be comprised of a single layer of
substantially continuous pre-impregnated fibers that are rolled or
layered to achieve the desired dimensions to fill the cavity.
Alternatively, the bead may be comprised of a non-continuous fiber
and resin mixture referred to in the industry as "bulk molding
compound." The fibers in the bulk molding compound may be selected
from the group of fibers previously identified with respect to the
substantially continuous fibers employed in plies 520. Once the
bead of fiber material is laid in the cavity between core elements
500a'" and 500b'", plies 520 a'", 520b'", and 520c'" are wrapped
around the foam core elements as illustrated in FIG. 14D to form a
uncured blade assembly (step 600 of FIG. 15A). The uncured blade
assembly then is inserted into a mold having the desired exterior
shape of the blade 30 (step 620 of FIG. 15A) and heat is applied to
the mold to cure (step 630 of FIG. 15B). The bead 590 of fiber
material forms an internal bridge structure 530' between opposing
sides of the blade 30 and is disposed between the core elements
500a'" and 500b'", the function of which is as previously noted in
relation to the bridge structure 530 discussed in relation to FIG.
14A.
[0074] Shown in FIG. 14E is a fifth preferred construction of the
hockey stick blade 30. In addition to the preferred steps set forth
in FIG. 15A, a preferred process for manufacturing this preferred
construction is set forth in more detail in FIGS. 16A-C. With
reference to FIG. 14E the preferred steps described and illustrated
in FIGS. 16A-C (steps 900 through 960) will now be discussed. First
as illustrated in FIG. 16A, a foam core 500 is provided and is
preferably configured to include a recessed tongue section 260a' at
the heel section 140 of the blade 30 (step 900). The foam core 500
may preferably be molded to have a partition 800 that generally
extends the longitudinal length of the blade 30 from the tip
section 130 to the heel section 140. Alternatively, it may be
preferable that the partition 800 be mechanically imparted to a
unitary foam core structure 500.
[0075] The foam core 500 is then separated along partition line 800
into foam core elements 500a"" and 500b"" and a inner layers 810a
and 810b are provided (step 910). As illustrated in step 910 the
inner layers 810a and 810b are preferably dimensioned so that when
they are wrapped around the respective core elements 500a"" and
500b"" they extend to the respective upper edges 820a and 820b of
the foam core 500a"" and 500b"" (step 920 of FIG. 16B). With
reference to FIG. 14E, each layer 810a and 810b is preferably
comprised of two plies 520a"" and 520b"".
[0076] Layers 810a and 810b at the partition 800 are then mated
together so that layers 810a and 810b are interposed within
the-partition 800 (step 930). Preferably, this may be achieved by
touching the mating surfaces of layers 810a and 810b to a hot plate
or hot pad to heat the resin pre-impregnated in the plies 520a"" of
the outer layers 810a and 810b and thereby facilitate adhesion of
the layers 810a and 810b to one another.
[0077] A cap layer 830 is preferably provided and wrapped around
the circumference of the blade assembly (step 940). The cap layer
830 is preferably dimensioned so that its length is sufficient to
completely circumference the outer edges of the foam core elements
500a"" and 500b"" when mated together at the partition 800 as
described in relation to step 930. In addition as best illustrated
in step 940 and FIG. 14F, the width of the cap layer 830 is
dimensioned so that when the cap layer 830 is wrapped around the
circumference of the foam core elements 500a"" and 500b"", the cap
layer 830 overlaps the outer surfaces of layers 810a and 810b. As
best illustrated in FIG. 14E the cap layer 830 is preferably
comprised of two plies, 560a and 560b.
[0078] As illustrated in step 950 of FIG. 16C outer layers 840
(only a single outer layer 840 is illustrated in step 950) and an
edging material 550 is provided. The edging material is preferably
twine or rope and may be comprised of a variety of materials
suitable for providing sufficient durability to the edge of the
blade 30, such as bulk molding compound of the type previously
described, fiberglass, epoxy, resin or any other suitable material.
It has been found preferable, however, that fiberglass twine or
rope be employed, such as the type manufactured by A & P
Technology, Inc. of Cincinnati, Ohio. Each of the outer layers 840,
as best-illustrated in FIG. 14E, are also preferably comprised of
two plies 520c"" and 520d'"". The outer layers 840 are preferably
dimensioned to be slightly larger than the foam core elements
500a"" and 500b"" when mated together as described in
[0079] As described and illustrated in step 960, the outer layers
840 are mated to the outer sides of the blade assembly illustrated
in step 950 so that a channel 860 is formed about the circumference
of the blade assembly. The edging material 850 is then laid in the
channel 860 about the circumference of the blade assembly to create
the final uncured blade assembly. The uncured blade assembly is
then inserted into a suitable mold configured to impart the desired
exterior shape of the blade 30 (step 610 of FIG. 15A), heat is
applied to the mold to cure (step 620 of FIG. 15A), and then the
cured blade 30 is removed from the mold and finished 30 for
attachment (step 630 of FIG. 15A). Notable is that the construction
process described in relation to FIGS. 16A-C has been found to be
readily facilitated by the inherent adhesion characteristics of the
pre-impregnated plies 520.
[0080] FIG. 14F illustrates a sixth preferred construction of the
hockey stick blade 30 which also comprises a plurality of inner
core elements 500a'"" and 500b'"" overlaid with plies 520a'"" and
520b'"". As in the construction illustrated in FIG. 14D, extending
between the inner core elements 500a'"" and 500b'"" is a bead 590'
of preferably pre-impregnated fiber material that forms an internal
bridge structure 530"". Around the circumference of the blade 30 is
preferably an edging material 550' such as that discussed in
relation to FIG. 14E. In application, the incorporation of the bead
of material may be achieved as discussed in relation to FIG. 14D.
Once the bead material is disposed between the core elements
500a'"" and 500b'"", the remaining construction is similar to that
discussed in relations to steps 950 and 960 of FIG. 16C. Namely,
(1) oversized outer layers are mated to the core elements having
the bead material disposed there between, (2) the edging material
550' is then preferably wrapped around the circumference of the
foam core members 500a'"" and 500b'"" in the channel created by the
sides of the outer layers, and (3) the uncured blade assembly is
loaded into a mold to cure.
[0081] FIG. 14G illustrates a seventh preferred construction of the
hockey stick blade 30 and FIG. 15B details the preferred steps for
manufacturing the blade 30 illustrated in FIG. 14F. In this
preferred construction, bulk molding compound 580 (i.e.,
non-continuous fibers disposed in a matrix material or resin base)
of the type previously described is loaded into a mold configured
for molding the desired exterior shape of the blade 30 (step 700 of
FIG. 15B). With respect to the loading of the mold, it has been
found preferable to somewhat overload the mold with compound so
that when the mold is sealed or closed the excess compound material
exudes from the mold. Such a loading procedure has been found to
improve the exterior surface of the blade 30 and the curing
process. Once the mold is loaded, heat is applied to the mold to
cure (step 710) and the cured blade 30 is removed from the mold and
finished, if necessary, to the desired appearance (step 720).
[0082] FIG. 17A-C illustrates a preferred embodiment of an adapter
member 1000. The adapter member 1000 is configured at a first end
section 1010 to receive the tongue 260 of the blade 30 illustrated
and previously described in relation to FIGS. 3 and 7. A second end
section 1020 of the adapter member 1000 is configured to be
connectable to a shaft. In the preferred embodiment, the second end
section 1020 is configured to be receivable in the hollow of the
shaft 20 illustrated and previously described in relation to FIGS.
10-12. In particular, the adapter member 1000 is comprised of a
first and second wide opposed walls 1030, 1040 and a first and
second narrow opposed wall 1050, 1060. The first wide opposed wall
1030 includes a front facing surface 1070 and the second wide
opposed wall includes a back facing surface 1080 such that when the
adapter member 1000 is joined to the blade 30 the front facing
surface 1070 generally faces in the same direction as the front
face 90 of the blade 30 and the back facing surface 1080 generally
faces in the same direction as the back face 100 of the blade 30.
The first narrow opposed wall 1050 includes forward facing surface
1090 and the second narrow opposed wall includes a rearward facing
surface 1100, such that when the adapter member 1000 is joined to
the blade 30 the forward facing surface 1090 generally faces toward
the tip section 130 of the blade and is generally perpendicular to
the longitudinal length of the blade 30 (i.e., the length of the
blade from the tip section 130 to the heel section 140) the
rearward facing surface 1100 generally faces away from the tip
section 130 of the blade 30.
[0083] The adapter member 1000 further includes a tapered section
330' having a reduced width. between the front and back facing
surfaces 1070 and 1080. The tapered section 330' is preferably
dimensioned so that when the adapter member 1000 is joined to the
blade 30 the front and back facing surfaces 1070, 1080 are
generally flush with the adjacent portions of the front and back
faces 90 and 100 of the blade 30.
[0084] The first end section 1010 includes an open-ended slot 230'
that extends from the forward facing surface 1090 of narrow wall
1050 preferably through the rearward facing surface 1100 of narrow
wall 1060. The slot 230' also preferably extends through the end
surface 1110 of the adapter member 1000. The slot 230' is
dimensioned to receive, preferably slidably, the recessed tongue
portion 260 located at the heel section 140 of the blade 30
illustrated in FIGS. 3 and 7.
[0085] As previously discussed in relation to the shaft illustrated
in FIGS. 1-2 and 5-6, when the slot 230' is joined to the tongue
portion 260, the forward facing surface 1090 on either side of the
slot 230' opposes and preferably abuts the front and back side
shoulders 280, 290 of the blade 30 to form a joint similar to an
open slot mortise and tongue joint. In addition, the
rearward-facing edge 320 of the tongue 260 is preferably flush with
the rearward facing surface 1100 of the adapter member 1000 on
either side of the slot 230'; the upper edge 300 of the tongue 260
opposes and preferably abuts with the top surface 360' of the slot
230'; and the front and back side surfaces 370, 380 of the tongue
260 oppose and preferably abut with the inner sides 430', 440' of
the wide opposed walls 1030 and 1040 of the adapter member
1000.
[0086] Moreover, when joined to the blade 30 configuration
illustrated in FIG. 3, the end surface 1110 of the adapter member
1000 on either side of the slot 230' is preferably flush with the
lower edge 310 of the tongue,260. Alternatively, when joined to the
blade 30 configuration illustrated in FIG. 7, the end surface 1110
of the adapter member 1000 on either side of the slot 230' opposes
and preferably abuts shoulders 240 and 250 and the forward facing
edge 340 of the tongue 260 is preferably flush with the forward
facing surface 1090 of the adapter member 1000 on either side of
the slot 230'.
[0087] The second end section 1020 of the adapter member 1000, as
previously stated is preferably configured to be receivable in the
hollow of the shaft 20 previously described and illustrated in
relation to FIGS. 10-12 and includes substantially the same
configuration as the mating section 460 described in relation to
FIGS. 10-13. In particular, the second end section 1020 in a
preferred embodiment is comprised of a rectangular cross section
having two sets of opposed walls 1030a, 1040a and 1050a, 1060a that
are adapted to mate with the lower section 60 of the shaft 20 in a
four-plane lap joint along the inside of walls 150, 160, 170, and
180 (best illustrated in FIG. 11). The outside diameter of the
rectangular cross-sectional area of the second end section 1020 is
preferably dimensioned to make a sliding fit inside the hollow
center of the lower section 60 of the shaft 20. Preferably, the
adapter member 1000 and shaft 20 are bonded together at the
four-plane lap joint using an adhesive capable of removably
cementing the adapter member 1000 to the shaft 20 as previously
discussed in relation FIGS. 10-13.
[0088] It is to be understood that the adapter member 1000 may be
comprised of various materials including the composite type
constructions previously discussed (i.e., substantially continuous
fibers disposed within a resin and wrapped about a foam core as
illustrated in FIG. 14A-E, non-continuous fibers disposed in a
resin as illustrated in FIG. 14F) and may also be constructed of
wood or wood laminate or wood or wood laminate overlaid with outer
protective material such as fiberglass. It is noted that when
constructed of wood, a player may obtain the desired wood
construction "feel" while retaining the performance of a composite
blade construction since the adapter member 1000 joining the blade
and the shaft would be comprised of wood.
[0089] Illustrated in FIG. 17D is a perspective view of a hockey
stick comprising the blade 30 illustrated in FIG. 3, the adapter
member 1000 illustrated in FIGS. 17A-C, and the shaft 20
illustrated in FIGS. 10-12.
[0090] It is to be appreciated and understood that shafts 20,
illustrated in FIGS. 1-2 and 5-6, may be constructed of various
materials including wood or wood laminate or wood or wood laminate
overlaid with outer protective material such as fiberglass. Such a
shaft 20 construction in combination with the blade 30 illustrated
in FIGS. 1-8 and 17D the construction of which being illustrated in
FIGS. 14A-G, 15A-B, and 16A-C results in a unique hybrid hockey
stick configuration (i.e., a traditional "wood" shaft attached to a
"composite" blade), which may provide the desired "feel" sought by
hockey players and the public.
[0091] In addition, it should be also understood that while all or
a portion of the recessed tongue portion 260 of the heel 140 may be
comprised of a foam core overlaid with plies of substantially
continuous fibers disposed in a matrix material; it may also be
preferable that all or a portion of the recessed tongue portion 260
of the heel 140 be comprised of plies of substantially continuous
fibers disposed in a matrix material without a foam core. Such a
construction may comprise of a build-up of additional plies
relative to the other portion of the blade and may improve the
rigidity of the joint and provide a more desirable flex as was
described in relation to the internal bridge structure(s) 530
described in relation to FIGS. 14A through 14F.
[0092] While there has been illustrated and described what are
presently considered to be preferred embodiments and features of
the present invention, it will be understood by those skilled in
the art that various changes and modifications may be made, and
equivalents may be substituted for elements thereof, without
departing from the scope of the invention.
[0093] In addition, many modifications may be made to adapt a
particular element, feature or implementation to the teachings of
the present invention without departing from the central scope of
the invention. Therefore, it is intended that this invention not be
limited to the particular embodiments disclosed herein, but that
the invention include all embodiments falling within the scope of
the appended claims.
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