I-beam construction in a hockey blade core

• US 9,044,658 B2
• Filed: 10/26/2012
• Issued: 06/02/2015
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Warrior Sports Incorporated (Warrior Lacrosse Incorporated)
• Original Assignee: Warrior Sports Incorporated (Warrior Lacrosse Incorporated)
• Inventors: Xun, Sean, Bautista, Carlos Raul Gutierrez, Llamas, Edmundo Gerardo
• Primary Examiner(s): Kim, Gene
• Assistant Examiner(s): CHAMBERS, MICHAEL S
• Application Number:
  US13/661,968
• Publication Number:
  US 20130116070A1
• Time in Patent Office: 949 Days
• Field of Search: 473560-563, 473519-520
• US Class Current: 1/1
• CPC Class Codes: A63B 2102/22 Field hockey
• CPC Class Codes: A63B 2102/24 Ice hockey
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 59/70 with bent or angled lower parts for hitting a ball on the ground, on an ice-covered surface, or in the air, e.g. for hockey or hurling
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: A63B 60/08 characterised by the material
• CPC Class Codes: A63B 60/50 with through-holes A63B60/18 takes precedence; for stringing purposes A63B49/00
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0872 Prepregs
• CPC Class Codes: B29K 2715/003 Cellular or porous
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/52 Sports equipment ; Games; Articles for amusement; Toys B29L2031/54 takes precedence

Abstract

A reinforced hockey stick blade and a related method of manufacture are provided. The hockey stick blade can include a core element defining one or more longitudinal channels bounded by an upper core portion, a lower core portion, and a bridge portion interconnecting the upper and lower core portions. The hockey stick blade can additionally include a plurality of fiber-reinforced plies substantially encapsulating the core element and a reinforcing material received within the one or more longitudinal channels. The reinforcing material can extend longitudinally from a first channel end portion to a second channel end portion, and can include woven or unidirectional fiber-reinforced plies. The reinforcing material can additionally extend transversely across the channel to form a blade structure having increased blade strength and durability over existing composite hockey stick blades.

Claims

1. A composite hockey stick blade including a heel portion and a toe portion, the composite hockey stick blade comprising:

a core element including a first core face opposite a second core face, the core element defining a through-hole therebetween, the through-hole extending longitudinally along a portion of the core element to define a channel having a first channel end portion and a second channel end portion, the core element including an upper core portion above the channel and a lower core portion below the channel, the core element including a core bridge member extending from the upper core portion to the lower core portion so that the upper core portion, core bridge member and lower core portion are joined and contiguous with one another, forming a unitary, monolithic structure, with the core bridge member bounding the first channel end portion;

a first fiber-reinforced strip disposed in the channel to increase the strength of the core element, the first fiber-reinforced strip extending longitudinally from the first channel end portion to the second channel end portion, the first fiber reinforced strip including a first strip end, a second strip end distal from the first strip end, and an intermediate portion therebetween, the intermediate portion extending transversely across the channel, the first strip end projecting out from the channel and positioned adjacent the first core face, the second strip end projecting out from the channel end positioned adjacent the the second core face; and

a plurality of outer plies substantially encapsulating the core element and the first fiber-reinforced strip, at least one of the plurality of outer plies engaging at least one of the first strip and the second strip end, wherein the channel and the first fiber-reinforced strip extend along a substantial portion of the blade length between the heel portion and the toe portion.

2. The composite hockey stick blade of claim 1 wherein the first strip end, intermediate portion and second strip end cooperatively form a C-shape.

3. The composite hockey stick blade of claim 2 comprising a second fiber reinforced strip disposed transversely through the channel, adjacent the intermediate portion.

4. The composite hockey stick blade of claim 3 wherein the second fiber reinforced strip includes a third strip end and a fourth strip end, the third strip end engaging the first core face, the fourth strip end engaging the second core face.

5. The composite hockey stick blade of claim 3 wherein the second fiber reinforced strip contacts the first core face the second core face.

6. The composite hockey stick blade of claim 5 wherein the second fiber reinforced strip is generally of a C-shape.

7. The composite hockey stick blade of claim 5 comprising a third fiber reinforced strip extending transversely through the channel, between the first fiber reinforced strip and the second fiber reinforced strip.

8. The composite hockey stick blade of claim 1 wherein the first reinforcing strip includes a plurality of fiber-reinforced plies.

9. The composite hockey stick blade of claim 8 wherein the plurality of fiber-reinforced plies include at least one of graphite, carbon, aramid, and fiberglass.

10. The composite hockey stick blade of claim 1 wherein the channel is a first channel, the core element further defining a second channel therein, below the lower core portion the second channel being substantially parallel to and vertically spaced apart from the first channel.

11. The composite hockey stick blade of claim 1 wherein the core element is a unitary structural foam core.

13. The composite hockey stick blade of claim 1 wherein the first strip end, intermediate portion and second strip end cooperatively form a C-shape.

14. The composite hockey stick blade of claim 13 wherein the second core bridge member is distal from the first core portion,

wherein the first core bridge member is in the heel of the blade,

wherein the second core bridge member is in the toe of the blade.

12. A composite hockey stick blade including a heel portion and a toe portion, the composite hockey stick blade comprising:

a core element including a first core face opposite a second core face and defining a through-hole therebetween, the through-hole extending longitudinally along a portion of the core element to define a channel having first and second end portions;

a fiber-reinforced material received within the channel to increase the strength of the core element, the fiber-reinforced material extending longitudinally from the first end portion to the second end portion, and extending transversely across the channel, the fiber-reinforced material engaging the first core face and the second core face; and

a plurality of outer plies substantially encapsulating the core element and the fiber-reinforced material, wherein the longitudinal channel and the fiber-reinforced material extend along a substantial portion of the blade length between the heel portion and the toe portion,

wherein the channel is bounded by an upper core portion and a lower core portion, with a first core bridge member and a second core bridge member joining the upper and lower core portions at the channel first and second end portions to form a unitary, one piece structural foam core,

wherein the fiber-reinforced material includes a first strip end distal from a second strip end with an intermediate portion therebetween,

wherein the first strip end is adjacent the first core face, and terminates adjacent the channel,

wherein the second strip end is adjacent the second face and terminates adjacent the channel.