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.

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.