Split Core Hockey Stick Blade

Abstract

A composite hockey stick blade having a paddle portion that includes an inner foam core overlaid, or sandwiched, with a plastic wrap. The inner foam core is formed having an upper section of a first foamed material and a lower section of a second foamed material, wherein the density of the upper foam core section is substantially less than the lower foam core section. More preferably, the upper foam core section has a density of about 3-5 pounds per cubic foot, while the lower foam core section has a density of greater than about 30 pounds per square foot. In addition, one or both of the foam core sections may be fiber reinforced. The location of the upper foam core section relative to lower foam core section within the paddle region may be varied to provide a hockey stick blade having different twisting and flexing characteristics.

1 . A hockey stick blade comprising:
 a hosel;   a heel section coupled to said hosel; and   a paddle portion coupled to said heel section, said paddle portion comprising a composite structure including an inner foam core overlaid with a plastic wrap, said inner foam core including an upper foam core section and a lower foam core section, said lower foam core section located along at least a portion of a bottom edge of said paddle portion from said heel section to a tip region, wherein said lower foam core section has a substantially higher density than said upper foam core section.   
   
   
       2 . The hockey stick blade of  claim 1 , wherein the density of said lower foam core section is at least 30 pounds per square foot. 
   
   
       3 . The hockey stick blade of  claim 2 , wherein the density of said upper foam core section between about 3 and 5 pounds per square foot. 
   
   
       4 . The hockey stick blade of  claim 1 , wherein said lower foam core section extends along the entire length of said bottom edge of said paddle portion from said heel section to said tip section. 
   
   
       5 . The hockey stick blade of  claim 1 , wherein a portion of said upper foam core section extends along a portion of said bottom edge near said tip region. 
   
   
       6 . The hockey stick blade of  claim 1 , wherein said upper foam core section comprises PVC foam having a density of between about 3-5 pounds per cubic foot and wherein said lower foam core section consists of epoxy thermoset foam having a density of at least  30  pounds per cubic foot. 
   
   
       7 . The hockey stick blade of  claim 1 , wherein the height of said upper foam core section is roughly equal to the height of said lower foam core section, wherein the height is measured along an axis of the paddle portion perpendicular to said top edge and said bottom edge of said paddle portion at a position wherein said upper foam core section is located along said top edge and wherein said lower foam core section is located along said bottom edge. 
   
   
       8 . The hockey stick blade of  claim 1 , wherein the height of said upper foam core section is less than the height of said lower foam core section, wherein the height is measured along an axis of the paddle portion perpendicular to said top edge and said bottom edge of said paddle portion at a position wherein said upper foam core section is located along said top edge and wherein said lower foam core section is located along said bottom edge. 
   
   
       9 . The hockey stick blade of  claim 1 , wherein the height of said upper foam core section is greater than the height of said lower foam core section, wherein the height is measured along an axis of the paddle portion perpendicular to said top edge and said bottom edge of said paddle portion at a position wherein said upper foam core section is located along said top edge and wherein said lower foam core section is located along said bottom edge. 
   
   
       10 . The hockey stick blade of  claim 3 , wherein at least one of said upper foam core section and said lower foam core section includes a plurality of chopped reinforcing fibers. 
   
   
       11 . The hockey stick blade of  claim 10 , wherein said plurality of chopped reinforcing fibers comprises approximately five weight percent of at least one of said upper foam core section and said lower foam core section. 
   
   
       12 . The hockey stick blade of  claim 11 , wherein said plurality of chopped reinforcing fibers comprises a plurality of milled carbon fibers. 
   
   
       13 . The hockey stick blade of  claim 1 , wherein the hockey stick blade comprises a replaceable hockey stick blade. 
   
   
       14 . The hockey stick blade of  claim 1 , wherein the hockey stick blade is integrally formed with a hockey stick shaft to form a composite hockey stick. 
   
   
       15 .- 22 . (canceled) 
   
   
       23 . A replacement hockey stick blade formed in accordance with the method of claim  15 . 
   
   
       24 . A hockey stick having a hockey stick blade formed in accordance with the method of claim  15 .