Hockey Stick Blade Having Fiber-Reinforced High Density Foam Core

Abstract

A composite hockey stick blade including a fiber reinforced, high-density foam polymeric core material overlaid with a plastic wrap. The fiber reinforcement material, in the form of a plurality of milled or long fibers, provides increased toughness and stiffness of the high density polymeric foam core material. The hockey stick blade may be utilized as a replacement blade for a two-piece hockey stick, or may be a portion of a one-piece hockey stick.

1 - 12 . (canceled) 
   
   
       13 . A method for forming a composite hockey stick blade having a hosel, a heel section, and a paddle portion, the method comprising:
 providing a multi-piece mold having an inner cavity defined therewithin, said inner cavity shaped to correspond in size and shape to the composite hockey stick blade;   coupling one or more plies of a plastic wrap along a front surface and a rear surface of said inner cavity, said front surface corresponding to a front face of the paddle portion and said rear surface corresponding to a rear face of the paddle portion;   coupling one or more strips of reinforcement along a bottom surface of said inner cavity, said bottom surface corresponding to a bottom edge of the paddle portion;   coupling a fiber reinforced high density polymeric foam core section onto said innermost one of said one or more strips of reinforcement between said one or more plies along said front surface and said one or more plies on said rear surface;   coupling at least one ply of said plastic wrap onto a top surface of said fiber reinforced high density polymeric foam core section;   closing said multi-piece mold such that said fiber reinforced high density polymeric foam core section contacts one said plies of plastic wrap along said front surface and said rear surface, said fiber reinforced high density polymeric foam core section also contacting one of said one or more strips of reinforcement along said bottom edge and further contacting one of said at least one ply along said top surface;   applying heat and pressure within said multi-piece mold for a period of time sufficient to cure said fiber reinforced high density polymeric foam core section, said one or more plies of said plastic wrap, and said one or more plies of said reinforcement;   opening said multi-piece mold; and   removing the composite hockey stick blade.   
   
   
       14 . The method of  claim 13 , wherein said fiber reinforced high density polymeric foam core section comprises a high density epoxy foam and a plurality of chopped fiber. 
   
   
       15 . The method of  claim 14 , wherein said plurality of chopped fibers comprises a plurality of milled fibers. 
   
   
       16 . The method of  claim 14 , wherein said plurality of chopped fibers comprises a plurality of long fibers. 
   
   
       17 . The method of  claim 14 , wherein said plurality of milled fibers comprises between about  0  and  5  weight percent of said fiber reinforced high density polymeric foam core section. 
   
   
       18 . The method of  claim 13 , wherein said fiber reinforced high density polymeric foam core section comprises a high density, non-expanding epoxy foam and a plurality of chopped fiber. 
   
   
       19 . The method of  claim 13 , wherein said fiber reinforced high density polymeric foam core section comprises a high density expanding foam and a plurality of chopped fiber. 
   
   
       20 . The method of  claim 13 , further comprising:
 providing a second cavity portion within said multi-piece mold that is open and continuous with said inner cavity, said second cavity portion corresponding to a hosel region of the composite hockey stick blade;   coupling one or more plies of said plastic wrap to each of the outer surfaces of said second cavity portion; and   optionally inserting a silicone plug within said one or more plies of said plastic wrap with said second cavity portion.   
   
   
       21 . The method of  claim 20  further comprising:
 coupling a foam core section within said second cavity portion.   
   
   
       22 - 23 . (canceled)