A composite hockey stick having a tubular hollow rectangular shaft and a blade is disclosed. The shaft comprises an inner layer and an outer layer, each of the inner and outer layers are formed of uni-directional substantially continuous fibers disposed in a hardened resin matrix and wrapped and molded around a middle elastomer layer. A new manufacturing method is also disclosed in which a cured hollow tubular composite hockey stick shaft is inserted between the front and back faces of an un-cured composite hockey stick blade and the blade is then cured in a mold around the hockey stick shaft to form a unitary composite hockey stick.
1. A method of manufacturing a hockey stick comprising:
a) providing a cured tubular composite hockey stick shaft configured at its lower region to be joined to the heel region of a hockey stick blade;
b) providing an uncured composite hockey stick blade pre-form configured to be joined to the lower region of the cured hockey stick shaft;
c) inserting the lower region of the cured hockey stick shaft into the heel region of the uncured hockey stick blade pre-form using a rotational motion in which said heel region comprises an open slot into which said lower region is rotated into position, such that upon full insertion, one side of said lower region becomes the back side of said blade portion;
d) inserting the uncured hockey stick blade pre-form and the joined portion of the cured tubular composite hockey stick shaft into a mold configured to receive the uncured blade pre-form and at least a portion of the lower region of the cured hockey stick shaft and to impart the desired exterior shape of the hockey stick blade upon curing; and
e) curing the hockey stick blade pre-form around the interposed lower region of the cured hockey stick shaft with application of heat.
2. The method of claim 1 wherein the step of providing a cured tubular composite hockey stick shaft configured at its lower region to be joined to the heel region of a hockey stick blade further comprises an inner composite construct and an outer composite construct of said cured tubular composite hockey stick shaft.
3. The method of claim 1 wherein the step of providing a cured tubular composite hockey stick shaft configured at its lower region to be joined to the heel region of a hockey stick blade further comprises an elastomer layer disposed between an inner composite construct and an outer composite construct of said cured tubular composite hockey stick shaft.
4. The method of claim 1 wherein the step of providing an uncured composite hockey stick blade pre-form configured to be joined to the lower region of the cured hockey stick shaft further comprises a core encased by one or more plies of fibers disposed in a hardened resin matrix.
5. The method of claim 1 wherein the step of providing an uncured composite hockey stick blade pre-form configured to be joined to the lower region of the cured hockey stick shaft further comprises a core encased by one or more plies of fibers disposed in a hardened resin matrix, wherein said encased core is comprised of elastomer material.
6. A method of manufacturing a hockey stick comprising:
a) providing a cured tubular composite hockey stick shaft configured at its lower region to be joined to the heel region of a hockey stick blade;
b) providing an uncured composite hockey stick blade pre-form configured to be joined to the lower region of the cured hockey stick shaft;
c) mating the lower region of the cured hockey stick shaft with the heel region of the uncured hockey stick blade pre-form in which said heel region comprises an open slot into which said lower region is inserted into position, such that upon full insertion, one side of said lower region becomes a portion of said blade portion;
d) inserting the uncured hockey stick blade pre-form and the mated portion of the cured tubular composite hockey stick shaft into a mold configured to receive the uncured blade pre-form and at least a portion of the lower region of the desired exterior shape of the hockey stick blade upon curing; and
e) curing the hockey stick blade pre-form with the mated lower region of the cured hockey stick shaft with application of heat.