Method of making a formable hockey stick blade

1. A method of making a formable hockey stick blade, the method comprising:

(a) providing a core having a blade element with a thickness, the core being made of expandable foam having a Poisson ratio of at least 0.33;

(b) forming a preformed stick blade by wrapping the core with a layer of fibers pre-impregnated with a thermoplastic material;

(c) placing the preformed stick blade in a mold;

(d) applying heat and pressure to the mold for bringing the thermoplastic material to its amorphous form and for compressing the preformed stick blade such that the thickness of the blade element of the core is reduced;

(e) cooling the mold such that the thermoplastic material is set; and

(f) removing the formable stick blade from the mold.

2. A method as defined in claim 1 , wherein the thickness of the blade element of the core is reduced by at least 10%.

3. A method as defined in claim 2 , wherein the thickness of the blade element of the core is reduced by at least 20%.

4. A method as defined in claim 3 , wherein the thickness of the blade element of the core is reduced by at least 30%.

5. A method as defined in claim 4 , wherein the thickness of the blade element of the core is reduced by at least 75%.

6. A method as defined in claim 1 , wherein the initial thickness of the blade element of the core is between 6 mm and 20 mm and the final thickness of the blade element of the core is between 1 mm and 3 mm.

7. A method as defined in claim 6 , wherein the temperature of the mold is maintained between 375° F. and 425° F. during step (d).

8. A method as defined in claim 6 , wherein the temperature of the mold is maintained between 375° F. and 425° F. during at least 2 minutes during step (c).

9. A method as defined in claim 6 , wherein the temperature of the mold is maintained between 375° F. and 425° F. during steps (c) and (d).

10. A method as defined in claim 6 , wherein the thermoplastic material is made of Nylon or polypropylene.

11. A method as defined in claim 1 , wherein the pressure exerted on the mold is sufficient to sustain the internal pressure created by the heated foam.

12. A method as defined in claim 11 , wherein the internal pressure created by the heated foam is sufficient to consolidate together the fibers and the thermoplastic material.

13. A method as defined in claim 12 , wherein the internal pressure created by the heated foam is sufficient to bond together the core and the consolidated fibers and thermoplastic material.

14. A method as defined in claim 13 , wherein step (a) comprises cutting first and second portions such that the first portion comprises a bottom surface following a longitudinal axis of the blade and the second portion comprises a top surface following the longitudinal axis, the first and second portion forming the blade element of the core once the first portion is aligned with and placed over the second portion.

15. A method as defined in claim 14 , wherein step (b) comprises wrapping the first portion in a first fiber braid and the second portion in a second fiber braid, the first and second fibers braid comprising fibers selected from the group consisting of carbon fibers, glass fibers, KEVLAR fibers, ceramic fibers, boron fibers, quartz fibers, spectra fibers, polyester fibers and polyethylene fibers.

16. A method as defined in claim 15 , wherein step (b) further comprises wrapping the first and second portions and first and second fiber braids in respective third and fourth fiber braids that comprise fibers selected from the group consisting of carbon fibers, glass fibers, KEVLAR fibers, ceramic fibers, boron fibers, quartz fibers, spectra fibers, polyester fibers and polyethylene fibers.

17. A method as defined in claim 16 , wherein step (b) further comprises wrapping the first and second portions and first, second, third and fourth fiber braids in a fifth fiber braid that comprises fibers selected from the group consisting of carbon fibers, glass fibers, KEVLAR fibers, ceramic fibers, boron fibers, quartz fibers, spectra fibers, polyester fibers and polyethylene fibers.

18. A method as defined in claim 17 further comprising trimming said formable hockey stick blade.

19. A method as defined in claim 1 , wherein the initial density of the blade element of the core is between 5 lbs cubic/foot and 6 lbs/cubic foot and the final density of the blade element of the core is between 6.5 lbs/cubic foot and 20 lbs/cubic foot.