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 hockey stick comprising:
(a) a composite hockey stick shaft that extends from a terminal top end to a terminal lower end, said hockey stick shaft includes an inner composite construct, an outer composite construct, an elastomer layer disposed between the inner composite construct and the outer composite construct, each of said inner and outer composite constructs comprising one or more plies of substantially parallel fibers disposed in a hardened resin matrix; and
(b) a cure molded composite blade extending from a tip region to a heel region comprising a multi-component core construct including one or more elastomer core components completely encased within one or more plies of fibers disposed in a hardened resin matrix and one or more non-elastomer core components encased within one or ore more plies of fibers disposed within a hardened resin matrix,
wherein said shaft is cure molded to said blade within an open-ended slot disposed at the heel of the blade.
2. The hockey stick of claim 1 , wherein the inner composite construct is comprised of a generally rectangular hollow tubular structure.
3. The hockey stick of claim 1 , wherein the outer composite construct is comprised of a generally rectangular hollow tubular structure.
4. The hockey stick of claim 1 , wherein the inner composite construct has a greater cross-sectional thickness dimension than the outer composite construct.
5. The hockey stick of claim 1 wherein said elastomer layer is constructed of a material that has an ultimate elongation that is approximately equal to or greater than 100%, such that it can be stretched to at least approximately double its length at rest without rupture, and when released, returns quickly to approximately its pre-stretched length.
6. The hockey stick of claim 1 wherein said elastomer layer has a thickness of loss than ⅙ inch.
7. The hockey stick of claim 1 wherein the periphery of said inner composite construct is only partially encircled by said elastomer layer.
8. The hockey stick of claim 7 wherein said elastomer layer encircles less than 50% of the periphery of said inner composite construct.
9. The hockey stick of claim 1 wherein said elastomer layer overlies less than the entire longitudinal length of said inner composite construct.
10. A hockey stick comprising:
(a) a composite hockey stick shaft that extends from a terminal top end to a terminal lower end, said hockey stick shalt includes an inner composite construct, an outer composite construct, an elastomer layer disposed between the inner composite construct and the outer composite construct, each of said inner and outer composite construct comprising one or more plies of uni-directional substantially parallel fibers disposed in a hardened resin matrix; and
(b) a cure molded composite blade extending from a tip region to a heel region comprising a multi-component core construct including one or more elastomer core components completely encased within one or more plies of fibers disposed in a hardened resin matrix and one or more non-elastomer core components encased by one or more plies of fibers disposed within a hardened resin matrix, wherein said terminal lower end of the composite hockey stick shaft is cure-moldedly lowered with the composite blade at said heel region.
11. The hockey stick of claim 10 , wherein the inner composite construct is comprised of a generally rectangular hollow tubular structure.
12. The hockey stick of claim 10 , wherein the outer composite construct is comprised of a generally rectangular hollow tubular structure.
13. The hockey stick of claim 10 , wherein the inner composite construct has a greater cross-sectional thickness dimension than the outer composite construct.
14. The hockey stick of claim 10 wherein said elastomer layer is constructed of a material that has an ultimate elongation that is approximately equal to or greater than 100%, such that it can be stretched to at least approximately double its length at rest without rupture, and when released, returns quickly to approximately its pre-stretched length.
15. The hockey stick of claim 10 wherein said elastomer layer has a thickness of less than 1/16 inch.
16. The hockey stick of claim 10 wherein the periphery of said inner composite construct is only partially encircled by said elastomer layer.
17. The hockey stick of claim 16 wherein said elastomer layer encircles less than 50% of the periphery of said inner composite construct.
18. The hockey stick of claim 10 wherein said elastomer layer overlies less than the entire longitudinal length of said inner composite construct.