Method of making a formable hockey stick blade

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

(a) making a core of synthetic material, the core extending along a longitudinal axis;

(b) recovering the core with a fibers layer for forming a preformed blade;

(c) placing the preformed blade in a mold;

(d) injecting in the mold, at a pressure between 45 psi and 60 psi and a temperature between 350° F. and 400° F., a thermoplastic resin having a viscosity below 25 cP while maintaining a negative pressure of at least 200 mm of mercury in the mold;

(e) curing the thermoplastic resin; and

(f) removing the blade from the mold.

2 . A method as defined in claim 1 , wherein the temperature of the mold is at least 375° F. during step (d).

3 . A method as defined in claim 2 , wherein the temperature of the mold is at least 375° F. during steps (c) to (e).

4 . A method as defined in claim 3 , wherein step (e) comprises maintaining the mold at a temperature of at least 375° F. for at least 8 minutes and injecting air in the mold at a pressure of at least 40 psi.

5 . A method as defined in claim 3 , wherein the core made of synthetic material is selected in the group consisting polyurethane foam, ethylene vinyl acetate (EVA) foam, polyvinyl chloride (PVC) foam, ethylene polypropylene foam, isotropic foam and polyisocyanurate foam.

6 . A method as defined in claim 5 , wherein step (a) comprises cutting first and second portions such that the first portion comprises a bottom surface following the longitudinal axis and the second portion comprises a top surface following the longitudinal axis, the first and second portion forming the core once the first portion is aligned with and placed over the second portion.

7 . A method as defined in claim 6 , 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.

8 . A method as defined in claim 7 , 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.

9 . A method as defined in claim 8 , 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.

10 . A method as defined in claim 9 further comprising trimming said formable hockey stick blade.

11 . A method of selling a hockey stick blade, comprising:

(a) providing to a customer a hockey stick blade that is formable between 425° F. and 500° F.;

(b) providing to the customer a plurality of curvatures;

(c) selecting a curvature in the plurality of curvatures;

(d) placing the hockey stick blade in a oven being at a temperature of at least 300° F. during a sufficient period of time such that the blade becomes formable; and

(e) shaping the blade in accordance with the selected curvature.

12 . A method as defined in claim 11 , wherein the blade is formable between 450° F. and 500° F.

13 . A method as defined in claim 12 , wherein the oven is at a temperature of 400° F. to 450° F.

14 . A method as defined in claim 13 , wherein, during step (d), the blade remains in the oven for a period of time between 1 minute and 3 minutes.

15 . A method as defined in claim 13 , wherein, during step (d), the blade remains in the oven for a period of time between 5 minute and 8 minutes

16 . A method as defined in claim 13 further comprising cooling the blade to the room temperature at a rate between 75° F. and 125° F. per minute.

17 . A method as defined in claim 13 further comprising applying on the blade a pressure between 10 psi and 40 psi during step (e).