# US 11,298,601 B2 · Hockey blade with pin-reinforced core

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,298,601 B2
- Document ID: US11298601B2
- Status: Granted
- Kind: B2
- Application number: 16/559,801
- Filed: 2019-09-04
- Published: 2019-12-26
- Granted: 2022-04-12
- Earliest claimed: 2016-09-29
- Assignees: Bauer Hockey, LLC
- Applicants: Bauer Hockey Ltd.
- Inventors: Jean-Frédérik Caron Kardos; Mathieu Ducharme
- Web page: https://patentgrep.com/patent/US11298601B2

## CPC

- A63B 59/70: with bent or angled lower parts for hitting a ball on the ground, on an ice-covered surface, or in the air, e.g. for hockey or hurling
- B29C 63/0004: {Component parts, details or accessories; Auxiliary operations}
- B29C 63/0073: {of non-flat surfaces, e.g. curved, profiled (B29C63/042 takes precedence)}
- B29C 63/02: using sheet or web-like material (B29C63/26 {and B29C63/38} take precedence)
- B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)}
- B29C 70/24: oriented in at least three directions forming a three-dimensional [3D] structure
- B29C 70/865: {completely encapsulated}
- A63B 2102/24: Ice hockey
- A63B 2209/00: Characteristics of used materials
- A63B 2209/02: with reinforcing fibres, e.g. carbon, polyamide fibres
- A63B 2209/023: Long, oriented fibres, e.g. wound filaments, woven fabrics, mats
- B29K 2715/003: Cellular or porous
- B29L 2031/52: Sports equipment {; Games; Articles for amusement}; Toys (B29L2031/54 takes precedence)
- A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a bottom core edge and a top core edge. Multiple pins are injected into the foam core, and one or more layers of resin preimpregnated tape are wrapped around the foam before forming a hockey blade structure in a heated mold.

## Claims

### Claim 1

A hockey blade structure formed by a method comprising the steps of:
forming a foam core, the foam core comprising a first core face, a second core face, a top core edge, and a bottom core edge;
injecting a first plurality of discrete pins into a first area the first core face having a first density, the first plurality of discrete pins having a first areal weight, and extending between the first core face and the second core face;
injecting a second plurality of discrete pins into a second area of the first core face having a second density, the second plurality of discrete pins having a second areal weight higher than the first areal weight to configure the second area of the first core face as a preferred impact area of the hockey blade with a puck, the second plurality of discrete pins extending between the first core face and the second core face;
wrapping the foam core with a layer of fiber tape to form a wrapped core, the layer of fiber tape extending along the first core face, the top core edge, the second core face, and the bottom core edge of the foam core, wherein the wrapped core has a first wrapped face, a second wrapped face, a top wrapped edge, and a bottom wrapped edge; and
molding the wrapped foam core in a mold,
wherein each of the first plurality and the second plurality of discrete pins has two opposing pointed ends,
wherein a portion of each of the first plurality and the second plurality of discrete pins extends out of the foam core beyond the first core face and the second core face, and
wherein the portion is configured to embed into the layer of fiber tape.

### Claim 2 (depends on 1)

The hockey blade structure of claim 1, wherein a selected pin, from the first plurality and the second plurality of discrete pins, is injected at an angle relative to a surface normal of the first core face at a point of injection of a first fiber pin.

### Claim 3 (depends on 2)

The hockey blade structure of claim 2, wherein the angle is approximately zero degrees.

### Claim 4 (depends on 2)

The hockey blade structure of claim 2, wherein the angle is between approximately 15 and 75 degrees.

### Claim 5 (depends on 1)

The hockey blade structure of claim 1, wherein the first plurality and the second plurality of discrete pins comprise epoxy-coated carbon fiber pins.

### Claim 6 (depends on 1)

The hockey blade structure of claim 1, wherein the first plurality and the second plurality of discrete pins comprise metallic pins.

### Claim 7 (depends on 1)

The hockey blade structure of claim 1, wherein the first plurality of pins have a first spacing density and the second plurality of pins have a second spacing density, less than the first spacing density.

### Claim 8

A hockey stick blade apparatus, comprising:
a molded preform structure, further comprising:
a foam core comprising a first core face, a second core face, a top core edge, and a bottom core edge;
a first plurality of discrete pins having a first areal weight injected into a first area of the first core face having a first density and extending between the first core face and the second core face within the foam core;
a second plurality of discrete pins having a second areal weight higher than the first areal weight injected into a second area of the first core face having a second density to configure the second area of the first core face as a preferred impact area of the hockey stick blade with a puck, the second plurality of discrete pins extending between the first core face and the second core face within the foam core; and
a layer of fiber tape extending along the first core face, the top core edge, the second core face, and the bottom core edge of the foam core,
wherein each of the first plurality and the second plurality of discrete pins has two opposing pointed ends,
wherein a portion of each of the first plurality and the second plurality of discrete pins extends out of the foam core beyond the first core face and the second core face, and
wherein the portion is configured to embed into the layer of fiber tape.

### Claim 9 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein the layer of fiber tape is preimpregnated with resin prior to molding of the molded preform structure.

### Claim 10 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein the first plurality and the second plurality of discrete pins are regularly spaced apart.

### Claim 11 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein the first plurality and second plurality of discrete pins extend through the layer of fiber tape.

### Claim 12 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein the first plurality and second plurality of discrete pins comprise fiver pins.

### Claim 13 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein a selected pin, from the first plurality and the second plurality of discrete pins, is injected at an angle relative to a surface normal of the first core face at a point of injection of a first fiber pin.

### Claim 14 (depends on 13)

The hockey stick blade apparatus of claim 13, wherein the angle is approximately zero degrees.

### Claim 15 (depends on 13)

The hockey stick blade apparatus of claim 13, wherein the angle is between approximately 15 and 75 degrees.

### Claim 16 (depends on 8)

The hockey stick blade apparatus of claim 8, wherein the first plurality of pins have a first spacing density and the second plurality of pins have a second spacing density, less than the first spacing density.