Blade constructs and methods of forming blade constructs
AssigneeBauer Hockey, LLC
InventorAdam Gans
Life of this patent
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Abstract
A dual-core blade and method for manufacturing a dual-core blade are disclosed. The blade is formed with a first core portion and a second core portion comprising an epoxy having a plurality of expanded microspheres. The method of forming the two foams generally comprises sizing a foam core to form a first core portion and providing and preparing an epoxy mixture to form a second core portion. The first core portion and the second core portion of the epoxy mixture are placed into a preform, and the preform is heated slightly so as to cause the epoxy mixture to flow into the shape of the preform and around the first core portion. The first core portion and the second core portion are then bonded in a molding operation. The formed structure can form part of a hockey stick blade.
Claims20
A method comprising:
- sizing a foam core to form a first core portion;
- providing an epoxy mixture to form a second core portion;
- placing the first core portion and the second core portion into a preform;
- heating the preform so as to cause the epoxy mixture to flow into the shape of the preform and around the first core portion;
- wrapping the first core portion and the second core portion with fiber tape to create a wrapped preform;
- stitching the first core portion with a thread, the thread extending between a first wrapped face and a second wrapped face of the wrapped preform;
- placing the wrapped preform in a mold;
- heating the mold to bond the first core portion and the second core portion;
- cooling the mold;
- and
- removing the formed structure from the mold.
A blade comprising:
- a first core portion formed of foam;
- a second core portion comprising an epoxy having a plurality of expanded microspheres;
- the first core portion and the second core portion forming a core comprising a first core face and a second core face;
- a layer of carbon fiber wrapped around the core;
- a layer of resin preimpregnated tape wrapped continuously around at least the first core face and the second core face;
- a thread stitched on the preimpregnated tape on the first core portion.
Dependencies are inferred from the claim text.