# US 2014/0194231 A1 · Blade constructs and methods of forming blade constructs

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- Number: US 2014/0194231 A1
- Document ID: US20140194231A1
- Status: Published application
- Kind: A1
- Application number: 14/209,324
- Filed: 2014-03-13
- Published: 2014-07-10
- Earliest claimed: 2010-09-20
- Assignees: Bauer Hockey, LLC
- Applicants: Bauer Hockey, Inc.
- Inventors: Adam Gans
- Web page: https://patentgrep.com/patent/US20140194231A1

## 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 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 70/342: {using isostatic pressure}
- B29C 70/78: Moulding material on one side only of the preformed part
- 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
- B29L 2031/52: Sports equipment {; Games; Articles for amusement}; Toys (B29L2031/54 takes precedence)
- Y10T 29/49337: Composite blade
- Y10T 29/49801: Shaping fiber or fibered material
- Y10T 29/4998: Combined manufacture including applying or shaping of fluent material
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The blade as in claim 1 wherein the first core portion and the second core portion are bonded to form a continuous core.

### Claim 3 (depends on 2)

The blade as in claim 2 wherein the first core portion has a bottom surface which is bonded to a top surface of the second core portion by cross-linking the epoxy.

### Claim 4 (depends on 1)

The blade as in claim 1 further comprising a non adhesive scrim applied to the portions of the resin preimpregnated tape that extend along the first core portion.

### Claim 5 (depends on 1)

The blade as in claim 1 wherein the first core portion has an oval-shaped end.

### Claim 6 (depends on 1)

The blade as in claim 1 wherein the second core portion has an oval-shaped end.

### Claim 7 (depends on 1)

The blade as in claim 1 wherein an end of the first core portion or the second core portion has a hook shape.

### Claim 8 (depends on 1)

The blade as in claim 1 wherein the core forms part of a hockey blade comprising a toe region and a heel.

### Claim 9 (depends on 8)

The blade as in claim 8 wherein the first core portion extends from the heel of the blade to the toe region of the blade.

### Claim 10 (depends on 8)

The blade as in claim 8 wherein the second core portion extends from the toe region of the blade to the heel of the blade.

### Claim 11 (depends on 9)

The blade as in claim 9 wherein the first core portion is thickest at the heel portion of the blade and tapers from the heel of the blade to the toe region of the blade.

### Claim 12 (depends on 10)

The blade as in claim 10 wherein the second core portion is thickest at the toe region of the blade and tapers from the toe region of the blade to the heel of the blade.

### Claim 13 (depends on 1)

The blade as in claim 1 wherein the first core is of a lower density than second core portion.