DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Referring first to FIG. 1, a hockey stick 10 is divided into three areas; a blade 12 , a shaft 14 and an end plug 16 . It is within each of these structural areas of the hockey stick 10 that various improvements are implemented in order to enhance the performance characteristics of the hockey stick 10 . The present invention focuses primarily on the shaft 14 of the hockey stick 10 and certain modifications therein.

[0026] In general, the shaft 14 of the hockey stick 10 has a first end 18 opposite a second end 20 . The first end 18 of the shaft 14 is found where the shaft 14 is coupled with the blade 12 of the hockey stick 10 . The second end 20 of the shaft 14 is found where the shaft 14 transitions to the end plug 16 . Many of the stresses that occur to a hockey stick during use occur at locations proximate to where the blade 12 and the shaft 14 meet. Stress regions are exhibited along the shaft 14 due to the large amount of stick-to-stick and stick-to-ice contact occurring during usage. One particular high stress region, known as the slash zone, is located proximate the first end 18 of the shaft 14 . More specifically, the slash zone is located within the lower portion 22 of the shaft 14 . Although high stress regions primarily occur in the lower portion 22 of the shaft, occasional stress areas may occur within the upper portion 24 of the shaft 14 proximate the second end 20 due to player to player contact.

[0027] In order to improve the durability and impact resistance of the hockey stick 10 at various stress regions along the shaft 14 , it is desirable to apply supplemental layers.

[0028] As can be seen in FIG. 2 , which is a cross-sectional view of the shaft 14 of hockey stick 10 taken along lines 2 - 2 of FIG. 1, a plurality of reinforcing layers surround the shaft 14 . The shaft 14 includes a body 26 longitudinally extending the entire length of the shaft 14 . The body 26 of hockey stick 10 can be comprised of various materials, which may include but are not limited to wood, composite, various metals, fiberglass, plastic, KEVLAR®, carbon and combinations thereof.

[0029] An energy absorbing layer 28 is disposed on the outer surface of the body 26 . The energy absorbing layer 28 is a cushioning material which provides an energy absorption medium along prescribed regions of the shaft 14 . The energy absorbing layer 28 is preferably made of a viscoelastic material which may include but is not limited to a variety of viscoelastic damping polymers, such as VHB®, Sorbothane®, T-lastic®, etc. The energy absorbing layer 28 is preferably approximately 0.015 inches to 0.025 inches thick. Although this particular thickness is generally preferred, the thickness of the energy absorbing layer 28 may be varied according to the particular stresses expected to be endured.

[0030] The preferred embodiment of the present invention employs 3M's VHB® tape as the energy absorbing layer. The VHB® tape is a double-sided viscoelastic tape 28 a having an acrylic adhesive 29 a , 29 b on each side. The acrylic adhesive is an aggressive adhesive which secures the energy absorbing layer 28 to the body of the shaft. Although VHB® tape is currently being used, alternate types of energy absorbing material may be used in combination with various adhesives, if desired.

[0031] The outer perimeter of the shaft 14 is enclosed by an impact resistant layer 30 . The impact resistant layer 30 preferably has an annular or sleeve-like configuration. The impact resistant layer 30 is most preferably composed of a polycarbonate material, such as LEXAN® (available from the General Electric Company), although a polycarbonate/ABS blend may also be used. The impact resistant layer 30 is preferably approximately 0.010 inches to 0.020 inches thick. Furthermore, the impact resistant layer 30 is preferably transparent, although a tint or full color embodiment may also be employed. The design of the impact resistant layer 30 allows the sleeve to be applied to the shaft of the hockey stick relatively easy. One preferred embodiment, as described below, provides a polycarbonate sleeve having a longitudinal slit 32 extending along the entire length of the sleeve. The longitudinal slit 32 provides a means for expanding the sleeve such that it snaps or slides over the shaft 14 of the hockey stick 10 .

[0032] As seen in FIG. 2 , the impact resistant layer 30 preferably includes a slightly thicker portion of polycarbonate material adjacent the corners of the shaft 14 . The additional material present in the corners of the shaft 14 enhances protection to the hockey stick where impact is most likely to occur. This slight modification provides the impact resistant layer 30 with a more durable configuration.

[0033] In addition to the multiple layers described above, various decals or designs may be added to the body of the shaft. The preferred application of a decal is provided by bonding the decal onto the acrylic adhesive 29 a present on the outer surface of the energy absorbing layer. A transparent polycarbonate impact resistant layer 30 is then placed over the decal in order to provide impact resistance for the hockey stick 10 . The transparent polycarbonate layer allows the decal to be viewed through the sleeve.

[0034] FIGS. 3 A- 3 C demonstrate various applications of the energy absorbing layer 28 and the impact resistant sleeve 30 to the shaft 14 of the hockey stick 10 and the various preferred embodiments.

[0035] FIG. 3A is a longitudinal cross-sectional view illustrating the application of the energy absorbing layer 28 and the impact resistant layer 30 to the lower portion 22 of the shaft 14 .

[0036] FIG. 3B is a longitudinal cross-sectional view illustrating the application of the energy absorbing layer 28 and the impact resistant layer 30 to the lower portion 22 and the upper portion 24 of the shaft 14 .

[0037] FIG. 3C is a longitudinal cross-sectional view illustrating the extension of the energy absorbing layer 28 and the impact resistant layer 30 from the lower portion 22 through the upper portion 24 and along the end plug 16 . In general, the energy absorbing layer 28 and the impact resistant layer 30 may be applied anywhere along the body 26 of the shaft 14 and at various lengths. Therefore, the length of the energy absorbing layer 28 and impact resistant layer 30 applied to the body 26 of the shaft 14 is preferably based upon the desired performance of the hockey stick 10 .

[0038] A preferred method of preparing the present invention is illustrated in FIGS. 4 A- 4 C. Initially, a shaft body 26 , which is usually rectangularly shaped, is provided. Next, the energy absorbing layer 28 having a sheet-like configuration is applied to the shaft body 26 . As seen in FIG. 4,A the energy absorbing layer 28 has a width substantially the same as the circumference of the shaft body 26 . The length of the energy absorbing layer 28 may vary depending on the desired region of the shaft body 26 covered. The energy absorbing layer 28 is folded around the circumference of the shaft body 26 thereby providing a continuous layer around the wrapped region of the shaft body 26 , as seen in FIG. 4A . The wrapping of the double-sided viscoelastic tape 28 bonds the interior side of the viscoelastic tape 28 to the outboard surface of the shaft body 14 . Alternate methods may be used for applying the viscoelastic layer to the shaft body 14 , such as helically wrapping the viscoelastic tape in a longitudinal direction along the shaft.

[0039] Although not shown in the figures, if desired, a decal or design bearing emblem may then be disposed on the outer surface of the viscoelastic tape. The bonding of the decal to the viscoelastic tape is preferably accomplished through use of the acrylic adhesive on the outer surface of the tape 28 .

[0040] Following the positioning of the viscoelastic tape and the application of the decal or design to the outer surface of the viscoelastic tape, the impact resistant layer 30 is applied to the shaft body 14 . Preferably, the impact resistant layer 30 is provided in the form of an annular sleeve 30 which is snapped over the body 26 of the shaft 14 by forcing the body 26 through the longitudinal slit 32 thereby expanding the sleeve. As seen in FIG. 4 b , the longitudinal slit 32 provides a passage to an axial bore 34 formed throughout the impact resistant sleeve 30 for accommodating the shaft body 14 . Following the placement of the impact resistant sleeve 30 around the body shaft 14 as seen in FIG. 4 c , a polyurethane tape 36 is placed along the longitudinal slit 32 to secure the placement of the impact resistant sleeve 30 . A section of polyurethane tape 36 may be applied around the opposing ends of the impact resistant sleeve in order to encapsulate the multilayered region of the shaft body.

[0041] As seen in FIG. 5 , an alternate embodiment impact resistant layer 30 ′ and method for mounting the layer 30 ′ to the shaft 14 ′ is illustrated. In this embodiment, the layer 30 ′ takes the form of a circumferentially enclosed polycarbonate sleeve (not having a slit). Following the application of the viscoelastic tape 28 ′ and bonding of a decal (if desired), the polycarbonate sleeve 30 ′ having an axial bore 34 ′ formed therethrough is telescopically slid over the shaft body 26 ′. Various lubricants may be used to assist in the receipt of the shaft body 26 ′ within the bore 34 ′ of the polycarbonate sleeve 30 ′. Upon the placement of the shaft body 26 ′ within the polycarbonate sleeve 34 ′, polyurethane tape 36 ′ may be used to affix the ends of the polycarbonate sleeve 34 ′ to the shaft body 26 ′.

[0042] FIG. 6 illustrates a cross-sectional view of an alternate embodiment of the present invention which provides a shaft 14 ″ of the hockey stick 10 ″ having an impact resistant layer 30 ″ applied directly on the body 26 ″. This embodiment enhances the impact resistance of the shaft 14 ″, without modifying the energy absorption characteristics of the shaft 14 ″.

[0043] A further alternate embodiment, as seen in FIG. 7 , provides a hockey stick 50 having a shaft 52 with a body 54 containing a recessed portion 56 annularly formed around the body 54 of the shaft 52 . The recessed portion 56 is provided for concentrically accommodating the energy absorbing layer 28 and impact resistant layer 30 along the body 54 of the shaft 52 . In the previously described embodiments of the present invention, the application of the energy absorbing layer and the impact resistant layer form a small ridge around the exterior circumference of the shaft. Depending on the desired length of the specific layers applied, the ridge formed by the ends of the energy absorbing layer and the impact resistant layer may be disfavored by certain players. In order to obtain a coplanar (smooth) external surface along the shaft 52 of the hockey stick 50 , the energy absorbing layer 28 and the impact resistant layer 30 are applied within the recessed portion 56 provided in the body 54 of the shaft 52 as previously described in the alternate embodiments. The depth of the recessed portion 56 is selected to match the thickness of the energy absorbing layer 28 and impact resistant layer 30 (and any adhesive used in combination therewith) if both layers are employed, or the impact resistant layer 30 (and any adhesive) if only the impact resistant layer 30 is employed. As such, the recessed portion 56 of the body 54 provides the player with a planar shaft 52 . The recessed portion 56 is preferably formed when molding the shaft 52 although other methods such as grinding may be used.

[0044] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.