Abstract:
An improved laminated bat is presented using a wood inner core that maintains a constant “feel” to the bat when a ball is struck. The use of a wood inner core further ensure consent thermal expansion and bending as the bat is used to impact a ball. Progressively narrower veneer sheets of wood are heated to bond thermoset glue on the inner core to approximate the finished contour of the bat. Veneer layers are also pressed onto the bat thereby providing a completely bonded bat with any air bubbles removed when the last layer of veneer is rolled onto the bat. This reduces the amount of post processing of the bat and results in a nearly finished shape when the veneer is applied. The overlapping wood grain increases the strength of the bat and eliminated inconsistencies with hitting a ball at a particular side of the bat.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of applicant&#39;s co-pending application Ser. No. 13/914,328 filed Jun. 10, 2013 and claims the benefit of Provisional Application Ser. No. 61/712,163 filed Oct. 10, 2012 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    This invention relates to improvements in construction of a baseball bat. More particularly, the present bat is constructed with a base dowel where layers of veneer are bonded and pressed onto the dowel to form a finished bat. 
         [0007]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98. 
         [0008]    The sports of baseball or softball are familiar games where a pitcher throws a ball at a hitter that tries to strike the ball with a bat. There are variations on the game that involves a person trying to hit a ball or similar object with a bat or club. The material and construction of the bat is critical to the comfort of the hitter as well as the resulting travel of the ball once it is struck with the bat. Original bats were simply sticks or trimmed limbs from a tree. Later versions of bats were turned from blanks of hardwood dowels of Ash, Birch and Maple. Maple wood bats generally have more pop than ash bats, but are more likely to break on miss-hits off the end of the barrel. Ash wood bats tend to have larger sweet spots than maple bats, but are more likely to break on miss-hits off the handle. Most bats are fabricated in lengths of between 31″-35″. 
         [0009]    Bats usually break with the grain of the bat and the label is often printed on the bat to indicate the best side to strike at a ball. While the optimal area to strike a ball can be marked onto a bat a player often swings at a ball in any orientation of the bat. To combat bat orientation issues, bat can be constructed with the grain placed in different orientations. A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below. 
         [0010]    U.S. Pat. No. 1,063,563 issued on Jun. 3, 1913 to L. S. May discloses a bat with an inner core of gain oriented in a first direction and an outer shell with the grain oriented in a second direction. While this disclosure provides a bat with varying grain direction, the optimal strike direction can be doubled, but the complexity to construct this type of bat has significantly increased. 
         [0011]    U.S. Pat. No. 2,379,006 issued on Aug. 30, 1943 to T. L. Johnson discloses a construction of striking Implements. The construction of this striking implement begins with a tapered inner metal core. Thin strips of veneer are progressively laid over the inner metal core until the desired size and shape of the bat is complete. The bat is then placed under pressure in an oven to cure. Weights are then added to the inside metal core to balance the bat. While this bat is made with layers of veneer, the veneer is placed over a tapered metal core and the curing of the bonding agent is applied after the veneer is completely laid. Setting the glue after all of the veneer has been applied results in air pockets and uneven bonding because the glue is escaping through the veneer layers. 
         [0012]    U.S. Pat. No. 4,572,508 issued on Feb. 25, 1986 to Chin-San You discloses a Composite Laminated Baseball bat. The bat is constructed with multiple layers of wood planks that are bonded together after. After the multiple layers of wood have been bonded the laminated blank is machined (turned) into a bat using conventional bat fabrication techniques. While this results in a stronger bat, the bonding direction of the planks of wood remains the same. 
         [0013]    U.S. Pat. Nos. 5,114,144, 5,458,330, 5,624,115 and 6,152,840 all issued to Charles S. Baum disclose a Composite Baseball Bat with Cavitied Core. The bat is constructed over an inner hollow or solid core of foam. Two halves of veneer are bonded to the outer sides of the foam core and then secured under pressure. Progressive halves are added to the bat until the desired size and shape is achieved. The construction of the bat requires that the bat be bonded and cured several times in the process and further the inner core is a soft material that can allow the core to collapse upon impact. 
         [0014]    What is needed is a laminate bat where the layers are rolled onto a wooden inner core and the laminated layers are heated and bonded as they are applied to the wooden inner core. The proposed rolled baseball bat provides this solution where the inner core starts as a wooden dowel and veneer is heated, stretched, pressed and bonded onto the inner dowel. 
       BRIEF SUMMARY OF THE INVENTION 
       [0015]    It is an object of the rolled baseball bat to utilize a wood inner core. The use of a wood inner core maintains a constant “feel” to the bat when a ball is struck. The use of a wood inner core further ensure consent thermal expansion and bending as the bat is used to impact an object such as a ball. The wood inner core is a constant diameter dowel and the contour of the bat is added to the initial dowel rod. 
         [0016]    It is an object of the rolled baseball bat to be constructed with progressive narrower veneer sheets of material. The each sheet is rolled onto the dowel, or the previous sheet, in progressively narrowing manner to approximate the finished contour of the bat. This reduces the amount of post processing of the bat and results in a nearly finished shape when the veneer is applied. A single progressively narrowing sheet can also be used. Because the initial dowel starts as a constant diameter the sheets of veneer do not “walk” in either direction on the dowel. Even the knob of the bat is rolled onto the dowel in layers that approximate the finished knob. 
         [0017]    It is another object of the rolled baseball bat for the veneer to roll onto the dowel with the grain of the veneer layer so the grain overlaps. The overlapping wood grain increases the strength of the bat and eliminated inconsistencies with hitting a ball at a particular side of the bat. While complete cross grain may vary based upon successive layers, the aggregate result will provide a nearly constant striking and bending response to the bat. 
         [0018]    It is still another object of the rolled baseball bat to be constructed by heating the veneer and or the base dowel as the veneer is laid onto the dowel. In addition to the heating that sets the thermoset glue, each layer of veneer is pressed onto the dowel or the previous layers thereby providing a completely bonded bat with any air bubbles removed when the last layer of veneer is rolled onto the bat. Other types of liquid, pressure or contact glues can also be used. 
         [0019]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0020]      FIG. 1  shows a perspective view of an initial dowel on a lathe with the elongated heating element. 
           [0021]      FIG. 2  shows a perspective view of the temperature control box for the heating element. 
           [0022]      FIG. 3  shows a perspective view of a veneer sheet being prepped with a thermoset sheet. 
           [0023]      FIG. 4  shows a perspective view of a veneer sheet being added to the evolving bat. 
           [0024]      FIG. 5  shows a plan view of a bat after the veneer has been applied. 
           [0025]      FIG. 6  shows the veneer sheets for a flex joint. 
           [0026]      FIG. 7  shows the flex joint in the bat. 
           [0027]      FIG. 8  shows an end view of the bat. 
           [0028]      FIG. 9  shows a plan view of the finished bat. 
           [0029]      FIG. 10  shows a single final wrap of veneer. 
           [0030]      FIG. 11  shows the progressive step of the bat with veneer sheets. 
           [0031]      FIG. 12  shows a flex sheet. 
           [0032]      FIG. 13  shows a knob and dowel detail. 
           [0033]      FIG. 14  shows the knob secured to the dowel. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]      FIG. 1  shows a perspective view of an initial dowel on a lathe with the elongated heating element  40 . The baseball bat begins with an elongated solid wooden dowel rod  20 . The wooden dowel rod  20  is securing into a rotating device. The inner dowel rod has diameter of between ¾ inch and 1½ inch and approximates the final diameter of the minimal inside diameter of the finished bat. Different types of dowel rod woods can be used to obtain different levels of weight flexibility to the bat. These woods include but are not limited to Ash, Birch or Maple. In the preferred embodiment the rotating device is a lath or similar device that secures both the ends  61  and  62  of the wooden dowel rod  20  and allows the rod  20  to turn on the central axis of the rod  20 . An elongated heating element  40  is used to heat the rod  20 , thermoset glue and sheets of veneer that are bonded to the rod  20 . 
         [0035]    The elongated heating element  40  also maintains a constant pressure on the rod  40  using one or a plurality of springs  41 ,  47  that are attached onto pivoting arms  42  pull the elongated heating element  40  into the rod  20 . The variable amount of springs  41 ,  47  allows the pressure to be adjustable throughout the roll and prevents walking of the veneer. In another contemplated embodiment the connection of the spring  41  or  47  can be connected to a turnbuckle that is adjusted to change the extended length of the spring  41 ,  47  to change the force on the veneer. The pressure from the springs  41  ensure complete bonding of the veneer layers and rolls out any air bubbles between successive veneer layers. While springs are shown and disclosed in this preferred embodiment, other pressure application mechanisms are contemplated including but not limited to hydraulic or pneumatic cylinders. While Veneer layers are available in different thickness, but typically are available in thickness of 0.010 to 0.031 inches in thickness. The arms  42  pivot on hinges  43  that are secured to the base  44  that is secured to the lath  60  or similar turning mechanism. The end(s)  45  of the arm(s)  42  are secured to the heating element  40 . In the preferred embodiment the elongated heating element is contained with thin a thermal mass structure that ensures a more constant temperature. The temperature of the elongated heating element  40  is controlled by a temperature control box that the elongated heating element  40  is plugged into or otherwise connected with wiring  50 . 
         [0036]      FIG. 2  shows a perspective view of the temperature control box  70  for the heating element. The elongated heating element from  FIG. 1  is wired  51 , plugged or otherwise connected into the temperature control box  70 . The temperature control box  70  is connected with a cord  53  and a plug  52  to an electrical outlet. The temperature control box  70  has a power switch  71  that turns the temperature control box  70  on and off. A thermostat  72 , or similar control knob, sets and or adjusts the amount of heat or temperature of the elongated heating element  60 . The temperature must be controlled to ensure proper heating of thermoset glue, without burning the veneer of increasing the production time to produce a single bat. A fuse  73  provides protection from an overload condition. A thermocouple may also be used to allow the temperature control box  70  to automatically maintain a desired temperature for the elongated heating element. 
         [0037]      FIG. 3  shows a perspective view of a veneer sheet being prepped with a thermoset sheet. Between the dowel rod and the veneer sheets a bonding agent is used. In the preferred embodiment the bonding agent is thermoset glue, but other cold or hide glues can be used including but not limited to pressure or contact glues or sheets. The use of thermoset glues ensure quicker production processing because the bat cools rather than requiring a drying time. Two part epoxy type glues are also contemplated, but the application of liquid glues often include requiring constant application thickness of the glue and can further result in dripping glue. The thermoset glue used in the preferred embodiment comes from a roll  25  of thermoset glue that is delivered on a roll  25  with a paper separation layer  26 . 
         [0038]    Thermoset glues are typically available in thicknesses of 0.1 mm to 2.0 mm. In the preferred embodiment, thermoset glues of 0.1 mm are used, but other thicknesses can be used depending upon the type and thickness of the veneer and the underlying dowel. The thermoset glue  27  is laid onto the veneer  30 . Heat is applied with an iron  80  or other heat setting mechanism with a user  81  applying the heat and even pressure to provide an initial bond with one side of the veneer  30  to provide a veneer  30  with a bonded thermoset material  28 . Once prepped the veneer sheet can be bonded to the dowel rod or previous layers of veneer. 
         [0039]      FIG. 4  shows a perspective view of a veneer sheet being added to the evolving bat. In the preferred embodiment the veneer sheets  32  are prepared as increasingly narrower strips to minimize shaping after all of the layers have been applied. It is also contemplated that a single veneers sheet can be used where the single sheet is formed in a taper from the initial layer to the final layer that will be applied. In another contemplated embodiment, veneers of different wood types can be applied to alter the response of the bat and or to alter the cosmetic appearance of the finished bat. 
         [0040]    This figure shows the lath  60  with one end  61  of the dowel rod  20  secured into the lath  60 . A user  82  is shows feeding a sheet of veneer  32  onto the previous veneer layer  31 . The inner side  27  of the veneer  32  has the thermoset material pre-applied as shown in  FIG. 3 . It is also contemplated that the thermoset material can be applied  29  from the roll between the veneer sheet and the dowel rod  20 . This figure shows the heating element  40  on the other side of the dowel  20 . The elongated heating element  40  maintains a constant pressure on the rod  40  using one or a plurality of springs  41  that are attached onto pivoting arms  42  pull the elongated heating element  40  into the rod  20 . The pressure from the springs  41  ensure complete bonding of the veneer layers and rolls out any air bubbles between successive veneer layers. The arms  42  pivot on hinges  43  that are secured to the base  46  that is secured to the lath  60  or similar turning mechanism. The figure shows the veneer being applied to the striking portion of the bat, and a similar application of veneer is applied to the knob portion of the bat. 
         [0041]      FIG. 5  shows a plan view of a bat after the veneer has been applied. The base wooden dowel rod  20  is shown with the original diameter. The wooden dowel rod ends extend out both sides  38  and  39  of the bat. These ends  38  and  39  where used to grasp the bat to support turning the veneer over the wooden dowel rod  20 . The progressive layers  31  and  32  of veneer are shown as the bat increases in diameter to achieve the final diameter  35  of the bat. The wood grain can be cross stitched wood grain bands of veneer. The cross stitched grain bands are applied to the entire length of the bat to create higher tensile and sheer strength and a greater “trampoline effect” or the exit speed of the ball from the bat. On the opposing side, layers of veneer are applied to achieve the desired diameter of the knob  36  of the bat. 
         [0042]      FIG. 6  shows the veneer sheets for a flex joint and  FIG. 7  shows the flex joint  59  in the bat between veneer  35  in the strike area on the wooden dowel rod  20 . The interior flex joint  59  leads away from a barrel of the rolled baseball bat. 
         [0043]      FIG. 8  shows an end view of the bat. This end view shows the original wooden dowel rod  20  from the grip portion of the bat and the end material  39  that is gripped in the lath. Successive layers of veneer are shown to achieve the desired finished diameter  35 . 
         [0044]      FIG. 9  shows a plan view of the finished bat. Ends  38  and  39  of the bat, from  FIG. 5 , have been removed and the exterior of the bat have been machined or sanded smooth to provide a finished surface where the bat gradually tapers  91  from the grip portion to the batting area  92 . The end  93  is rounded along with the knob  90  of the bat. After the layers have been bonded onto the baseball bat the barrel and cap are honed to approximately ⅛ inch to ensure that the bat is concentric. A final wrap of two ½ wraps  94 ,  95  are scored and bonded to the opposing sides of the honed baseball bat. 
         [0045]    Separate end caps are secured to the ends  96  and  97  of the trimmed bat to reduce moisture from entering any end grain and provide a more finished appearance. The bat can then be varnished or sealed to create a finished product.  FIG. 10  shows a single final wrap of veneer that can be applied to the honed bat. 
         [0046]    In an alternate contemplated embodiment, veneer sheets  30  are cut to the desired length and width. The length of each veneer sheet  30  must achieve two rotations around the bat. The wood grain of each rolled veneer sheet must run in opposite directions. On the first one, three and five rolls and interior flex joint  59  will occur leading away from the barrel of the bat. This reduces the vibration that is transferred through the bat when a ball is struck. 
         [0047]    All of the veneer sheets  30 , are edged or skived  57 , as shown in  FIG. 6 , on both ends of each veneer sheet, and are placed longitudinally on the dowel. After each completed roll the dowel or the unfinished bat is rotated 90 degrees in the lath. If this is not done, the finished bat will be unbalanced, this also ensure a continuous radius throughout the bat building process. A drawing of completed bat showing the exterior flex joints and the wood grains running in there appropriate directions. Pressure sensitive adhesive (PSA) is applied on one side of each veneer sheet. 
         [0048]    After completing the rolling process, the unfinished bat form is placed into an air pressure tank at 2,000 PSI for two to four hours. 
         [0049]    The bat is return to the lath/press and the veneer is sanded to the desired shape. Depending upon the bat model, cut two to six veneer sheets into the bat shape, after each completed bat shaped veneer wrap the center of the following bat shaped wrap must overlap the created two seams of the previous bat wrap. These markings  48  (from  FIG. 11 ) at each end of the veneer must be placed at the balanced center of the bat. Each bat shaped veneer sheet will wrap halfway around the sanded form. The bat shaped veneer will be edged or skived  57  as shown in  FIG. 6 . The veneer is shaped longitudinally. 
         [0050]    Skive  57  or edge the bat shaped veneer. PSA is then applied to the Apply PSA to the bat shaped veneer  94  and  95 . The first bat shaped wrap will end 10″ to 12″ above the knob of the baseball bat, and the second and third bat shaped wrap will end at 18″ to 20″ above the knob. 
         [0051]    Apply 1 to 2 wraps of veneer  99  from  FIG. 12  at 10″ to 20″ from the knob. The wood grain on these wraps will run in the opposite direction of the bat shaped wrap. The width of these veneer sheets will vary from 6 to 10 inches, depending on the bat model. The top is contoured in order to rap evenly around the bat (there are two). This rap strengthens the weakest part of the bat, and also provides two exterior flex joints  59 . This also reduces the vibration that is transferred through the bat when a ball is struck. 
         [0052]    Return the bat form to the air pressure tank at 2000 PSI for 2 to 4 hours. 
         [0053]    The bat is then returned to the lath/press for a finishing sanding. 
         [0054]    A pocket  101  is created in the bat dowel  20  to receive the knob  110  as shown in  FIG. 13 . The pocket  101  shown here is square  102 , but other shapes can be used to create a knob that will not turn in the bat. The multi-sided shape  102  extends proud from the dowel. The knob  110  is then glued into the bat ( FIG. 14 ) and the joint is finish sanded between the knob  110  portion and the bat dowel  20 . 
         [0055]    A hot melt Epoxy or Polyurethane finish is placed over the bat to seal the grain. 
         [0056]    Thus, specific embodiments of a rolled baseball bat have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.