Structural damage repair elements and kit

Structural damage repair elements including inserts and a structural damage repair kit is provided. The structural damage repair elements typically include two or more layers of materials having an adhesive therebetween that are subsequently compressed together. The structural damage repair kit includes a chemical molding agent, an optional jig, one or more structural damage repair elements and a sealant. Both hollow and solid elongated objects, as well as relatively flat, curved objects may be repaired with the kit. The structural damage repair elements include rods, wafers, and/or adhesive saturated inserts.

BACKGROUND OF THE INVENTION

Objects comprised of or coated with fiberglass, carbon fiber, wood, etc. may develop or incur surface fractures or through-fractures. Surface fractures are typically breaks, cracks, splits, etc., that occur or develop in the surface of an object, but do not extend entirely through the wall of an object (i.e., a hockey stick (shaft, hozel, or blade), a boat hull, etc.). Through-fractures are those breaks, cracks, splits, etc. that extend entirely through the wall of an object.

Conventional repair kits and methods of repair generally involve removing the fractured section altogether, replacing the fractured section and/or repairing the fracture. However, these kits and methods compromise the structural integrity of the object to be repaired because the repair does not restore and/or enhance the structural integrity of the repaired object, but rather, either creates one or more shear points where the replaced or repaired material contacts the original material or provides a temporary repair that is weaker than the original material. These conventional repair kits and methods of repair compromise the repaired section of the object and potentially compromise the safety of the person(s) using the repaired object. Additionally, these conventional repair kits and methods of repair are very costly, very labor intensive, and can drastically alter the appearance or performance of the repaired area.

In addition, objects made or formed from hollow support pieces and/or objects typically do not provide similar strength and support as compared to the same objects which are made of the same materials, but are solid in design and not hollow. However, hollow formed objects offer many advantages over solid formed objects including, but not limited to, hollow formed objects typically use less overall material and therefore are lighter in weight, more maneuverable and easier to transport. Additionally, because less material is used in the construction of hollow objects, these hollow objects typically cost less money to produce.

While objects that are hollow offer the above advantages, these hollow objects, when in use, may undergo sudden impact or extreme flexural stress, and may also undergo structural stress with use over time. Therefore, these hollow objects may develop fissures, develop cracks and/or fracture into multiple pieces. Once the hollow object is cracked or fractured, replacing the cracked section of the object, or completely replacing the fractured section of an object may either be very costly, or in many cases, not possible. In order to obtain a hollow object that is comparable in support and strength to the original uncracked or unfractured hollow object, a user is left with either purchasing, if possible and if available, a new hollow piece to replace the cracked or fractured piece of the object, or the user must replace the entire object all together. Both of these options are very costly and may take significant amounts of time.

Accordingly, there is a need for structural damage repair kits that provide great strength and yet are cost-effective. These elements and the kit should restore and/or enhance the structural integrity of fractured objects, reduce any potential shear points and typically cost much less than conventional repair kits and are much less labor intensive than conventional repair kits and methods.

SUMMARY OF THE INVENTION

The present invention comprises external structural damage repair elements and may comprise a structural damage repair kit including an adhesive or molding agent (hereinafter referred to as “adhesive”), reinforcing members and one or more sleeves. These elements (and use of the kit) restore and/or enhance the structural integrity of fractured objects, reduce any potential shear points, typically cost much less than conventional repair kits, and are much less labor intensive than conventional repair kits and methods. Also, the structural damage repair elements of the present invention may be used with any type of fracture and are not limited to just surface fractures or through-fractures.

One aspect of the present invention includes a repair kit for hollow objects. The repair kit includes an insert comprised of at least one inner section and at least one layer of material at least partially covering the inner section and a liquid hardening system.

Another aspect of the present invention includes a method of repairing a hollow object. The method includes the steps of providing a first hollow piece of an object and a second hollow piece of an object and providing an insert, at least a portion of which is a material external of a center section of the insert. In addition, the insert is positioned into the first hollow piece and positioned into the second hollow piece. A liquid hardening system is inserted into one of the hollow pieces to contact the insert.

Yet another aspect of the present invention includes a hockey stick repair kit including an insert comprised of at least one center section and at least one layer of material at least partially covering the center section. The kit also includes a stopper, a liquid hardening system, and a bracket system.

Still another aspect of the present invention includes a method of repairing a hollow object. The method includes providing a first hollow piece of an object and a second hollow piece of an object and providing an insert, at least a portion of which is a material external of a center section of the insert. A bracket system is provided for holding the first hollow piece and second hollow piece in place. The first hollow piece and the second hollow piece are inserted into the bracket system and the first hollow piece is aligned with the second hollow piece. The insert is positioned in the first hollow piece and also positioned in the second hollow piece. A hardening system is then inserted in one of the hollow pieces to contact the insert.

Yet another aspect of the present invention includes a structural strength enhancing insert comprising one or more layers of reinforcing fabric. An adhesive is disposed between each layer of reinforcing fabric and the layers are subsequently compressed together to form a structural strength enhancing member.

Another aspect of the present invention includes a method of repairing an object using a structural damage repair kit including providing one or more structural strength enhancing members and an adhesive. The object shaped to a desired shape. Grooves are created in the area of the object to be repaired and one or more structural strength enhancing members are inserted into each of the grooves. An adhesive is applied to the object adjacent the structural enhancing members and excess adhesive is removed from the object.

Yet another aspect of the present invention includes a method of repairing a hollow object. The method includes removing a damaged portion of the hollow object and inserting a foam plug into the hollow object. Also, a plurality of reinforcing members are inserted into the hollow object. An adhesive is applied over the reinforcing members.

Another aspect of the present invention includes a method of repairing a hollow object, including providing an object with a first hollow portion and a second hollow portion, the first hollow portion having a first end. A plug is inserted into the first end of the first hollow portion and a plurality of reinforcing members are inserted into the first hollow portion, adjacent the plug. The reinforcing members are positioned so that the reinforcing members extend beyond the first end of the first hollow object. The second hollow portion is placed over the reinforcing members to abut the first hollow portion, and adhesive is inserted into the second hollow portion into contact with the reinforcing members.

A method of repairing an object using a structural damage repair kit including providing one or more structural strength enhancing members, and an adhesive. The object is shaped to a desired shape and grooves are created in the area of the object to be repaired. One or more structural strength enhancing members are inserted into each of the grooves and adhesive is applied to the object adjacent the structural enhancing members. In addition, excess adhesive is removed from the object.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented inFIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and/or photographs and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. The term “hollow” is not meant to be limited by any shape of the given object, but instead refers to an object having an unfilled space within. However, the present invention could also be used on products which are not entirely tubular, or are not completely enclosed on one side.

Referring toFIG. 1, reference numeral1generally designates a hockey stick embodying the present invention. The hockey stick1includes a shaft2, hozel3, and blade4. The shaft may have a solid or hollow construction and may be of varying lengths. The hozel3and blade4may also be of varying sizes and angles.

Referring toFIG. 2, insert8of the preferred embodiment includes a porous substance, such as a foam, or otherwise solid center section10and a fabric11covering at least a portion of the center section10. The center section10may be any type of open-cell or closed-cell foam, depending upon the porosity desired. The foam is at least partially surrounded by at least one layer of a fabric or cloth11. This configuration of at least one center section10surrounded by at least one layer of fabric or cloth11is hereinafter referred to as insert8. Fabric11of insert8may be secured at two opposing ends (top end and bottom end) of insert8. Securing devices (not shown) can be used to prevent the unraveling of the fabric. Such securing devices may include common hot melt adhesives, zip ties, rubber bands, tape, and the like. Preferably, however, a rubber cement is used to stabilize the ends of the fabric sleeving. Use of rubber cement also allows compression and decompression of insert8.

Center section10is preferably porous enough to allow a liquid hardening system discussed below, such as an epoxy or adhesive9, to flow through it. Typically, open-cell foam is preferred over closed-cell foam due to the greater porosity provided by open-cell foams, although a closed-cell foam may be used with the present invention. As used herein, “open-cell” foams include what are sometimes referred to as “open pore” foams. This greater porosity allows liquid hardening systems to be absorbed into the pores and completely saturate and fill the pores. The greater porosity also causes the liquid hardening system to reach the fabric11quickly. This allows maximum time to wet out and saturate fabric11and the grooves in the side walls of a hollow object13, as described below. A liquid hardening system absorbed into the cells of an open-cell foam typically provides a stronger center section as compared to an open-cell foam without a liquid hardening system absorbed therein. In open-cell foam, the cell walls, or surfaces of the cell bubbles, are broken and air fills these spaces in the material. Therefore, when a liquid hardening system is introduced to an open-cell foam, the liquid hardening system fills at least some of the broken or air-filled cell bubbles.

Alternatively, when a closed-cell foam is used as center section10, the liquid hardening system essentially coats the closed-cell foam center section creating an internal chamber of closed-cell foam. In closed-cell foams, most of the cells or bubbles in the foam are not broken, and thereby the closed-cell foam may not absorb or become saturated with much of the liquid hardening system like an open-cell foam. When utilized as center section10, closed-cell foam typically has varying degrees of hardness, depending upon its density. Also, the use of closed-cell foams as center section10may also result in a lighter center section10because the closed-cell foams do not absorb as much of the liquid hardening system.

When either an open-cell or closed-cell foam is utilized in insert8, the foam may be in a shape according its intended use. The shape preference of insert8depends on the shape of the space insert8is to be inserted into. The foam center section10enhances the ability of the insert8to be customized to any shape desired or required in use. The foam may be comprised of any material, including, but not limited to, polyvinyl chloride (PVC), polystyrene (PS), polyurethane (PU), polymethacrylamide, polyetherimide (PEI), styreneacrylonitrile (SAN), polyethylene (PE), man-made honeycomb, or any combinations or any derivations of any of the above. These foams may be crosslinked, uncrosslinked and/or laminated foams. Reticulated polyurethane foams are typically preferred. An example of such a reticulated polyurethane foam is FilterCrest™ T-20 “open pore” foam from Crest Foam Industries, Inc., of Moonachie, N.J.

Alternatively, insert8of the present invention may not contain a foam center section, but instead contain other materials as center section10, including, but not limited to, wood, plastic, metal, or any derivations or combinations of any of the above. Section10may be made of any object which forces fabric11to the wall of the hollow object13by rebound action or inflation, including but not limited to balloons, torsion arms, springs, foaming, expanding compounds, and inflatable devices. When any of these materials are used as the center section of insert8, these materials essentially become an internal chamber having a liquid-hardening-system-coated fabric external layer. Also, when any of these materials are used as center section10of insert8, these materials may be any shape according to the intended use of insert8. Center section10may also be made of any of the materials above in combination with an open-cell or a closed-cell foam.

Insert8contains at least one layer of fabric or cloth11which at least partially covers center piece10. The fabric or cloth11may include, but is not limited to, KEVLAR®, carbon fiber fabrics or materials, fiberglass, and/or any fabric capable of reinforcing a structure and/or enhancing performance of a structure when exposed to a liquid hardening system. Two layers of a biaxially-weaved carbon fiber sleeve is preferred. The amount of the fabric used depends on the shape and size of center section10. Also, the shape of the fabric11typically conforms to the shape of the center section10which the fabric at least partially surrounds.

A liquid hardening system is utilized in the present invention to harden center section10and preferably fabric11surrounding center section10. A single component or multi-component liquid hardening system may be used in the present invention. Such a liquid hardening system may include, but is not limited to, a polyester resin system, an epoxy resin system, a urethane system, an acrylic system, hot melt adhesives, moisture cure epoxies, polymer systems, polyurea, polyurethane, bisphenol-A epoxy system, bisphenol-F epoxy system, a mercaptan-based epoxy system, a combination of a bisphenol-A and bisphenol-F system, or any other liquid hardening system or derivations and/or combinations of any liquid hardening system including, but not limited to those discussed above. Typically, a bisphenol-A epoxy system is preferred. When the liquid hardening system contacts center section10and the fabric11surrounding center section10, fabric11may also be at least partially hardened thereby providing support for the hollow object13to which the insert is incorporated within. A “liquid hardening system” includes systems that dry, cure, or harden for any reason, including but not limited to, evaporation or chemical reaction.

Insert8may take other configurations as well, depending on the size and shape of the hollow object13and the desired stiffness or flexibility of the resultant shaft, and desired weight of the insert8.FIGS. 3-8show a cross-sectional top view of various configurations of insert8. AlthoughFIGS. 3-8depict the hollow object13as generally rectangular, the hollow object13may be many shapes, including round or oval.FIG. 3shows an embodiment of insert8with an outer layer of fabric11, and an inner fabric layer16. Inside the inner fabric layer16is a center section10A, which is preferably an open-cell foam. The embodiment ofFIG. 4has an outer layer of fabric11and two inner fabric layers16B′,16B″. Within each of the two inner fabric layers16B′,16B″ is a center section, denoted as10B′, and10B″, respectively. InFIG. 5, insert8has three center sections10C′,10C″, and10C′″, and surrounded by a fabric layer,16C′,16C″, and16C′″, respectively. Middle center section10C″ may be a less porous or non-porous foam, which provides structure, but helps reduce the weight of insert8because the liquid hardener will not penetrate, or will only penetrate minimally, middle center section10C″. The insert8ofFIG. 6is very similar to that shown inFIG. 4, but its center sections10D′ and10D″ are wider than those ofFIG. 4.FIG. 7shows an insert8with four center sections,10E′,10E″,10E′″, and10E″″. Ultimately, the more center sections there are, the stiffer the insert8, which may be preferred for certain hollow items.FIG. 8shows another alternate design with a center section10F, that is generally X-shaped and may be of extruded foam. Center section10F may be porous or non-porous and coated or non-coated. This configuration allows for the liquid hardening system to flow more freely and quickly into the interior of the fabric layer11.

A grooving bit30, shown inFIG. 9, can be used in the repair of the hollow objects13such as composite hockey stick shafts. Grooving bit30has at least one raised grooving area for creating “locking” channels in the inside of the hollow object13to add strength and durability to the repaired object. Grooving bit30preferably has at least three raised grooving areas (although it is not necessary to have that many) and as shown inFIG. 9, grooving bit30more preferably has at least four raised grooving areas32,34,36,38on its outer diameter. It may have more or less raised grooving areas, depending on the desires of the user and the object being repaired. Grooving bit30preferably is sized and shaped to fit in a high speed rotary device, such as a DREMEL® ADVANTAGE™ high speed rotary saw Model 9000.

The repair of hollow object13may include the use of a bracket system40(FIG. 10) that may be utilized in the repair of a single- or multi-piece object. Bracket system40is used for generally immobilizing a single- or multi-piece object while the liquid hardening system cures or dries. Bracket system40is in communication with at least one face of the single- or multi-piece object at least on each side of the fracture or break in the hollow object13(seeFIG. 20). Bracket system40has a generally flat surface52and a receiving space53, which is formed by sections54and56, which are preferably at a 90° angle with respect to each other. The bracket system40preferably includes a clamp42so that a user may position the bracket system40on a work surface so that the hollow object13may be worked on at a more desired height. Clamp42is preferably adjustable vertically so it may be used at a comfortable position. This can be achieved by loosening knob43, which allows adjustment of clamp42. Bracket system40also preferably includes two tensioning devices44,46, each attached to surface52, to apply an appropriate amount of tension to the single- or multi-piece hollow object13to immobilize and/or position the single- or multi-piece hollow object13. Tensioning devices44,46generally include soft, flexible bumpers48,50to contact the hollow object13and immobilize it without damaging its structure. The use of flexible bumpers48,50also allow the bracket system40to be used with different sized objects. The tensioning devices44,46also preferably have a lock which holds the tensioning devices44,46in a locked position. Bracket system40does not typically contact the face of the hollow object13in or around the crack or fracture in the hollow object13. This allows a user to apply tape, wax, or any other type of adhesive9or sealant to the external surface of the hollow object13. This is done around the break or fracture while the hollow object13is immobilized via an opening58, and is placed there to prevent leakage of liquid at the joint where the two shaft halves meet.

In another embodiment of the present invention, a kit is provided which includes insert8, a plug/stopper62, a liquid hardening system and optionally an adhesive9tape and/or a wax based sealant for the shaft2. The kit of the present invention may be utilized by the following steps as detailed below. A kit of the present invention may be utilized on any of the single- or multi-piece hollow objects13as previously discussed in this application.

In operation, the support system of the present invention may be used to repair a hollow stick. A hockey stick having a fracture therein, or a hockey stick1which has been completely broken into more than one piece, may be repaired by utilizing the support system of the present invention. In utilizing the support system of the present invention, the following steps may be performed (provided the hockey stick1is in more than one piece):

1. Make any stick surface repairs desired and remove the cap16b(i.e., the cap at the non-blade end of the hockey stick1) or the blade4if it is replaceable. The completely open end16awill hereafter be referred to as the “pouring end”16aand the partially closed end (or if also completely open, it will be sealed off by use of a plug/stopper62as described below) will hereafter be referred to as the “sealed end.”

2. Cut the stick1to remove any damaged areas20in the repair joint area of the stick1.

3. Remove any plastic sheeting or other material that may inhibit the liquid hardening system from contacting the inside surface of the hockey stick1.

4. Sand or abrade the inside of both ends of the joining halves of the hockey stick1. Sand up to about 2 inches from the joint.

5. Using grooving bit30in a power rotary device, such as a high speed rotary saw, ream grooves on the inside walls of both halves of the hockey stick1to enhance physical adhesion and remove any dust and loose debris from the inside of the shaft2. Preferably, four grooves should be created, but more or less may be used.

6. Gently position a plug/stopper62into the sealed end (bottom half)64of the stick1. Position the plug/stopper62down the hockey stick shaft2(i.e., the sealed end of the shaft2). For most applications, the preferred position is 1-¾ inches down the stick of the shaft2. The insertion tool70(seeFIG. 11) may be used to insert the plug/stopper62to achieve the desired positioning. The end72of the insertion tool70is of a predetermined length that can motivate the plug/stopper62into the sealed end64the desired distance. Plug/stopper62is to hold the position of the insert8and/or rods12and to prevent the liquid hardening system from seeping to the bottom of the sealed end64of the stick1and thus from weighing the bottom of the stick1down. Plug/stopper62also keeps a user from improperly fixing the joint by starving the repair area of needed liquid hardening volumes (i.e., the liquid hardening system is kept in the area in and around the fracture area of the stick). Plug/stopper62is preferably made of a non-porous/closed-cell foam that is relatively springy so it will hold itself at the desired position inside the bottom half of the hockey stick1, and not allow entry or seepage (or just a minimal amount) of the liquid hardening system.

7. Attach bracket system40onto a stable work surface using clamp42.

8. Insert the sealed end64of the stick into bracket system40, using tensioning device46to hold the shaft2in place. The top of the sealed end64is preferably centered with respect to the opening58of bracket system40.

9. Using tensioning device44, secure the pouring end16ain the bracket system40.

10. Using alignment guides80(FIG. 12), align or “shim” the sealed end64of the stick1with the pouring end16aso that the two portions are properly aligned (vertically or otherwise). Alignment guides80are preferably long, substantially rigid structures. They may be straight or curved, depending on the shape of the hollow object13. It is preferable to use two alignment guides80simultaneously to perform the alignment. If both ends of the stick1do not align properly as demonstrated through the use of alignment guides80, either portion of the stick1may be adjusted slightly while in the bracket system40to achieve alignment.

12. Position the pouring end16a(i.e., handle portion) of the hockey stick1over insert8.

13. Seal the external joint of the two stick ends with an adhesive9tape.

14. Mix the liquid hardening system and pour the liquid hardening system directly into the top of the pouring end16a(seeFIG. 8), down the shaft of the hockey stick1. It is important that the liquid hardening system permeate, saturate, or otherwise contact insert8while the liquid hardening system is in its most liquid state. It is possible that the liquid hardening system could be inserted by other means such as injection from the side or top.

15. Keep the stick1in a straight upright secure position where it will not be disrupted for an extended period of time. Preferably, the stick1is left in the bracket system40for approximately 24 hours, but shorter or longer times are possible depending on the liquid hardening system employed. After removal of the stick1from the bracket system40, it should not be flexed for an additional period of time, preferably 72 hours. The optimal times vary depending on the liquid hardening system used and the temperature of both the liquid hardening system and the shaft2.

Not all of the foregoing steps are necessary to effectuate repair of a hockey stick or other hollow object13, but are preferred.FIG. 21shows the inside of a repaired hollow object13such as a hockey stick1. The first hollow portion14and second hollow portion15are joined together with the aid of the insert8. Some excess dried or cured hardening system90may accumulate above the insert8, but is mostly consumed within center section10and fabric11.

As an alternative, carbon-fiber rods12(seeFIG. 16A) may be used to provide structural support to a hollow object13having first and second hollow portions14,15. The second hollow portion has a top end16athat may be uncovered or covered by a cap16b, as shown inFIG. 13. The carbon-fiber rods12are preferably hollow and approximately 3 to 6 inches in length. Typically, the rods12have an open end17and a closed end18, however, both ends may be closed. The closed end18may be solid, but may be covered by glue, tape, a cap, etc. As illustrated inFIG. 13, to apply the rods12, the damaged portion20of the first and second hollow portions14,15is cut off just above the damage20to remove any loose carbon-fiber strands, epoxy, laminate, etc. Next, the grooving bit30is used to create locking channels21(shown inFIG. 14) inside the first hollow portion14and the second hollow portion15. After the locking channels21are created, a plug/stopper62(seeFIG. 15) is inserted into the first hollow portion14and forced to a predetermined position via the end72of the insertion tool70(shown inFIG. 11). The end72of the insertion tool70has a length adequate to allow the rods12to rest approximately half-way inside the first hollow portion14. As illustrated inFIG. 16, the rods12are inserted into the first hollow portion14, with the open end17in contact with the plug/stopper62. The closed end18of the rods12protrudes outside of the first hollow portion14.

As shown inFIG. 17, after a predetermined number of rods12have been inserted into the first hollow portion14, the second hollow portion15is placed on top of the first hollow portion14and over the protruding rods12. Consequently, about half the length of the rods12is inside the first hollow portion14and half the length of the rods12is in the second hollow portion15(seeFIG. 18). After the second hollow portion15has been inserted on top of the first hollow portion14and over the protruding rods12, a seam23between the first and second hollow portions14,15is covered with tape24, thereby sealing the seam23. Next, the hollow portions14,15are placed in a generally vertical orientation, if they are not already vertically oriented, and an adhesive9is poured into an end of the hollow object13and into contact with the rods12. At this time small reinforcing shapes such as carbon fiber beads, mini rods, cylinders, cones, pyramids, microspheres, macrospheres, tiny hollow balls, tiny foam filled balls, etc. may also be poured into the end of the hollow object13. The closed end of the rods12prevents the adhesive9from filling the rods12. It may be appropriate to gently shake the materials inside the hollow object13to settle all the materials. The adhesive9is allowed to fill the gaps25between the rods12and cannot flow past the plug/stopper62.

The structural damage repair method may be or also include a solid shaft repair system (seeFIGS. 22 and 23). Wafers100, as discussed in further detail below, may include specifically angled edge cuts101. This allows two or more wafers100to fit together when angled edge cuts101are placed in contact with one another. It is also conceivable that these angled edge cuts101may lock or interlock with one another so as to be connected via means other than just to be in contact with one another. In a shaft repair system, through grooves102are created generally perpendicular to the fracture in the shaft2. It is conceivable that these through grooves102may be positioned otherwise in relation to the fractures in the shaft2, however, through grooves102must at least intersect the fracture in the shaft2. A chemical molding agent, wafers100and/or rods12, and a sealant, discussed further below, may also be utilized in a manner substantially the same as previously discussed. This shaft repair system may be utilized in hollow shafts or solid shafts.

Alternatively, a sleeve200may be used to repair the shaft2, including at the hozel region of a hockey stick1. In this instance, a carbon fiber sleeve200, as will be discussed in further detail below, is used to externally around the shaft2to provide support at the break. After the damaged ends20are removed from both the first and second hollow portions14,15, adhesive is added to an outer circumference of both the first and second hollow portions14,15where the first and second hollow portions14,15will be joined. A sleeve200is then added over the epoxied area with approximately half of the sleeve200covering the first hollow portion14and half of the sleeve200covering the second hollow portion15. Additional adhesive is then added to an outer portion of the sleeve200and allowed to cure. Once the adhesive has cured, it can be sanded and painted, or additional sleeves200can be added. It is also foreseen that fabric may be added to any side or sides to further aid in connecting the first and second hollow portions14,15.

The present invention includes a method for repairing structural damage to a flat or slightly curved object such as a hockey stick blade4. The repair can be accomplished by using an adhesive9(chemical molding agent), one or more rods12or wafers100, one or more sleeves200, and a brush112. The kit may also optionally include flexible flat supports114, wrapping tape103and/or a sealant. The method of repairing a flat or curved item, such as a hockey stick blade4, is described in further detail below.

Initially, any loose fibers or splinters115(seeFIG. 24) should be trimmed to get the parts to return to close proximity and original alignment. A radius restorer116(shown inFIG. 25) is used to keep the parts in alignment during the curing time of the adhesive9. The radius restorer116includes two pins117that connect first and second clamping members118,119. The first clamping member118may be moved relative to the second clamping member119by sliding along the two pins117. In addition, as illustrated inFIG. 26, the radius restorer116has contact portions120that are slightly curved. The slight curve of the contact portions120assists in obtaining and maintaining the desired blade radius/curve. To maintain the proper blade curvature, radius restorers116used in conjunction with a hand clamp121, shown inFIG. 27, may be preferable, depending on how damaged the blade4is. If the curve is out of alignment after 24 hours, it is possible to readjust and reclamp for another two days. The adhesive is somewhat pliable for the first 48 hours and may be bent slightly. After 48 hours, however, this is no longer possible. On a completely broken off blade, it is imperative that the blade be reassembled with the proper “lay.” This may be accomplished by using a flat support form to ensure proper angulation or “lay.” The radius restorers116may be applied directly over flat supports204(seeFIG. 42).

The adhesive may be applied to the structurally damaged area of the object to be repaired. Often, the adhesive is applied by troweling, brushing, or pouring the adhesive on the damaged area. Typically, the adhesive9has sufficient shape-retaining characteristics to allow a user to reshape the structurally damaged object to its original and/or desired shape. The adhesive will then harden and retain the original and/or desired shape of the object. Any adhesive may be used in this embodiment of the present invention. The adhesive may be any adhesive agent, molding agent, shape-retaining compound, reinforcing agent, restructuring agent and/or restitution agent. Of course, the adhesive may also be any combination and/or derivation of any of the above. The adhesive may include but is not limited to, epoxy, epoxy resin, epoxy for wet applications (i.e., marine epoxy), multi-party epoxies, flex-epoxy, mercaptans, polyesters, urethanes, polyvinylchloride (PVC) cement, polyvinyl acetate, cellulose nitrate, polyvinyl butyral, polymethacrylates, methacrylates, polyvinyl alcohol, methylacrylate/ethyl methacrylate, polyurea, etc. and any combinations or any derivations of any of the above including polymers and/or copolymers of any of the above, however, epoxy resin is typically preferred. After the adhesive9is applied to the object to be repaired, it is allowed to cure. Once the sealant has cured/dried, the remaining cured sealant is removed, typically by using a sanding device, however, any device may be used. By sanding off this excess sealant and adhesive9, the surfaces of the object are smoothed.

Most typically, the adhesive alone is insufficient to repair and/or restore the object to its original strength and/or increase the strength of the object. Accordingly, methods to enhance the strength of the repaired area are necessary. Specifically, reinforcement members and/or fabric and sleeving members are typically necessary to strengthen the object to be repaired.

To apply reinforcement members, such as rods12or wafers100, grooves must first be made in the object to be repaired. Two methods have been developed for preparing the grooves. The first method involves use of a drill with a jig to assist in aligning and angling the grooves, and the second method involves using a grinding wheel attached to a drilling tool.

Regarding the first method and referring toFIG. 29, a jig130is optionally used as a guide to cut grooves131which are preferably staggered, or apertures in the object to be repaired. Jig130may be made of any type of material, including, but not limited to, wood, metal, plastic, or any combinations or derivations thereof. Jig130is typically a rectangular shape, however, it is conceivable that jig130may be any shape depending upon the shape and size of the object to be repaired. The jig130has a centerline that is typically placed approximately perpendicular to the fracture of the object to be repaired. In the case of a pocket fracture, jig130may not be necessary. Generally grooves131are staggered relative to center-line132. These staggered grooves131reduce creating a shear point and/or a shearline in the object to be repaired. That is to say, typically if all grooves131were the same length and had the same starting points and end points (i.e., non-staggered grooves), relative to center-line132, and if the wafers100or rods12were positioned about parallel axes wherein their respective surfaces also positioned about parallel planes typically it is more likely that a shearing plane and/or shearline would be created at both the starting points and the end points of non-staggered grooves131between the non-staggered grooves131and the non-fractured and/or non-damaged material of the object to be repaired. Therefore, when applying force(s) to the object that has been repaired, including the non-staggered grooves131, there is more likely to be a discrepancy between the strength of the newly repaired part of the object and the existing non-repaired part of the object. This discrepancy may create a likely place for future damage and/or fractures. In the present embodiment of this invention, these staggered grooves131reduce these shearing planes and/or shearlines by having different groove starting points and end points than the groove131immediately adjacent to it such that these shearing planes and/or shearlines are virtually eliminated. As shown in FIGS.30and30A-30D, these grooves131may be cut at any desired angle relative to one another which also reduces shearing planes and/or shearlines.

Jig130also includes clamp section(s)136. Clamp section(s)136are on either end of the substantially rectangularly-shaped jig130. Of course, clamp section(s)136may be any shape to accommodate the clamp(s) that may be used to clamp jig130to the object to be repaired. In the event that it is not possible to clamp jig130to the object to be repaired, clamp section(s)136of jig130may be modified to accommodate any other type of device utilized to secure jig130to the object to be repaired. This may include, but is not limited to, suction cups, adhesives, magnetics, etc. However, when possible, a secure clamped connection between jig130and the object to be repaired is preferred. Guides137in jig130may be any length, including a length range of from about ½ inch to 72 inches, more typically from about 2 inches to about 48 inches, and most typically from about 3 inches to about 12 inches. Guides137may be any width, including, but not limited to, 1/32 inch to about 2 inches, more typically from about 1/16 inch to about 1 inch, and most typically from about ⅛ inch to ¾ inch. Guides137or apertures may be any shape and have any pattern within jig130. Also, guides137in jig130may have a knurled cut or surface so that when a user uses a cutting device within jig130to create grooves131, the resulting grooves131are knurled or they have the specific surface of the guides137in jig130.

Once jig130has been secured to the object to be repaired, grooves131are cut in or on the object to be repaired. This cut may be made by any type of tool138, however, typically a variable speed rotary saw or a DREMEL® tool is preferred. While not necessary, it is preferred that the wafers100have a width of less than or equal to the thickness of the fractured area of the object to be repaired. While not necessary, it may be beneficial in repairs involving smaller narrow surfaces or surfaces having many angles to sleeve over the area to be repaired once the wafer100has been inserted into the object. This sleeve process may involve covering the area with a portion of reinforcing fabric11and a chemical molding agent to aid in reinforcing the damaged area20and to further hold the wafer100in place during the chemical molding drying process, as will be further discussed below. This method is frequently used to create grooves for wafers100.

A second method of making the grooves131does not involve use of a jig130, in which case, a user manually staggers the grooves131keeping them relatively centered over the damaged area20. Specifically, the grooves should be staggered so that between one-third and two-thirds of the groove is on one side of the break. This alternating alignment helps eliminate any shearing planes or lines that can be formed at the interface between the repaired and unrepaired areas. Optionally, the damaged areas20on the backside of the blade4can be marked with a silver or white marker. The top and bottom groove lines should be drawn first, about a ½″ (10 mm) from the edge of the blade4. The next two lines should each be evenly spaced between the top and bottom. It is important that the lines cross the damaged area. Preferably, the damaged area crosses each line at point approximately within the middle one-third of the line. If the break runs diagonally across the blade4, the grooves131will need to be staggered to accommodate the diagonal break. If the damaged area20runs down the blade4a long distance, it is sometimes desirable to grind a line of grooves131one after another down the blade4and then stagger each line of grooves131under it. This creates a continuous area of reinforcement that still accommodates the curve of the blade4. As shown inFIG. 35, a drill150having a grinding wheel152can be used to create the grooves131in the surface of the object. The grooves131should be cut with a 3/16″×2″ grinding wheel152. Ideally, the grooves131are only cut partially into the blade4, as depicted inFIG. 36. However, if the grooves131penetrate the blade4creating holes through the blade4, adhesive can be used to fill the holes. This method of making grooves is generally used when rods are to be used.

In the preferred embodiment, rods are used for grooves that only partially penetrate the object to be repaired. In another embodiment, wafers are used in grooves that fully penetrate the object to be repaired.

After the grooves131have been prepared by either method above, each of the grooves131is fitted with an appropriate sized rod12. The rods12are used in a similar manner described in relation to the shaft repair above. However, the rods12, when used in objects having a thin, curved, construction, frequently have an angle cut at each end of the rod12. However, the ends of the rods may also be dual angle cut, rounded, square cut, cone-shaped, or cut on a curve. In addition, the rods are frequently solid, rather than hollow. Further, the rods are generally comprised of carbon fiber, but may be constructed from any suitable material, including, but not limited to fiberglass, KEVLAR®, carbon fiber, wood, plastic, metal, etc.; however, typically carbon fiber is preferred. In addition, the rods12generally have a diameter that is slightly less then the width of the grooves131. However, the rods12may also have a diameter that is substantially smaller so that more than one rod12can be inserted into a single groove131.

If there are several areas of damage, it may be best to overlap the rod12sections to provide continuous reinforcement over longer grooves131. One difficulty is that the blade4has a curvature and the rods12do not. However, it is possible to follow the curve of the blade4by using two or more pieces of rod12and interlocking them. To perform an extended repair, several long continuous grooves131are cut for the entire length of repair on the backside of the blade4. The rod12ends should fit together and overlap each other, thereby creating a continuous reinforcement. The rods12in other grooves131should not have overlaps in alignment with adjacent grooves131, if possible. The rods in the grooves should stagger over the break and between one-third and two-thirds of the length of the rods should be on one side of the break. Also, typically the repair grooves131for the rods12are not created in the front side. Because of the curve of the blade4, this would cause the middle of the rods12to lay shallowest over the break.

Once the grooves131have been cut in the object to be repaired, the grooves131are filled with an adhesive9(FIG. 37) to aid in completely sealing the grooves131when the rods12are placed in the grooves131. The adhesive used herein may be any type of an adhesive, however, an epoxy resin is preferred. After the adhesive has been properly mixed, the adhesive mixture should be spread into the grooves131. The grooves131need not be filled completely. The grooves131should be filled approximately half way, but the bottom of the grooves131should be completely covered with no bubbles or gaps.

The appropriate rod12should be placed into each adhesive filled groove131. The rods12should be oriented so that the cut angle is at the bottom of the groove131. After the rods12have been inserted in the proper position, the entire repair area should be smeared with adhesive. All gaps around the rods12and in the grooves131should be filled. The rods12should not be allowed to move much during this process. If the rods12move too much, bubbles will be formed in the adhesive, thereby reducing the repair strength. When finished, the blade4should be stored undisturbed in a warm dry place. The blade4should be stored at an angle so that gravity pulls the rods12and adhesive deeper into the grooves131. With a thicker adhesive, storing the blade4at an angle may not be necessary.

Optionally, rods12may be coated with an adhesive, of one of the types previously mentioned. The rods12are then inserted into the staggered grooves131.

Wafers

Alternatively, reinforcement wafers100, as previously shown inFIGS. 22 and 23, comprised of compressed materials may be used in conjunction with, or instead of, the rods12. More specifically, the wafers100are typically comprised of layers of reinforcing fabric having an adhesive substance in between the layers which are then compressed together. Any type of adhesive may be used, including, but not limited to epoxy, epoxy resin, epoxy for wet applications (i.e., marine epoxy), multi-party epoxies, flex-epoxy, mercaptans, polyesters, urethanes, polyvinylchloride (PVC) cement, polyvinyl acetate, cellulose nitrate, polyvinyl butyral, polymethacrylates, methacrylates, polyvinyl alcohol, methylacrylate/ethyl methacrylate, polyurea, etc., and any combinations or any derivations of any of the above including polymers and/or copolymers of any of the above. It is conceivable that adhesive tapes may also be used. The material layers may be the following types of materials, including, but not limited to fiberglass, KEVLAR®, carbon fiber, wood, plastic, metal, etc. However, typically carbon fiber is preferred. Also, the wafers100may be made from any combinations or derivations of the above-mentioned material layers compressed together. The wafers100may be made of any number of layers of these materials within the range of from about 1-20 layers, more typically from about 4-12 layers, and most preferably from about 4-8 layers of the above-mentioned materials.

The wafers100may optionally be knurled as shown inFIGS. 31A-31B. A knurled surface typically will hold or retain more sealant thereby creating a stronger bond between the wafers100, the sealant and the object to be repaired. Additionally, a knurled surface typically offers more resistance to movement once placed in the object to be repaired. Any type of knurled surface is acceptable, including, but not limited to, checker grooved surface (seeFIG. 31A), lateral grooved surface, longitudinal grooved surface (seeFIG. 31B), diamond grooved surface, or any other type of knurled surface or any combinations or derivations of the above type of knurled surfaces. It is conceivable that the knurled surface may include a combination of any of these types of above-noted surfaces. The edges of the wafers100may be any configuration to better fit into the grooves131, including, but not limited to rounded edges, square edges, etc., however, typically rounded edges are preferred. It is also conceivable that the grooves131in which the inserts are placed may have a knurled cut to create a better fit between the wafer100and the groove131. These wafers100may be sized to any shape. However, they will typically be sized to the shape of the corresponding groove131in which the wafers100are to be placed.

The wafers100may be any width, any thickness and/or length. Unlike the rods12, the wafers100should protrude through both ends of the blade. Of course, the width, thickness and length ranges will vary depending upon the shape of the grooves131cut into the object to be repaired. The grooves131cut into the object to be repaired may vary depending upon the size of the fracture within the object to be repaired. Additionally, these wafers100may have tongue and grooved ends or edges, or some other type of interlocking, overlapping or other type of connection so that multiple wafers100may be used to fill larger grooved areas or to custom fit a series of wafers100into a grooved area. Any type of interlocking, overlapping or adjacent connection may be used.

Regarding typical surface and/or through fractures, once the epoxy has cured, jig130is placed adjacent to the object to be repaired. More specifically, jig130is positioned to create the desired grooves131or apertures, whether angled or not. Additionally, a jig having a wafer angulation configuration may be used with the wafers100(seeFIGS. 32 and 33). Referring toFIG. 32, the wafers100are configured at angles to create more reinforcement than if the wafers100were positioned along parallel axes and parallel surfaces to one another. Typically, as shown inFIG. 32, “A” represents the inside, or typically the puck-receiving portion of the hockey stick blade4. Referring toFIG. 32, a greater surface area reinforcement is achieved by using the wafer angulation configuration. As seen inFIG. 33, generally the surface area reinforcement and strength withstanding capabilities can be described as follows: (B>A), (C>D) and (E>F). The typical shearlines in this wafer angulation configuration are not similar to conventional shearlines. By employing this wafer angulation configuration, the wafers100reinforce where conventional shearlines would be and reduce the likelihood of creating shearlines due to impact distribution. However, staggered wafer100configuration may also be employed. Of course, these wafers100used in the wafer angulation configuration may be independent of one another when used in a repair, may be connected to one another as described above and may be made of the materials as described above.FIG. 34shows one example of the wafer angulation configuration. These wafers100are placed at approximately a 45° angle relative to the flat face of the hockey stick blade4. While any angle may be used, typically a 30° or a 45° angle are preferred and provide an increased resistance to fracturing.

If a custom length wafer100is required, it should be fashioned by cutting or sanding. It is important that the wafers100are organized relative to the position of each wafer100in the blade4. Specifically, after the proper sized wafers100have been removed from the grooves131, they should be placed in order (on a bench, for example) relative to their location in the blade4. This is of particular importance if multiple wafers100are being used in an extended groove131, as explained below.

Once the rods12and/or wafers100are inserted into the grooves131, an adhesive or sealant, of the type previously discussed, is applied to the surface of the object (seeFIG. 38). While this adhesive9is still wet, a small brush may be used to brush and smooth the surface of the sealant on the object. This smoothes the adhesive coated surface, distributes the sealant over the area to be repaired, and eliminates any voids (i.e., air pockets) in the adhesive-coated surface. The adhesive is allowed to cure for approximately 24 hours. After curing, the excess adhesive and wafer100material is removed from the surface of the object. This may be done by any means, including, but not limited to, a mechanical removal process (i.e., sanding, scrapping, chiseling, etc.) or any type of a chemical process (i.e., using a solvent or other type of chemical removal liquid and/or process).

Sanding

After the adhesive is cured, holding the rods12or wafers100in the blade4is preferably sanded to smooth rough edges and to conform the repaired area to the general shape of the blade4. The sanding method best suited for sanding repair entails use of any angle drill150(die grinder) and small 2″ (50 mm) sanding disks. Grit can run from 36 to 100, depending on preference and precision. The bigger grit requires a delicate touch, but does scarify (i.e., rough up) the surface well. A shop vac or some type of dust collection system should be operated near the sanding disk to keep flying dust to a minimum.

The original stick1surface serves as a guide as to how much material should be removed. The areas over the rod12/wafer100inserts should be sanded until the outlines of the grooves131that were cut in the blade4can be clearly seen. The blade4should be sanded at least 1″ (40 mm) past the area to be sleeved. The area to be sleeved and that should be sanded should extend 1 inch past the rods12/wafers100that extend furthest from the break. The sleeved area should extend two inches (50 mm) past the rods12/wafers100toward the tip. This helps the blade4to flex more naturally and prevents wear on the repaired area. If the blade4is sleeved just slightly past the ends of the repair, the ends of the rods12/wafers100create a shearing plane for future breakage. In addition, the sleeved area should extend slightly up the hozel3if possible. This is a prime breakage area and with this preventative maintenance completed, the end-user will have a more durable repair.

The edges of the blade4should be sanded very carefully. Because these surfaces are narrow, they can be notched or gouged quickly. Smooth long passes should be made on these areas. Hidden damage to the blade4that was previously overlooked may be visible at this time. These areas can usually be reinforced and repaired in the sleeving process. One of the most typical types of damage that shows up is a split along the bottom edge of the blade4. When the blade4is sleeved, adhesive should be rubbed into this crack and then reinforced with carbon fiber tape. The bottom edge should usually be reinforced with tape as part of the final sleeving process. If further reconstruction is necessary, it is appropriate to do so before any sleeving takes place.

Sanding should remove all of the finish and external paint/coating from the stick blade repair area. Most shafts2and sticks1will show a dull dark gray carbon fabric or weave under the paint. Any repairs made should be smoothed into the adjoining shaft. Bumps or hard edges should not be left on the blade4. In addition, all shaft and repair edges should be rounded slightly. This aids in longevity of the repair. Hard edges or bumps create fracture lines for future damage. When the sanding is complete, the fabrics11and sleeves200may be installed.

Fabrics and Sleeves

Typically, a sleeve200and/or separate piece of fabric are added over the repaired area to enhance strength and durability. Preferably both a sleeve and a fabric are used. The structural strength enhancing sleeves200and fabrics202are generally comprised of woven materials. More specifically, the sleeves200and fabrics202(seeFIGS. 40 and 41) are typically comprised of one or more layers of woven fabric. The sleeves200may be the same or similar length, but may be different lengths depending on the repair and geometry of the object being repaired. An adhesive substance can be used to adhere the sleeve200to the damaged object and to hold the object together. Any type of adhesive may be used, including, but not limited to epoxy, epoxy resin, epoxy for wet applications (i.e., marine epoxy), multi-party epoxies, flex-epoxy, mercaptans, polyesters, urethanes, polyvinylchloride (PVC) cement, polyvinyl acetate, cellulose nitrate, polyvinyl butyral, polymethacrylates, methacrylates, polyvinyl alcohol, methylacrylate/ethyl methacrylate, polyurea, etc., and any combinations or any derivations of any of the above including polymers and/or copolymers of any of the above. A bis-A based epoxy is preferred. The woven material202layers may be the following types of materials, including, but not limited to fiberglass, KEVLAR®, carbon fiber, wood, plastic, metal, etc., however, typically carbon fiber is preferred. The sleeves200may be made of any number of layers of these materials202within the range of from about 1-4 layers, more typically from about 1-3 layers, and most preferably 2 layers. The sleeves200may be any width and thickness. The width and thickness will vary depending upon the size and shape of the object to be repaired.

The sleeves200and the fabric202should be cut to length. For shaft side breaks, the length should be enough to cover up the hozel3slightly and at least half of the blade4. For breaks on the tip half of the blade4, the sleeve200should extend 1″ (40 mm) past both ends of the reinforcing rods12.

The shaft2should be clamped firmly in a vise to ease painting of the adhesive over the entire sanded repair area, including the bottom of the shaft2. The fabric202should be applied to the bottom of the repair area. The fabric202should cover the bottom edge and wrap just slightly to the front side. The majority of the fabric202should be on the backside of the blade4. The purpose of the fabric202is to double up the reinforcement near the puck impact zone.

After the fabric202has been applied to the backside of the blade4, adhesive can be painted over the fabric202. The adhesive should be rubbed into the fabric202from the middle out toward the ends until it appears smooth. When the fabric202is flat and completely saturated with adhesive, additional adhesive should be applied. The additional adhesive enhances the wetting out of the sleeve200that goes over the fabric202. Once the additional adhesive has been applied, the sleeve200may be slid over the blade4and fabric202. The sleeve200should then be stretched outward from the middle to shrink the sleeve's diameter and tighten the sleeve200onto the blade4. The sleeve200should be painted with adhesive outwardly from the middle toward the ends in a similar fashion to the fabric202. The sleeve200should be fully saturated and smooth. Once the sleeve200is fully saturated and smooth, additional adhesive should be applied to be sure that enough adhesive has been added to the entire sleeved area. Multiple sleeves200and fabric202may be applied to the damaged area to increase the durability of the damaged area after the repair is complete.

Curing

After the adhesive has been fully applied, one or more flat supports204(seeFIG. 42), that are generally shaped similar to the shape of the object are then placed on at least one side, and preferably two sides, of the damaged object. An appropriate flat support204will have a height that is less than the height of the blade4. This ensures that the blade4edges are not covered by the flat support204and instead are in contact with a molding tape205that will be wrapped around the blade4and flat supports204. This facilitates additional compression to the edge of the blade4. The supports204are preferably made of a resilient but slightly flexible material, such as polypropylene. After one or more flat supports204have been added to each side of the blade4, the blade4and flat supports204are then completely wrapped in the silicone tape210, preferably 1-½″ wide “square” EXTREME® brand tape (seeFIG. 43). The flat supports204are clamped to the blade4using any clamping means desired, such as by a standard commercially available clamp121, and the adhesive9is allowed to cure.

Optionally, holes216may be punched in the tape210after it has been thoroughly wrapped over the blade4and flat supports204. This allows excess adhesive9to ooze from the blade4area. In addition, this area may be wrapped with two layers of tape210to prevent splitting.

As shown inFIG. 44, after the tape210has been applied, clamps121are added to compress the repair securely within the blade4. Ideally, the clamps121will squeeze the repair to a thin, light, and smooth construction. Any number of clamps121may be necessary. Once the clamps121are in position and securely tightened, the tape210may be punctured to release excess adhesive. Any punctures in the tape210should not exceed ½ inch in distance along the top and bottom edges of the blade4. Too many holes216may result in tearing of the tape210.

Preferably, the repair should be allowed to cure for two days at approximately 70° F. at constant temperature. Once the adhesive is cured, the tape210is cut and removed, and the flat supports204are removed by peeling them away from the object. After the tape210and flat supports are removed, raised edges of cured adhesive9on the repair will be visible. This material should be removed by an angle drill150equipped with small sanding disks. Any adhesive that has been squeezed out onto the non-repair area should also be ground away. If any paint is removed, it can be repainted at a later time.

The adhesive may be removed by any means, including, but not limited to, a mechanical removal process (i.e., sanding, scrapping, chiseling, etc.) or any type of a chemical process (i.e., using a solvent or other type of chemical removal liquid and/or process). Cuts should not be made on the flat supports204, as any imperfections, nicks or cuts may show on future repair jobs.

Once the excess adhesive has been ground away and any raised edges have been flattened, it is important to finish sand the edges and transition areas (areas going from original to repair). Finish sanding the edges ensures that there are no carbon fiber burrs or raised adhesive areas. Generally, 80 grip spinning sand paper and Scotch-Brite pad combi wheels made by 3 M may be used. After smoothing all edges in the surface of the object to be repaired, the newly repaired area is ready to be sealed, painted, or to have some other type of chemical application applied to the surface thereof (seeFIG. 45). The repaired area is preferably sprayed with a sealant, more preferably a sealant lacquer.

The lacquer is applied to the surface of the sleeve200and to the surface of the object. The lacquer is then allowed time to cure or dry. The lacquer may include any type of sealant, including, but not limited to, a lacquer, an adhesive, a water-sealant, a UV-resistant sealant, a moisture-resistant sealant, etc. A lacquer sealant is typically preferred.

The sealant is allowed to cure for approximately 24 hours. The resulting repaired object is returned to its original strength, if not stronger. The repaired area250is generally the same size and shape as the original object (seeFIG. 45).

Rebuilding with Adhesive

Alternatively, if only a portion260of a curved, thin object, such as a hockey stick blade4, is broken off, reconstruction may be possible if the portion is lost or otherwise too damaged to be reinstalled. In this case, as shown inFIG. 46, the above method of preparing grooves131in the damaged area20is necessary. Rods12(as shown inFIG. 47) or wafers100, are fitted to the grooves131and additional adhesive9is added around the rods12to create a shape substantially similar to the portion260of the blade4that was broken off. The adhesive9and blade4should rest on a flat or slightly curved surface262so that the adhesive9does not substantially change shape during curing. The adhesive is allowed to harden and is later sanded to conform with the shape of the missing/broken off portion of the blade4(FIG. 48). After sanding, adhesive9and sleeve200are added to the portion260(FIG. 49). Adhesive9is added to the sleeve200after the sleeve200covers the damaged area20to make sure full saturation of the sleeve200has occurred. The blade4is then secured between two compression members211(FIG. 50) having an inner soft layer212and an outer hard layer214. The compression members211are placed around the sleeve200, adhesive9and blade4and clamps121are applied to the outer hard layer214. The clamps121apply pressure to the repaired blade4through the soft inner layer212. As a result, the general shape of the blade4as it was formed is maintained.

In a similar manner, any other external portion of a hockey stick blade4may be repaired. Referring toFIGS. 51 and 52, a heel portion of a hockey stick blade4is damaged and is therefore reinforced using either straight wafers100(FIG. 51) or grooved surface wafers100(FIG. 52).

The above-noted structural damage repair method and system may be used on any type of damaged object, including, but not limited to, hockey sticks (including blades, hozel, and shafts), boat hulls, automobiles, or any other type of object. The above-noted wafers100and the structural damage repair method and system restore and/or enhance the structural integrity of the repaired object resulting in less twisting and more strength of the repaired object.