Lacrosse stick

A lacrosse stick includes a flared (e.g., forked) end and a flexible head frame adapted to receive a mesh thereon.

TECHNICAL FIELD

The present invention relates generally to lacrosse sticks.

BACKGROUND

In the game of lacrosse, players use sticks to receive and shoot a ball. Lacrosse sticks generally include an elongated shaft and a head frame. The player grips a handle located toward the butt end of the shaft, and utilizes the head frame, which includes mesh, to receive and shoot the ball during play.

Decades ago, some lacrosse sticks were manufactured as one-piece, integral wooden structures. Such sticks were not only difficult and costly to fabricate, but owing to their unitary mechanical properties, also limited the maneuvers that a player could execute. For example, the stiff wood, while necessary for shaft strength, was poorly suited to the head frame; the lack of flexibility would, for example, limit the player's ability to scoop up the ball from the ground or make it more difficult for a player to receive a hard pass without feeling excessive vibrations.

As a result, it has become commonplace to fabricate lacrosse sticks using a shaft element formed of straight grained wood, or wood laminate, or a tough, lightweight metallic or reinforced plastic tubular element and to affix to the forward end of the shaft a flexible head frame (composed, for example, of a tough synthetic thermoplastic material such as high impact-strength nylon). Indeed, most lacrosse sticks today are sold as separate head and shaft portions.

A typical head frame for a lacrosse stick includes a socket to receive the forward end of the shaft. The shaft is then coupled to the head frame by a fastener, such as a screw. One problem with such a construction is that the connection between the head frame and shaft may loosen during play, compromising the player's ability to effectively control his stick. Worse, in some instances the head frame may detach entirely from the shaft.

Some lacrosse sticks exist that reinforce the connection between the head frame and the shaft to prevent disengagement of the head frame from the shaft. Unfortunately, regardless of reinforcement or attachment techniques, the head frame may still loosen or become detached over time. What is needed, then, is a lacrosse stick that integrates a head frame and a shaft into a unitary construction that does not become loosened or disengaged, but still retains flexibility in the head frame and rigidity in the shaft.

SUMMARY OF THE INVENTION

The invention provides a novel lacrosse stick having a rigid shaft with a terminal end, which may be forked or otherwise flared in certain embodiments. A flared end provides a larger area of contact with the molded flexible head frame than was possible with prior art devices. In fact, in one embodiment, the contact area may increase dramatically by overmolding the head frame directly onto the flared end of the shaft, thereby creating a unitary structure. Because of its structure, the lacrosse stick of the present invention is more durable than prior art devices, while still retaining the desirable rigidity in the shaft and flexibility in the head frame.

In one aspect, the invention relates to a lacrosse stick having a rigid terminal end, and a flexible head frame adapted to receive a mesh thereon, a portion of the head frame being overmolded onto the terminal end. The terminal end may be forked or otherwise flared. A forked end typically includes at least two tines, the head frame at least partially surrounding the tines so as to resist disengagement. A forked end may include at least one shoulder portion, the head frame at least partially surrounding the shoulder portion. Each tine may include a base, the head frame at least partially surrounding each base. Other embodiments of the stick further include a shaft, either forming a unitary structure with the forked end, or the mechanically engaging the forked end. Even in embodiments including a mechanical joinder, the problems of the prior art are avoided by, for example, ensuring that the throat of the fork is as rigid as the shaft it engages.

In another aspect, the invention relates to a lacrosse stick having a rigid forked end, and a head frame adapted to receive a mesh thereon, at least a portion of the forked end engaging at least a portion of the head frame. In certain embodiments, the head frame is mechanically joined to the forked end or overmolded onto the forked end to form a unitary structure. The head frame further includes a flexible distal end and a proximal end, wherein at least a portion of the forked end engages at least a portion of the proximal end of the head frame. The head frame may be symmetrical on opposite sides of an axis extending from the distal end to the proximal end, and forked end generally includes at least two tines diverging from the axis and positioned on opposite sides thereof. Other embodiments also include a shaft, such that the shaft the forked end are mechanically joined, and may include a sheath surrounding the joint of the shaft and the forked end. Such a sheath may be integral with the head frame. In another embodiment, the shaft and the forked end form a unitary structure.

In yet another aspect, the invention relates to a method of making a lacrosse stick, the method including the steps of providing a rigid element having a forked end, and overmolding a flexible head onto the forked end. The method may further include overmolding the connection of the rigid element and a second rigid element. The method may be utilized to overmold the flexible head onto tines and/or shoulder portions of the forked end. The base of the tines may also be overmolded.

DETAILED DESCRIPTION

Referring first toFIG. 1, which illustrates one embodiment of a lacrosse stick10in accordance with the invention. The stick10includes an elongate shaft12, a butt end (not shown), and, in this embodiment, an integral forked end16. A head frame18is overmolded onto the forked end16.

Coupled to the butt end of the shaft12is a handle (not shown) which a player grips during use of the lacrosse stick10. A variety of handles can be used in accordance with the invention. For instance, in one embodiment, the handle is a hollow rubber knob that slides onto and caps the butt end of the lacrosse stick10. In another embodiment, the handle is an injection-molded plastic grip that slides onto the lacrosse stick10and has grooves designed to accommodate a player's fingers. Similarly, another handle may be located proximate the forked end16of the stick10. Exact placement of the handle or handles may be determined by particular user needs or preferences, and the handle is not limited to those described; rather, it can be any handle that is typically used in a lacrosse stick or a hockey stick.

FIGS. 2A and 2Bdepict the stick10with the forked end16exposed. The forked end16can be integrally formed with the shaft12or, as depicted inFIG. 2B, may be a discrete element joined to the shaft12. If the forked end16is discrete from the shaft12, numerous ways to connect the two elements are available. For example, if a hollow shaft12is utilized, a male component20extending from the forked end16may be received within the body of the shaft12. The component20may be secured with epoxy or other mechanical means such as screws or bolts. Regardless of connection method, a sheath (not shown) may be fitted over the point of connection to provide increased stability to the stick10. In certain embodiments, the sheath may be integral with (or fully cover) one of the handle elements described above, or may be an extension of the head frame18as described below. Alternatively, or in addition, the shaft12may include a male component to be inserted into the forked end16.

The forked end16includes at least two tines22a,22bthat diverge from the terminal end of the shaft12, forming a generally U-shaped or V-shaped opening24. The tines22a,22bextend a predetermined distance from the shaft12and terminate at flat, pointed, round, or blunt ends26a,26b. The lengths of the tines22a,22bmay vary, but generally should extend a sufficient distance to provide an adequate area of contact with the head frame18, but not so far as to adversely effect the flexibility of the head frame18. The thicknesses of the tines22a,22bmay also vary with the distance from the base28of the tines22a,22b, or the tines22a,22bmay have a uniform thickness along their entire lengths. The forked end16also may include one or more raised shoulders30at or near the base of the U-shaped opening24. The shoulders30follow the contour of the frame18and aid in retaining an overmolded head frame, as described below.

As shown inFIGS. 3A-3G, the head frame18is defined by at least one wall member32extending from the forked end16. Generally, the head frame18is symmetrical about a centerline axis34. The distal end36of the wall member(s)32forms a generally arcuate nose element38, which bridges the sides that converge towards the proximal end40of the head frame18. The wall member32includes an upper rim42and a lower rim44. The sidewall46between the two rims42,44includes a plurality of openings to increase flexibility and to reduce weight. The lower rim44may have a plurality of apertures48spaced about its periphery to receive a mesh (not shown). In use, the mesh is suspended from the apertures48to define a bottom closure of the head frame18. In another embodiment, the mesh is coupled to the head frame18by fasteners (not shown). In general, the mesh can be coupled to the head frame18using any suitable means.

The upper rim42of the head frame18defines a mouth50in which a lacrosse ball is received into and shot from the lacrosse stick10. The mouth50is generally divisible into two functional portions. The first is a throat portion52adjacent the juncture of the wall member32with the forked end16. The mesh suspended from the throat52of the head frame18defines a pocket54, where the lacrosse ball resides during the player's retention of the ball in the lacrosse stick10. The throat portion52of the head frame18terminates in an arcuate contour56, the radius of curvature of the contour56being selected to define an accommodating surface against which the lacrosse ball rests while retained in the pocket54. Typically, the contour56is lined with a soft, resilient padding which assists a player in maintaining the ball in the throat portion52.

The mouth50also includes a receiving and shooting portion58defined by the portion of the mesh distal to the throat portion52and extending to the nose element38of the head frame18. The receiving and shooting portion58where the lacrosse ball is initially received and entrapped by the player and from which the ball is ultimately passed or shot.

The nose element38of the head frame18has a generally flexible wall portion42; for example, the wall portion42may be thinner than other portions of the wall member32. The wall portion60is angled such that the upper rim42of the head frame18protrudes distally of the lower rim44. The angle α (seeFIGS. 3C and 3D) of the wall60can range from about 10° to about 80°. The thin, angled wall portion60of the nose element38assists a player in scooping a ball off the turf, since the flexibility of the wall portion60allows it to yield without excessive effort, sparing the player the need to lean excessively forward. Moreover, the wall portion60of the nose element38facilitates the fielding of ground balls since there is less of a lip for the ball to pass over before reaching the receiving and shooting portion58.

The lacrosse stick of the present invention utilizes a large contact area between the forked end16and the head frame18to increase the connection strength between those two elements. In one embodiment, the two contacting elements, the forked end10and the head frame18, are manufactured separately. Once manufactured, the proximal end40of the head frame18is inserted into the U-shaped opening24of the forked end16. The sizes of the two elements, coupled with the complementary curvatures of the proximal end58and U-shaped opening24, provide for contact along at least a portion of the length of the tine22a, around the curvature of the U-shaped opening24, and along at least a portion of the length of the second tine22b. Naturally, if a V-shaped opening24is utilized, contact with the proximal end40of the head frame18may be limited, but sufficient contact area will still be present along the lengths of the tines22a,22bto prevent disengagement of the two elements16,18. To secure to the forked end16to the head frame18, any suitable mechanical connectors such as screws, bolts, and the like may be utilized, but such connectors should be countersunk within the head frame to avoid interference with the lacrosse ball during play. Increasing the number of such mechanical connectors will increase the strength of the overall device, as will utilizing an epoxy or other similar means of adhesion. Alternatively, an epoxy of sufficient holding strength may be utilized alone, in lieu of mechanical connectors.

Another embodiment of the lacrosse stick utilizes a head frame18overmolded onto the forked end16as depicted inFIG. 4(with the forked end16visible through the head frame18). In such an embodiment, the forked end16is first manufactured, then placed in a mold (not shown) for the overmolding of the head frame18. The overmolded head frame18is constructed such that it contacts at least a portion of the inner surface of the U-shaped opening24, and at least a portion of the inner and outer surfaces of the tines22a,22b. Such a construction forms a unitary device that resists disengagement of the two main elements16,18of the lacrosse stick10. Similarly, additional wrapping portions62of the head frame18may be overmolded onto the shoulders30of the forked end16to further resist disengagement, even if the head frame18is pulled substantially in the direction of the shaft's axis.

Alternatives to the forked end16are also possible. For example, as shown inFIG. 5, the shaft12may terminate in a flat, disk-shaped element70that has a diameter larger than the diameter of the shaft12. This disk70may be integral with the shaft12or may be otherwise secured to the terminal end of the shaft12. In this embodiment, the head frame18may be overmolded onto the disk and, if desired, a portion of the shaft12proximate the disk70, thereby securing the head frame18to the shaft12. In another embodiment illustrated inFIG. 6, the shaft12terminates in a T-shaped end portion72. It will be understood that other flared terminal ends are also possible, the purpose being to increase the contact area between the head frame18and the terminal end of the shaft12. Still other embodiments may incorporate one or more openings either completely or partially through the terminal end of the shaft12. During overmolding, the head frame material may be introduced into the holes to secure the frame18to the terminal end.

Although the embodiment depicted inFIG. 1shows the overmolded head terminating at the wrapping portions62, alternative embodiments may extend the overmolding a predetermined distance along the length of the shaft12. Such an overmold may extend to and/or beyond the bases28a,28bof either or both tines22a,22b. This may provide a more secure connection of the two elements16,18. Other overmolds may form a handle as described above, or may be used to reinforce the connection between the forked end16and the shaft12. In the latter embodiment, the overmold functions effectively as a sheath over the point of connection of the forked end16and the shaft12. With reference toFIGS. 1-2B, the lacrosse stick10has a shaft12and forked end16that are more rigid than the head frame18. The shaft12and forked end16may be made from composite materials, which generally comprise a thermoplastic or thermoset polymer-based resin matrix impregnated with a material, such as a fiber, to reinforce the matrix. Exemplary fibers include glass, polymer arimides such as KEVLAR, carbon, boron, or ceramics. A composite may include two or more different types of fibers in a single matrix. In one embodiment, the shaft12and forked end16are molded (typically by injection molding) from a plastic material, for example, CAPRON polymer produced by Honeywell Plastics. To provide greater stiffness, a reinforcing material, such as KEVLAR or the like, may be overlaid onto the plastic material. Alternatively, the shaft12and forked end16may be manufactured from any durable, lightweight metal, such as titanium. Casting, tooling, or other techniques may be used to form the shaft12and forked end16.

The head frame18may be made, for example, from a flexible plastic such as polyethylene or copolymers of polypropylene, or a durable synthetic thermoplastic material such as high impact-strength nylon. Materials such as ZYLON or ZYLON-based materials also display sufficient properties. Regardless of which material is used, generally, the head frame18material should be more flexible than the shaft12, to allow the user to properly control the lacrosse stick10during play.

As indicated above, the particular configuration of the terminal end of the shaft allows for a greater area of contact between the head frame and the shaft, providing a more secure connection than that available in prior art lacrosse sticks. One embodiment of the invention utilizes overmolding to ensure adequate connection strength between those two components. The overmolding process generally includes placing a first finished component (here, a rigid shaft) into a second mold (here, a head frame mold). By molding the flexible plastic material over the terminal end of the more rigid shaft, a single unitary device made of two different materials is produced. This overmolding process mechanically traps the rigid end of the shaft within the flexible head frame once the head frame material cools and cures. This creates a strong structural bond, free of traditional mechanical fasteners such as screws, bolts, or adhesives, that securely joins the two components together. This process allows the head frame to effectively trap any shaft, regardless of terminal end configuration. The geometry of the two components, coupled with the overmolding, produces a final device that is difficult to separate into component parts. Also, because the two components are may be made of different materials, a unitary device having different properties is produced.

While there have been described herein what are to be considered exemplary embodiments of the present invention, other modifications of the invention will become apparent to those skilled in the art from the teachings herein. The particular methods of manufacture and geometries disclosed herein are exemplary in nature and are not to be considered limiting. It is therefore desired to be secured in the appended claims all such modifications as fall within the spirit and scope of the invention. Accordingly, what is desired to be secured by Letters Patent is the invention as defined and differentiated in the following claims.