Method for manufacturing a lacrosse head pocket

A lacrosse head pocket includes a plug unit having first and second plugs disposed on a cross lace. The plugs are overmolded by first and/or second runners constructed from a polymeric material so that the plugs are joined with the first and/or second runners. The cross lace extends outwardly from the plug and the overmolded first and/or second runners. Some plug units can have cross laces that cross one another, while other plug units might not include cross laces that cross one another. A method is also provided including: forming a first plug on a first cross lace, placing the first plug in a mold, overmolding a first runner over at least a portion of the plug so the plug and first runner are joined, and optionally overmolding a second plug joined with the cross lace with a second runner or the same first runner.

BACKGROUND OF THE INVENTION

The present invention relates generally to lacrosse equipment, and more particularly, to a lacrosse head pocket and a related method of manufacture.

Conventional lacrosse sticks include a head joined with a handle. The head includes a frame that forms a region within which a lacrosse ball can be caught, held or shot. A netting structure is joined with the back side of the frame, typically laced through multiple small holes defined by the frame. The netting structure typically forms a pocket within which the ball is held while a player is in possession of the ball, and can be a determinant factor as to the player's ability to catch, retain and shoot the ball.

Many conventional pockets wear out after extensive play, and are subject to change in performance due to climate. The mere thought of replacing a pocket can be daunting to many, particularly younger or less experienced lacrosse players. The reason for this is because most pockets require a complex lacing procedure, which is mastered by only a limited number of individuals, to secure the netting to a lacrosse frame in a desired pocket configuration. Thus, many lacrosse players, particularly youths and newcomers to the sport, are left at the mercy of having to wait for their lacrosse sticks to be restrung by someone else, and even then, after the pocket is strung, they usually must wait several weeks or months until it is properly broken in. In addition, many conventional pockets are constructed from lacing and/or conventional leather thongs. When rained upon, or when heated, these components sometimes can perform differently from ideal conditions, which can present inconsistency in the feel and performance of the pocket.

Some manufacturers have attempted to resolve the above issues, but few have succeeded. A decent approach is implemented in a pocket called the Paramount, commercially available from Warrior Sports, Inc., of Warren, Mich. Certain technology of this pocket is presented in U.S. Pat. No. 8,500,577 to Winningham, hereby incorporated by reference, which generally describes a pre-formed pocket including single layer polymeric runners, which in some cases are joined with one another via cross pieces constructed from a nylon webbing, which is overmolded directly by the single layer runner material. While the Paramount pocket provides an easy-to-install, climate resistant runner pocket, its runners are disposed a fixed distance from one another. In some cases, this can affect the way that a lacrosse ball is caught within or shot from the pocket. In further cases, the pocket is slightly less dynamic, and less able to react to movement of the ball within it. Thus, while the above systems work, there remains room for improvement.

SUMMARY OF THE INVENTION

A lacrosse head pocket that is durable and easy to replace relative to a lacrosse head is provided. A method of making the pocket is also provided.

In one embodiment, the lacrosse head pocket includes a plug unit having first and second plugs disposed on a cross lace. The plugs can be overmolded by first and/or second runners constructed from a polymeric material so that the plugs are inextricably joined with the first and/or second runners.

In another embodiment, the cross lace can extend outwardly from the plug and the overmolded first and/or second runners. Some plug units can have cross laces that cross one another, while other plug units might not include cross laces that cross one another.

In still another embodiment, the plugs can be molded to opposing ends of the cross laces, leaving a central portion of the cross lace exposed and not concealed or covered by the plugs. Optionally, the plugs can be formed as first and second plugs disposed at opposite ends of the cross lace.

In yet another embodiment, the length of cross lace exposed between the respective plugs can vary, depending on the intended location of the plug unit between the scoop and base of a lacrosse head to which the pocket is attached. For example, some plug units can include exposed cross laces between the plugs of a first length, while other plug units can include exposed cross laces between the plugs of a second length, where the second length is greater than the first length or vice versa.

In even another embodiment, the distance by which the plugs are separated along a cross lace can be modified in different regions between the scoop in the base. For example, near the base, the plugs of first plug units can be separated along the cross lace by first distance. Thus, near the base, where the plugs can be attached to respective first and second runners, the runners can separate from one another by the first distance. Near the scoop, the plugs of second plug units can be separated along the cross lace by a second distance, which is greater than the first distance. Thus, near the scoop, where the plugs are attached to the respective first and second runners, the runners can separate from one another by the second distance. Because the second distance is greater than the first distance, in some cases this can provide better grip to the ball as it transitions along the pocket.

In a further embodiment, the pocket can include a first plug unit and a second plug unit, each including respective plugs and cross laces. The cross lace of the first plug unit and the cross lace of the second plug unit can be transverse to one another, crossing over one another in transitioning from a first runner to an adjacent second runner. In these regions as well, the cross laces can be curved as they extend between the first runner and the second runner. Thus, when a ball travels over the first and second plug units, the force generated by the ball can cause the cross laces of the respective first and second plug units to straighten, which operates to separate the first second runners from one another, more than when no ball is present near those plug units.

In still a further embodiment, a method is provided including: forming a first plug on a first cross lace, placing the first plug in a mold, and overmolding a first runner over at least a portion of the plug so the plug and first runner are inextricably joined.

In yet a further embodiment, the method includes forming a second plug on the first cross lace distal from the first plug, placing the second plug in the mold simultaneously with the first plug, and joining the second plug with the first runner by overmolding the second plug with the first runner. In this manner, the cross lace extends outward from the first runner and then back to the first runner. Optionally, a similar return cross lace on a second runner can be interlooped with the first lace to connect the respective first and second runners.

In still a further embodiment, the method includes forming a second plug on the first cross lace distal from the first plug, placing the second plug in the mold simultaneously with the first plug, and joining the second plug with a second runner by overmolding the second plug with the second runner. In this manner, the cross lace extends outward from the first runner toward the second runner and directly joins the first runner with the second runner. Optionally, cross laces of different plug units can be crisscrossed with one another in preselected regions.

In even a further embodiment, the plug units can be joined with the respective first and second runners so that at least a portion of the cross lace is curved and/or rounded as it extends from the first runner to the second runner, or from the first runner back to the first runner. With these curved or rounded sections of the cross lace, the cross lace can straighten when a ball pushes against the first and second runners. When this occurs, the cross lace can enable the runners to move a first distance away from one another to a second, greater distance away from one another.

In yet another further embodiment, the runners can be constructed from a polymeric material, for example, thermoplastic elastomers, such as thermoplastic polyurethane (TPU), thermoplastic copolyester, thermoplastic polyamides, polyolefin blends, styrenic block polymers, and/or elastomeric alloys, as well as rubber, formable but flexible resins, hydrophobic flexible materials, and/or other similar flexible materials. The plugs can be constructed from similar materials, but can have different physical properties from the runners, such as different durometers, tensile strength and/or elasticity.

The lacrosse pocket and method herein provide a lacrosse net structure that is easily replaceable relative to a lacrosse head, even by youth and newcomers to the sport. Multiple different, custom pocket profiles can be formed with the present method, thereby offering a high degree of pocket customization to lacrosse players. Where the material is constructed from hydrophobic or waterproof materials, the pocket is virtually unaffected by weather changes, temperature changes and moisture, which enables it to have a substantially consistent profile and configuration throughout such conditions. Further, due to the plug units and different structures of the cross laces, the runners can dynamically move relative to one another when forces are exerted on the runners by a lacrosse ball within the pocket. In turn, this can provide enhanced ball control and shooting accuracy.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A current embodiment of a lacrosse head pocket is shown inFIGS. 1-6and generally designated10. The lacrosse head pocket10is secured to a frame112to form a strung lacrosse head100. The lacrosse head100can be further joined with a handle (not shown) to form a lacrosse stick. As shown inFIG. 1, the lacrosse pocket10includes first21and second22runners which are longitudinally disposed along a pocket longitudinal axis LA. Although shown as being generally parallel to the axis LA, the runners21and22can diverge or converge toward one another, and optionally can change the distances D1and D2between these elements as described below.

The respective runners21,22can be formed as elongated unitary, runners overmolded and joined with one or more plug units30,40,50to hold those units in a fixed position relative to the runners, which in turn secure the first and second runners to one another. The plug units themselves can include first31,41,51and second32,42,52plugs that are joined via respective cross laces33,43and53. The cross laces33,43,53can be transverse, and optionally perpendicular, to the runners. The cross laces33and43can be curved or rounded, and attached via plugs to the respective runners in a staggered manner. In some cases the cross laces33,43can cross or extend transversely relative to one another, crisscrossing one another as they extend from the first runner to the second runner. With this combination of crisscrossed and/or rounded or curved cross laces, the runners21,22can dynamically move relative to one another as a lacrosse ball101travels along the pocket10, as explained further below. This can enhance the shooting and catching capabilities of the pocket, and in turn improve the overall confidence of a player using the same.

Construction of the current embodiment ofFIGS. 1-7will now be described. The pocket10is described in connection with a women's lacrosse head100. The pocket, however, can be readily used with men's lacrosse heads. The pocket10can be joined with a lacrosse head100, and in particular, the frame112, which includes a base113, a pair of opposing sidewalls116, and a scoop118joining the pair of opposing sidewalls opposite the base. The lacrosse head100can include a socket extending rearward from the frame for attachment to a lacrosse handle (not shown). A lacrosse ball101can be caught or shot along the pocket10.

The sidewalls116and/or scoop can define multiple netting structure connections117, which as shown, can be holes that pass through the scoop, sidewalls or the frame. Optionally, the netting structure connections can vary in number, size and location from those shown in the figures. Even further optionally, depending on the application, the netting structure connections can be replaced with other alternative structures, such as a series of hooks or posts (not shown) that allow the attachment ends of the netting structure to be joined with the frame112.

The pocket10can be joined with the frame112in a variety of manners. For example, the runners21,22can include throat ties21T and22T that can be tied in a conventional manner to the frame112. The runners21,22also can include upper ends21E and22E, each defining a respective hole21H and22H that receive secondary lacing118to secure those ends to the scoop118. The pocket10can also be connected to the sidewalls and other portions of the frame element113via additional net lacing which is looped around the runners21,22, extending toward the sidewall, scoop and/or base.

With reference toFIG. 2, the runners will be described in more detail. In particular as shown inFIG. 2, only the first runner21is illustrated. It will be appreciated that the second runner22can be similar to the first runner so the second runner will not be described again here. The first runner21can include a first end21E and a second end21F distal from one another. The first end21E can define a first hole21H, which as mentioned above is configured to receive lacing to attach that end to the frame. The second end21G can be structured so that it is overmolded over the end of the throat tie21T, thereby joining the throat tie to the body of the first runner.

The first runner21can include a first or front surface21F and a second or rear surface21R, as shown inFIG. 2. Usually, the first surface21F can generally face the front side of the head, so that it can contact the ball101, while the rear surface21R can generally face the rear of the head100, where it does not contact the ball. In some lacrosse activities, however, such as face-off or the draw, the rear surface21R will contact the ball101while a player takes the draw. The first runner21also can include an inner surface211which faces generally toward the longitudinal axis LA, and also faces toward the inner surface221of the second runner22. All of the first, second and inner surfaces of the runner21can extend generally from the first end21E to the second end21G of the runner.

The first runner21can include multiple different regions along its length, as can the second runner21. For example, as shown inFIG. 2, the first runner can include multiple join units21J1,21J2which are intermittently disposed along the length of the runner. These join units21J1and21J2are integrally and monolithically formed with the intersection units21K1and21K2, which themselves are intermittently disposed among the join units along the length of the runner21. As further described below, these intersection units contain or otherwise are joined with portions of plug units. Generally, due to this inclusion of the portions of the plug units within the intersection units, the intersection units21K1and21K2can be of a width W1that is greater than a width of the join units W2as illustrated inFIG. 1. This can promote weight savings yet still adequately anchor the plugs of the respective plug units within the material from which the runner is constructed. The width W1can in some cases be twice the width W2, or some other multiple. As an example W1can be 10 mm and W2can be 5 mm. In addition, by having a slight taper in the surfaces of the intersection units at width W1, there can be more pocket flexibility when the pocket is moving from front to back, or in a throwing/catching motion of the pocket.

As shown inFIG. 2, the first runner21can include different thicknesses, as can the second runner. For example, the join units21J1and21J2can define thicknesses T1. In contrast, the intersection units21K1and21K2can define thicknesses T2. The thickness T2can be approximately twice the thickness T1. As an example, the thickness T2can be about 5 mm to about 10 mm, while the thickness T2can be about 2 mm to about 4 mm. The increased thickness T2can effectively accommodate the height of a respective plug of a plug unit that is overmolded by the first runner or second runner.

The first runner21from the scoop end21E to the throat tie end21G can generally be of a length suitable for the appropriate lacrosse head, generally ranging from optionally 22 centimeters to 28 centimeters, further optionally from 23 centimeters to 25 centimeters, and further optionally 24 centimeters. Of course other dimensions may be suitable, depending on the application.

The cross section of the runners taken perpendicular to the longitudinal axis LA also can vary. For example, the runners can be rectangular with rounded edges in the region of the join units21J1,21J2. In the region of the intersection units21K1,21K2, the cross section can be generally rectangular, with the upper and lower surfaces being convex or concave if desired. Of course, these cross sections can be of a variety of other shapes, including circular, triangular, square, diamond shaped, polygonal or irregular shapes.

The first and second runners can be constructed from a variety of polymeric materials, which include, but are not limited to, elastomeric materials, such as the thermoplastic polymers, thermoplastic polyurethane, thermoplastic resins, thermoplastic copolyesters, thermoplastic polyamides, polyolefin blends, styrenic block polymers, and elastomeric alloys, as well as rubber, formable but flexible resins, hydrophobic flexible materials, or similar flexible materials, or combinations of the foregoing. Where the material is hydrophobic, the runners and the resulting pocket can be resistant to shrinkage or shape alteration due to moisture, and in many cases changes in ambient temperature.

Optionally, the entire structure of each runner is formed from a single, monolithic piece of polymeric material, having different thicknesses and cross sections of components as desired.

As shown inFIGS. 1 and 2, each of the respective runners21,22can be joined directly with the respective plug units30,40,50. This is accomplished via the plugs31,41,51being overmolded by the first runner, and in particular the polymeric material for which the first runner is constructed, and the plugs32,42,52, likewise being overmolded by the second runner. As used herein, the term overmolded can refer to insert overmolding, in which one polymeric material, sometimes elastomeric, is molded over a second substrate material (optionally a plug and/or cross lace herein), which can be in the form of a rigid already formed object. Further, when an object, such as a plug, is considered overmolded by another object, such as a runner, it is considered that this provides a structural relationship between the parts, rather than simply a process by which the parts are joined. For example, a plug or plug unit overmolded by a runner is joined at a plug/runner interface having a high level of molecular adhesion between these components. The runner thereby is mechanically joined with the plug or plug unit, and also can be joined directly with the plug or plug unit on a molecular level at the interface of the runner and plug or plug unit.

The plug units, and their respective components such as the plugs and cross laces will now be described in further detail. Optionally, a pocket constructed in accordance with the embodiments herein can include different combinations of plug units30,40and50as described above in combination. Of course, a pocket can also be constructed so that it includes only one of these different types of plug units. For example, a pocket can include only plug units50, only plug units40and/or only plug units30. Alternatively, additional types of plug units can be formed and included in the constructions. It is also contemplated herein that when the plug units are formed, the plugs themselves can be formed along different portions of the cross lace. For example, instead of being formed at a terminal end, a cross lace, a plug can be formed about a third of the distance between a first end and a second end, while another plug can be formed about two thirds of the distance between that first end and second end. Plugs can generally be formed anywhere along the cross lace in those, depending on the particular application.

Referring toFIG. 1, there can be different constructions for the respective plug units30,40and50. As an example, the unit30, as shown inFIG. 4, can include a first plug31and a second plug32. These plugs are joined via the first cross lace33. In particular, the first end31E1of the cross lace is overmolded by the first plug31. The second end33E2is overmolded by the second plug32. Accordingly, each of the respective plugs are in inextricably joined with the cross lace, and unable to be removed therefrom without damaging the structure of one or both of these components.

This plug unit30can be constructed so that the cross lace separated the first plug31and the second plug32, as shown inFIG. 5, by predetermined distance L1. This distance L1illustrates the plug unit in a straightened configuration. When installed within the pocket10and joined with the respective first and second runners21,22, however, the cross lace33attains the rounded or curved shape shown inFIG. 4andFIG. 1. This rounded shape can be an S-shape or a reverse S-shape. It will be appreciated that when the plugs31and32are moved away from one another, the S-shape straightens from the configuration shown inFIG. 4, more toward an elongated configuration shown inFIG. 5as described in further detail below.

As noted above, the plug units30and50can be different from one another. This can be due to the differences in the lengths of the respective cross laces between plugs in a plug unit. InFIG. 6, plug unit50includes a cross lace53extending between a first plug51and a second plug52. The length L2of this cross lace53can be less than the length L1. For example, the length L2extending between the respective first and second plugs51and52can be 1, 2, 3, 4, 5, 10 mm shorter than the length L1of the cross lace33extending between the respective first and second plugs31and32. This shorter length L2can provide a relatively fixed distance between the first and second plugs51and52along a portion of the pocket near the base or middle of the pocket. Thus, a ball101traveling along the respective first and second runners21,22generally will not push those first and second runners away from one another, changing the distance between the runners.

In contrast, with the rounded or curved configuration of the cross lace33in the plug unit30, near the ramp of the pocket10and/or the scoop118of the head100, that type of cross lace can convert from the rounded or S-shape configuration to a more straightened configuration of the cross lace33′ as shown in broken lines inFIG. 1. This conversion or straightening of the cross lace can occur when a lacrosse ball101exerts forces on the respective first and second runners21and22, thereby forcing those runners to separate from one another. This is further illustrated inFIG. 1, where in an unloaded state, the first cross lace33and second cross lace43maintain the runners at a distance D1from one another. This distance D1can be achieved when a ball is not resting adjacent these cross laces or where the stick is generally static. However, these cross laces33and34can convert from the rounded or curved shape shown inFIGS. 1 and 4to a generally straightened shape shown in broken lines, for example at33′ inFIG. 1, particularly when a lacrosse ball101rolls or is forcibly shot along the pocket10. The forces F from the ball on the runners push the runners outward, away from one another, and generally away from the pocket longitudinal axis LA. In this manner, the runners separate from one another to a dynamic or extended distance D2from the static distance D1. This allows runners and thus the pocket to dynamically guide the ball along the pocket. When the ball passes beyond those cross laces, or otherwise exits the head, the runners no longer have the force of the ball F being exerted thereupon. Therefore, the runners return to a static state in which the cross laces33and43retain their generally rounded or curved shapes, and the runners reattain the static distance D1therebetween.

The plug units50can operate differently from the above plug units30,40. Plug units50can maintain the runners generally consistently at the distance D1from one another. This distance D1can be maintained via the cross lace53of the length L2(FIG. 6), even when the lacrosse ball101exerts forces F upon the runners21,22. This is because the cross lace53of the plug units50generally extends perpendicular to the pocket longitudinal axis LA of the pocket10. Thus, there is no slack or slack that can be taken up along the length L2of the cross lace53to enable the runners to move away from one another.

Returning to the plugs of the plug units themselves, reference is made toFIGS. 6A and 6B. In these figures, the plugs51and52are described in connection with the plug units50. However, it will be understood that the plugs of this plug unit can be utilized equally in any of the other types of plug units described herein. As shown inFIG. 6B, a first plug51is shown. It further will be appreciated that the opposing second plug52can be similar or identical to this plug, but reversed in construction. The first plug51can include an upper surface51U and a lower surface51L. These surfaces are joined and transition to with a side surface51S. The side surface optionally can form a cylindrical shape. Alternatively, although now shown, this side surface51S can form a spherical shape or other irregular, or polygonal shape depending on the application. The upper surface51U can transition at a shoulder51N directly to the side surface. Optionally, the upper surface51U can be flat, convex and/or concave. Likewise, the lower surface51L can be convex, concave or flat, depending again on the application. Optionally, the upper surface51U can be shaped differently from the lower surface51L. For example, the upper surface51U can be flat while the lower surface can be convex. The upper surface and/or the lower surface can face upward so that it can contact a ball101moving along the pocket. Optionally, the upper surface51U can transition directly to a shoulder41S of the runner that is overmolded over the plug51. This portion of the shoulder can also be generally convex and/or stepped so that the upper surface51U of the plug51and that shoulder41S of the runner smoothly transition to one another and provide sufficient engagement with a lacrosse ball101traveling along a lacrosse pocket.

As shown inFIG. 6B, the plug51can include a projection or flange51F. This flange can extend radially outward away from the longitudinal axis PLA of the plug51between the upper surface51U and the lower surface51L. The flange51F can project outwardly from the side surface51S. The flange can be located about midway between the respective upper and lower surfaces, or it can be offset closer to one of these two surfaces, depending on the particular application. Further, the flange51is shown as a generally continuous structure circumferentiating the plug. In other constructions, it can be in the form of multiple individual and isolated projections extending outwardly from the side surface51S. In other cases, it can be in the form of multiple threads or ridges extending outward from the side surface51S of the plug.

FIG. 6Aillustrates the flange51F being overmolded and generally encapsulated by the material from which the first runner21is constructed. Generally, the flange51F can provide additional structural and mechanical attachment of the plug to the material from which the runner is molded. This can prevent the removal of the plug from the surrounding runner structure upon the application of excessive force during use of the pocket.

As shown inFIG. 6Bthe cross lace53optionally can extend outward within a portion of the flange51F. In this case, the flange itself is molded over at least a portion of the cross lace53. As also shown inFIG. 6B, the plug51can define a bore51B. This bore51B can be formed when the cross lace is overmolded by the polymeric material from which the plug is constructed. The bore also can be formed due to pins that project into a mold cavity in which the plug51is formed. These pins, as described in further detail below, can anchor and hold the respective ends of the cross lace53in position so that when the plug51is formed from a polymeric material, it satisfactorily overmolds and bonds directly to the end53E1of the cross lace53.

The cross lace33can be a string, lace, cord, web or other elongated member that is comprised of one or more strands of yarn, filament, or other smaller elongated elements. In the embodiment illustrated, the cross lace can be constructed from nylon string. Of course, combinations of different stranded materials such as nylon and Kevlar can be utilized in some constructions. Generally, the cross lace can have a diameter of 1 mm to 4 mm, further optionally 2.5. Other diameters for the cross lace can be utilized depending on the particular application and the forces to be applied to the cross laces.

The bores51B of the plugs51can be constructed so that they are not concealed or molded over by the runners21when the plugs themselves are overmolded. For example, as shown inFIG. 6A, the bores51B can be aligned with a bore21B that is defined within the upper surface21U of the respective first runner. The aligned bores51B and21B of the respective plug and runner can also provide a viewer V with a visual confirmation that the cross lace53is fully molded within the plug and satisfactorily anchored therein. In addition, as shown inFIG. 6A, a portion of the upper surface51U of the plug51extends slightly upwardly above the uppermost surface of the upper surface21of the runner. If desired, of course, this upper surface51U can be generally flush with and transition directly to the upper surface21U of the runner. In this construction, optionally the upper surface51U of the plug is generally visible along the upper surface21U of the runner. To attain this construction, the runner21is overmolded over the side51S and flange51F of the plug, but not over the entire upper surface51U of the plug. The same effect can be realized with the lower surface51L of the plug so that it is visible within the lower surface21L of the runner21. This visibility can be enhanced by utilizing contrasting colored material to form respective plugs and runners. Without the contrasting material, colors, it might be difficult to discern the plugs from the runners.

FIG. 6Aalso illustrates attachment of the cross lace to the plug and runner. Optionally, the cross lace53is overmolded by the plug51so that the end53E1of the cross lace extends at least through the bore51B of the plug51. The cross lace further extends outwardly toward the longitudinal axis LA of the pocket, generally toward the second runner22. The cross lace thus crosses through at least a sidewall51SW (FIG. 6B) of the plug51. It also can pass through an inwardly facing sidewall21SW of the runner as well as an inner surface211associated with the outermost extent of that sidewall21SW. Thus, in traversing toward the longitudinal axis LA, the cross lace53can extend through a portion of the plug, the plug as well as a portion of the runner molded over the plug. Because the plug is covered by the overmolded runner on the side of the runner near the longitudinal axis LA, it can appear that the cross lace projects merely from the runner, as the plug is concealed under the sidewall21SW of the runner. Optionally, in the location where the cross lace extends through the plug sidewall S1SW and the runner sidewall21SW, two parallel and aligned bores are formed, one within the plug and the other within the runner.

III. Method of Manufacture and Use

A method of manufacturing the lacrosse pocket10of the current embodiment will now be described with reference toFIGS. 1-6B, 9, 9A and 10. In general, the pocket10is configured, shaped and dimensioned to fit a lacrosse head100including opposing sidewalls extending between a scoop118and a ball stop113as shown inFIG. 1. To manufacture this pocket, different molding techniques, and separate molds with separate materials can be utilized. For example, the cross laces can be joined with respective plugs to form plug units in a first molding process. Those completed plug units can be taken and utilized in a second molding process, in which the plug units are configured as desired within a mold. First and second runners (and any additional runners, if such are desired) can be overmolded over the respective plug units and portions thereof to join those plug units with the runners in a predetermined configuration.

Turning toFIGS. 9 and 9A, a first or plug unit mold70is provided. The plug unit mold can include a first mold portion71and a second mold portion72shown in broken lines. This first mold70can define a first plug cavity71P1and a second plug cavity71P2. These plug cavities are spaced a preselected distance D3from one another. Generally, this distance can correspond to the lengths L1or L2or other lengths of the cross laces that are desired to be exposed between the respective plugs in the finished product. The plug cavities71P1and71P2can include internal surfaces that correspond to the respective external surfaces of a finished plug, for example, those surfaces shown inFIGS. 6A and 6Band described above.

The first mold70can include or define a retaining channel73extending between the respective plug cavities. This retaining channel73can accommodate a cross lace33placed within the mold to hold it in a predetermined location, particularly so that the ends33E1and33E2thereof project satisfactorily into the respective mold cavities71P1and71P2to achieve a desired bonding of injected material with those ends. The first mold70also can include a supply S of a first polymeric material that can be injected into the mold70.

After the cross lace33is satisfactorily placed in the retaining channel, and the ends extend satisfactorily into the respective plug cavities, the first polymeric material is introduced into the cavities71P1and71P2. When this first polymeric material enters the cavities, it can fill them substantially. It also extends over and encapsulates or otherwise overmolds at least a portion of the cross lace33, and in particular the cross lace ends. The polymeric material introduced in the cavities generally flows within the interstitial spaces between strands from which the cross lace33is constructed. It also bonds directly to and impregnates portions of the ends of the cross lace33.

After the polymeric material is satisfactorily introduced into the cavities to form the respective plugs, the material is allowed to cure, thereby forming a first plug and a second plug in the respective plug cavity and second plug cavity. These plugs are disposed a distance D3(or L1or L2) from one another along the cross lace33. The respective first plug, second plug and cross lace form the first plug unit upon curing. The plug unit50can be removed from the first mold70and generally will appear as the plug units shown inFIGS. 4-6 and 6B, and will include the features described in connection with those plug units.

Optionally, the first mold70can be modified slightly as shown in the alternative construction inFIG. 9A. There, the first mold70′ defines a mold cavity71P′ which is similar to the mold cavity shown inFIG. 9. However, this mold cavity can include additional pins or projections75P′ and76P′. These pins can extend inwardly from upper and lower portions of the cavity71P′. They can be of a preselected dimension so that the ends of these pins gage the end33E1of the cross lace33and pinch it with sufficient predetermined force to hold that end in a fixed location during introduction of the polymeric material into the mold cavity to form the respective plugs. These pins can be cylindrical in shape. Of course, other shapes can be utilized depending on the particular application. Optionally, the pins, when removed from a cured plug, can assist in forming a bore51B, for example as shown inFIG. 6B.

Further optionally, the molds used herein can be configured to accommodate single cross laces or multiple cross laces. For example, the mold70shown inFIG. 9can be replicated to form an array of identical molds configured to form multiple individual plug units. With this construction, mass production of the plug units can be facilitated. Further, the first mold70can be modified to accommodate and form plug units having different lengths between the respective plugs. In this manner, different plug units such as30and50can be formed having different lengths.

Returning to the method of constructing the pocket of the current embodiment after the respective plug units are formed, they can be placed in a second mold80as shown inFIG. 10. There, only plug units50are illustrated, but of course, other types of plug units such as30and40can likewise be installed in the mold in respective locations. The plug units50are disposed in the second mold80, with the already formed first plug51disposed within a first runner cavity91. The second plug52is disposed in a second runner cavity92. These plugs can be located in specific enlarged portions91E and92E of the runner cavities92to accommodate those plugs. Other portions of the runner cavities can be of a reduced dimension, for example, region91R and92R can be of smaller dimensions than the enlarged portions91E and92E. This can be so that the runner cavity corresponds to the dimensions and shapes of the runners as described above in connection withFIGS. 1-3. The respective cross laces53of the already formed plug units50can be disposed in retaining channels93. These retaining channels can help properly position the plugs51and52within the respective portions of the first and second runner cavities91and92.

After the plug units have been satisfactorily placed, the second mold80is closed via the second mold portion82being closed against the first mold portion81to complete the respective runner cavities. After the mold is closed and the runner cavities are complete, a second polymeric material is introduced from a supply into the second mold80.

Optionally, the second mold portion82and/or the first mold portion81can include pins82P that are configured to fit within the bores51B of the plugs. This can further assist in centering and precisely placing the plugs within the runner cavities91and92.

With the second mold80closed, a supply S of the second polymeric material is introduced into the cavities91and92. This second polymeric material encapsulates the plugs51and52and a small portion of the cross lace53that extends into those cavities. As mentioned above, certain portions of the respective plugs might not be engaged by the material, allowing those surfaces to be exposed in a final product. During the injection process, in the second mold80, a second polymeric material can substantially engage the side surfaces51S and flange51F of the plug51, but can be restrained from engaging the upper51U and/or portions of the lower51L surfaces of that plug51. Of course, depending on the particular applications, different portions and different surfaces can be engaged by the polymeric material to bond the runners to the plugs. Optionally, the second polymeric material is molten and at a specific temperature. This temperature, however, is insufficient to substantially melt or deform the respective plugs. Thus, the plugs retain their structure even as they are overmolded by the runner material.

After the second polymeric material cures, the second mold80is opened. When the pocket10is removed from the second mold, the respective cross laces that extend between the first runner and the second runner secure those runners to one another.

Optionally, the second polymeric material used to mold the runners can be different from the first polymeric material used to construct the plugs of the plug units. For example, the second polymeric material can be constructed so that it has a lower melt temperature than the first polymeric material, and/or the first polymeric material has a softer durometer than the second polymeric material. As a further example, the second material of the runner can have a durometer of 60 on the Shore A scale. The first material of the plugs can be 80 to 100, or 50 to 100 on the Shore D scale, or a harder durometer, depending on the application.

When the plug units30and40are placed in the second mold80, the respective cross laces33,43of those units can be oriented transverse to one another, and specifically can cross over one another. This is illustrated inFIG. 3where the cross lace33crosses over the cross lace43at the cross intersection C. In this construction, the plug units30and40are also configured so that their respective plugs, for example31and32, or41and42, are not disposed diametrically across from one another across the longitudinal axis LA. Instead, a first plug31of the first plug unit30is disposed diametrically across from the second plug42of the second plug unit40. Likewise, the first plug unit41is disposed diametrically across the longitudinal axis LA from the second plug32of a second plug unit30. In this manner, the respective plugs of a plug unit can be offset or staggered from one another along the lengths of the respective first and second runners21and22.

IV. First Alternative Embodiment

A first alternative embodiment of a lacrosse pocket is illustrated inFIGS. 7 and 8and generally designated110. This pocket110is generally identical to the pocket of the current embodiment described above with several exceptions. For example, in this embodiment, the pocket110includes first121and second122runners. It also includes one or more different types of plug units130,140and150. The plug units150can be identical to the plug units50described in the current embodiment above. In this embodiment, however, plug units130,140are formed so that their cross laces are attached and joined directly with only one of the two runners. For example, the plug unit130includes a first plug131which is joined with a first cross lace133. To an opposite end of the cross lace, a second plug132is joined. The plugs131and132of the plug unit130, however, are consecutively spaced along the length of the runner121. Thus, instead of one plug being disposed in and overmolded by one runner and another, second plug being disposed in and overmolded by a second runner122, both of the plugs131and132of this plug unit130are overmolded and disposed within the first runner121only. The same is generally true for the second plug unit140, however, its plugs141and142are disposed and overmolded by the second runner122.

These plug units operate to cooperatively join the first121and second runners122. This is achieved by interlooping the cross lace133of the plug unit130with the cross lace143of the second plug unit140. This construction forms an interloop I located between the first runner121and second runner122, optionally along the longitudinal axis LA. With this type of interlooped cross laces, and particularly the curved or rounded construction of the respective cross laces, those cross laces can elongate upon reconfiguration, thereby enabling the first and second runners to move dynamically away from one another when a force by a ball is exerted upon those runners.