Abstract:
A hand-held implement grip and protectant, preferably for a hockey stick, is described. The invention mainly consists of a blade attached to a composite shaft integrally enshrouded with a rubber sheath. A method of forming the same is also provided as laying up a number of sheets of composite material, wrapping those sheets about a mandril, enshrouding the layup with a rubber sheath, vulcanizing the combination, removing the mandril, and inserting a blade therein.

Description:
FIELD OF THE INVENTION 
     This invention relates to hand-held implements, especially sports equipment, such as hockey sticks. More specifically, the instant invention is directed to a hockey stick handle formed from composite material having an integrally formed outer elastomeric shroud to protect the composite material and improve gripping ability. 
     BACKGROUND OF THE INVENTION 
     The necessity for adequately gripping hand-held implements has been a long-known and recurring problem. A variety of grips have been explored, but problems still persist. Although it is known to include a rubberized grip about the handle of an implement, certain drawbacks still exist. 
     One problem encountered with prior art gripping means (such as U.S. Pat. Nos. 5,050,289 and 5,005,254) is the slippage of the grip vis-à-vis a handle. Whether a grip is glued to a handle or friction-fitted, such rubberized grips have a tendency to dislodge from a shaft. Furthermore, the longer the shaft, and the longer the grip vis-à-vis the shaft, the greater the likelihood of the grip rolling up on itself or slipping. Many attempts have been made to correct this problem, but to no avail. Ultimately, the hand-held implement is either replaced, or the grip is replaced, wasting much time and material. 
     Another problem involves the now frequent use of hockey stick shafts formed from composite material. “Space-age” materials, such as Kevlar®, boron and graphite, while extremely strong in compression, tension and flexing, have been found to be susceptible to fracture when sharply impacted, such as by a hockey puck or another hockey stick. 
     It is desirable therefore to provide a hand-held implement with a resilient grip capable of extending a greater distance along the hockey stick shaft, and providing a grip that endures greater impacts and pressures without fracture or slippage. 
     One particular application where a shock damping is desirable along an entire shaft and where a grip is required to adhere strongly is that of a hockey stick. Currently, hockey stick grips tend to be just near the top of a shaft and are of a short length. If extended further down the shaft, or preferably all the way down the shaft, the grip tends to slip, roll or bunch in the prior art. To overcome these problems would be a great benefit to the sport and overall safety. 
     The following prior art reflects the state of the art of which applicant is aware and is included herewith to discharge applicant&#39;s acknowledged duty to disclose relevant prior art. It is stipulated, however, that none of these references teach singly nor render obvious when considered in any conceivable combination the nexus of the instant invention as disclosed in greater detail hereinafter and as particularly claimed. 
     
       
         
               
               
               
             
           
               
                   
               
               
                 INVENTOR 
                 ISSUE DATE 
                 PATENT NO. 
               
               
                   
               
             
             
               
                 2,201,706 
                 Sukohl 
                 05-21-1940 
               
               
                 2,649,133 
                 Just 
                 08-18-1953 
               
               
                 2,674,557 
                 Boggs 
                 04-06-1954 
               
               
                 2,964,065 
                 Haroldson, et al. 
                 12-13-1960 
               
               
                 3,020,192 
                 Stephens, et al. 
                 02-06-1962 
               
               
                 3,125,478 
                 Pratt 
                 03-17-1964 
               
               
                 3,606,326 
                 Sparks 
                 09-20-1971 
               
               
                 4,016,640 
                 Briggs 
                 04-12-1977 
               
               
                 4,080,879 
                 Hoden, et al. 
                 03-28-1978 
               
               
                 4,134,198 
                 Briggs 
                 01-16-1979 
               
               
                 4,273,601 
                 Weingart 
                 06-16-1981 
               
               
                 4,579,617 
                 Oberg, et al. 
                 04-01-1986 
               
               
                 4,923,541 
                 Burger 
                 05-08-1990 
               
               
                 5,005,254 
                 Uffindell 
                 04-09-1991 
               
               
                 5,024,712 
                 Lecourt, et al. 
                 06-18-1991 
               
               
                 5,050,289 
                 Uffindell 
                 09-24-1991 
               
               
                 5,373,616 
                 Biersdorf, et al. 
                 12-20-1994 
               
               
                 5,458,330 
                 Baum 
                 10-17-1995 
               
               
                 5,655,981 
                 Reed 
                 08-12-1997 
               
               
                   
               
             
          
         
       
     
     The prior art listed above, but not specifically discussed, teach gripping devices and further catalog the prior art of which the applicant is aware. These references diverge even more starkly from the references specifically distinguished above. 
     SUMMARY OF THE INVENTION 
     This invention is directed toward addressing the problems of providing an anti-fracture gripping means to an elongate member, such as a hockey stick shaft, wherein that gripping means will protect the underlying composite and still will be substantially free from unwanted vibration, slipping, bunching, or rolling up on itself vis-à-vis the shaft. To overcome these problems, this invention provides a means for integrally forming a grip to a shaft. This integral formation is accomplished, essentially, by forming the grip and shaft composite as an integrated unit and ultimately heating the shaft and grip combination at a desired temperature to integrate both the shaft and grip into one. 
     The most common shaft types (wood, metal, plastic) will not optimally accept heating to combine with a grip. This invention provides, in particular, for resin pre-impregnated into fiber, such as graphite impregnated with epoxy, to be heated and cured together with the grip and the invention also alternatively provides for a similar integration with thermoplastic. 
     By first wrapping epoxy-impregnated uncured graphite about a heat conductive mandril to form a shaft, a heat susceptible medium is provided. By next placing the mandril and shaft combination into a vacuum tube lined with the grip on the tube interior by evacuating the tube to conform the grip to the tube, the graphite shaft receives the grip by releasing the vacuum and next providing some pressure on the now grip-lined shaft. Thereafter, by heating the shaft and rubber sheath combination at an appropriate temperature for an appropriate amount of time, the integration of the shaft and sheath is accomplished by vulcanization. All then that remains is the removal of the mandril from the core of the shaft to provide an elongate hollow shaft integrated with a grip. With this grip provided over the entire shaft or substantially all of the shaft, it is also far less susceptible to damage versus the prior art. 
     In particular, in a hockey stick, the hockey stick handle is also to be provided with a rubberized cuff at one end to receive a blade thereafter in a hollow of the shaft. Prior to this invention, such a shaft/grip combination was not provided in the hockey sports industry. 
     OBJECTS OF THE INVENTION 
     The overall object of the present invention is to provide a handle and grip means which are integrally formed for a long-handled or shafted device, particularly a hockey stick. 
     It is a specific object of the present invention to provide a grip means on an elongate shaft that is not susceptible to slipping and delamination vis-à-vis the shaft. 
     It is another object of the present invention to provide a grip means on an elongate shaft that is not susceptible to rolling or bunching on the elongate shaft. 
     It is another object of the present invention to provide an elongate shaft, such as a graphite impregnated epoxy-type shaft cooked and cured with a rubber sheath for gripping about the entirety of the shaft to protect the graphite. 
     It is another object of the present invention to provide a method of manufacturing an elongated shaft having a grip means provided about its entirety and integrated therewith to cushion sharp blows to the shaft. 
     Viewed from a first vantage point, it is an object of the present invention to provide a hockey stick, comprising, in combination, a shaft, a blade attached to the shaft, the shaft formed from a composite layup including a hollow core, and a sheath formed from resilient material ensconcing the shaft. 
     Viewed from a second vantage point, it is an object of the present invention to provide a method for forming a hockey stick, the steps including, laying up a composite material, forming the layup of composite material about a mandril defining a layup wrapped mandril, ensconcing a resilient sheath over the layup wrapped mandril, vulcanizing the sheath and layup wrapped mandril combination, removing the mandril, and inserting a hockey blade hosel in a central core of the layup formed by removal of the mandril. 
     Viewed from a third vantage point, it is an object of the present invention to provide a hockey stick, comprising, in combination, a shaft, and a blade attached to the shaft, the shaft formed by laying up a plurality of uncured resin-impregnated sheets of composite material, forming the plurality of sheets about a mandril, defining a layup wrapped mandril, ensconcing a resilient sheath over the layup wrapped mandril, vulcanizing the sheath and layup wrapped mandril combination, and removing the mandril. 
     Viewed from a fourth vantage point, it is an object of the present invention to provide a shaft for a hockey stick, comprising, in combination, a composite layup including a hollow core, and a sheath formed from resilient material ensconcing the shaft. 
     These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of composite layers on a vacuum table. 
     FIG. 1A is an exploded perspective view of the composite layers shown in FIG.  1 . 
     FIG. 2A is a side view of a device for wrapping layup about a mandril in an open position. 
     FIG. 2B is a side view of a device for wrapping layup about a mandril in an closed operational position. 
     FIG. 3A is a cutaway perspective view of a vacuum pipe and rubber sheath. 
     FIG. 3B is the cutaway view of FIG. 3A with a layup wrapped mandril therein. 
     FIG. 3C is a perspective end view of a layup wrapped mandril enshrouded with elastomer. 
     FIG. 4 is a front cross-sectional view of that which is shown in FIG.  3 C. 
     FIG. 5 is a cutaway perspective of a heating chamber. 
     FIG. 6 is a side view of a mandril being removed from the invention. 
     FIG. 7 is a perspective view of the invention. 
     FIG. 8 is a flowchart of the method of the invention. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Considering the drawings, wherein like reference numerals denote like parts throughout the various drawing figures, reference numeral  10  (FIG. 7) is directed to a hockey stick integrally formed with a shaft and gripping means thereabout according to the present invention. 
     The grippable shaft  10  is formed of three main components: layers of a thermoset synthetic material  12 ; an elastic sheath  30 ; and a hockey blade B having a hosel  13 . 
     As seen in FIGS. 4 and 7, a grippable sheath  30  is integrally formed with a plurality of fabric layers  12  wherein the fabric layers  12  are preferably pre-impregnated graphite epoxy and wherein the sheath  30  is preferably then a rubber tube. Whereas the sheath  30  becomes integrally formed with the fabric layers  12  and the elastic cuff  14  by means of a heating and curing process. The elastic cuff is preferably made of urethane. 
     In manufacture, as first depicted in FIG. 1, as a first step, adhesive transfer sheets are removed from sheets  12  to expose the resin thereunder to other sheets  12 , save for the uppermost and lowermost sheets  12 , where transfer sheets  58  remain temporarily. Next, urethane strip  14  is added atop the stack and the entire layup  56  is placed within vacuum table  48  supported by legs  54 . When lid  52  is closed, a vacuum is produced via vacuum holes  50 , causing sheets  12  and strip  14  to be pressed together (had uppermost and lowermost transfer sheets  58  not remained, adherence to the lid  52  and/or table  48  would likely result). The size of urethane strip  14  is preferably less than both the length and width of fabric layers  12 . More preferably, strip  14 &#39;s length L is as long as the circumference of mandril  18 . 
     Next, as depicted in FIGS. 2A and 2B, the shaft  10  is formed by first providing multiple epoxy-impregnated graphite sheets  12 , having the remaining transfer sheets  58  now removed, and a urethane or rubber elastomer  14  thereby which are then wrapped about a mandril  18 . The sheets  12  are preferably the graphite type wherein the grains of graphite can be a mixture of longitudinal, latitudinal or crossed grains. That is, each individual graphite sheet  12  may have the same or different grain varieties included. One, for instance, may have graphite strands all longitudinally drawn. Another sheet  12  may have all the graphite grains perpendicular to the previous sheet  12 . Yet another sheet or sheets may have the grains of graphite running at various angles. By utilizing different grain striations on sheets  12 , different shaft strength characteristics can be achieved. By providing a strip of elastomer such as urethane  14  immediately next to sheets  12 , the elastic receptacle or cuff  14  can later be formed. 
     As the strips  12  and elastomer  14 , known as layup  56 , progress down the conveyer belt  16  as depicted in FIG. 2B, they are wrapped around and adhered to a heat conductive mandril  18 . Conveyor belt  16  is rotated by motor  22  coupled to pulleys or rollers  20 . Likewise, belt  16 , also driven by motor  22  when tightened by moving lever  68  along arrow O and activating tension means  26  and thereby raising arm  28 , will thereby rotate mandril  18  around arcuate arrow R and wrap layup  56  about it in turn. Mandril  18  with sheets  12  and urethane  14  wrapped about it is then removed. 
     As relates more particularly to mandril wrapping machine  100 , the device is made up of the following. As shown in FIG. 2A, when lever  68  is in a resting (or open) position, belt  16  is loosely wrapped about rollers  20 . Motor  22 , coupled to motor wheel  88  by belt  90 , will cause belt  90  to turn motor wheel  88 , thereby causing belt  92  to likewise rotate wheels  20  via belt  16 . Thereafter, when lever  68  is moved in the direction of arrow O about pivot  80 , resulting in the FIG. 2B, tension means of pump  26  causes arm  28  to raise and tension the upper roller  20 , thereby tensioning conveyor belt  16  about the plurality of rollers  20 . That tensioning causes the belt  16  to tightly wrap around a mandril  18 . In particular, when lever  68  is moved along arrow O, the V-shaped coupling  76  likewise rotates into arcuate notch  78 , locking the device into a closed position and tensioning tension support  82  coupled to arm  84  when arm  84  likewise pivots about pivot point  86 . When tightly tensioned as indicated above, mandril  18  will be caused to rotate around arcuate arrow R by belt  16  next to bight  94  as contained by hooked stop  70 . As the layup  56  is conveyed along belt  16  to mandril  18 , layup  56  will likewise be tightly wrapped about mandril  18  and held in place by hooked stop  70  at the end of guide arm  84 . After, to remove the layup wrapped mandril from apparatus  100 , lever  68  is moved in the opposite direction of arrow O to unlock the device  100  so that the layup wrapped mandril may be removed therefrom. A supporting frame  74  provides a rigid structure for the above-described apparatus. 
     Thereafter, as shown in FIGS. 3A and 3B, the mandril  18  wrapped with sheets  12  is inserted into an air pressurized sheath  30 , which is clamped about a pipe  64  at both ends to cause cavity  72  to be formed. As can be seen in FIGS. 3A and 3B, sheath  30  is longer than pipe  64 , and once inserted into pipe  64 , the ends of sheath  30  are wrapped back onto the outside of pipe  64  to be clamped by clamp means  60 . Pipe  64 , therefore, has an inside diameter greater than the mandril  18  and layup  56  combination. The cross-section of pipe  64  can be circular as depicted or any other shape as necessary. The sheath  30  is expanded via an air pressure means  62 , or evacuated, to so accommodate the mandril-wrapped shaft. Then the vacuum between sheath  30  and sheets  12  and mandril  18  is released from valve  62 , so that sheath  30  conforms completely about the mandril-wrapped sheets  12  as shown in FIGS. 3C and 4. At this point, the grippable sheath  30  is frictionally affixed to sheets  12  which are wrapped about mandril  18 . 
     To further integrate sheath  30  with sheets  12 , the combination must be allowed to be heated and cured, or vulcanized, as the process is known, as depicted in FIG. 5 in heating chamber  34 . FIG. 5 shows a rack  36  of a plurality of the inventions with an inner mandril core  18  wrapped with sheets  12  encased in sheath  30  having an elastic receptacle  14  combined therewith, ready for heating by element  66 . Once heated to the desired temperature and cooked for the desired period of time, racks  36  are removed from oven  34  where the shafts have been vulcanized. They are thereafter allowed to cure. For thermoplastics, heating at 350° F. to 550° F. (176° C. to 288° C.) for thirty seconds to ten minutes with a subsequent dwell or hold time to allow bubbles and gases to escape, is preferred. It may be beneficial to heat the thermoplastic prior to applying the rubber sheath  30 . For epoxies, heating at 150° F. to 350° F. (65° C. to 177° C.) for one to two hours is preferred. 
     Once cured and cooled, the mandril  18  can be removed from within the core of the sheets  12  by sliding the shaft to a stop  40  and pushing or pulling mandril  18  out from within as depicted in FIG.  6 . Thereafter, one has a grip ensconced shaft as depicted in FIG. 7 which may be mated, preferably with a blade B, by inserting blade B&#39;s hosel portion  13  into receptacle or cuff  14  to form a hockey stick  10 . The entirety of this process is depicted in a flowchart at FIG.  8 . In one form, the sheath  30  ensconces the entirety of the shaft, In another, the sheath  30  initially ensconces the entirety of the shaft, but later, a few inches are melted off during the blade mating process. 
     Moreover, having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims.