Note: Descriptions are shown in the official language in which they were submitted.
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SPORTS EQUIPMENT WITH WOUND FIBER
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
62/979,093, filed on February 20, 2020. The entire disclosure of the
application
referenced above is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to sporting equipment and more
particularly to
composite sports equipment and more particularly to composite sports equipment
having fiber wound around a tubular member.
BACKGROUND
[0003] The background description provided here is for the purpose of
generally
presenting the context of the disclosure. Work of the presently named
inventors, to the
extent it is described in this background section, as well as aspects of the
description
that may not otherwise qualify as prior art at the time of filing, are neither
expressly nor
impliedly admitted as prior art against the present disclosure.
[0004] Various different types of equipment are used in various different
sports. For
example, golf clubs are used to strike golf balls in golf. Golf clubs include
a golf shaft, a
grip, and a club head. The golf shaft has a butt end and a tip end. The club
head
attached to the tip end of the golf shaft. The grip is attached to the butt
end of the golf
shaft.
[0005] Other types of sports equipment also includes shafts. For example,
lacrosse
sticks include a shaft and a head that is attached to the shaft. Hockey sticks
also
include a shaft. A blade is attached to the shaft of a hockey stick.
SUMMARY
[0006] In a feature, a golf club shaft includes: a butt end; a tip end, where
the golf club
shaft is tapered between the butt end and the tip end; coils of fiber wound
helically
relative to an axis of the golf club shaft; and one or more layers of
composite material
wrapped around the coils of fiber and disposed radially outwardly of the coils
of fiber.
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[0007] In further features, the golf club shaft further includes a second one
or more
layers of composite material, where the coils of fiber are wound helically
around the
second one or more layers of composite material, and the second one or more
layers of
composite material are disposed radially inwardly of the coils of fiber.
[0008] In further features, at least one of the one or more layers of
composite material
include graphite, an epoxy, and a resin.
[0009] In further features, a diameter of the fiber is less than 15 microns.
[0010] In further features, the golf club shaft includes at least five
thousand of the coils
of fiber wound helically relative to the axis of the golf club shaft.
[0011] In further features, each of the coils is disposed approximately
perpendicular to
the axis.
[0012] In further features, each of the coils is disposed approximately
parallel to the
axis.
[0013] In further features, each of the coils is disposed at an angle of
between 1
degree and 89 degrees relative to the axis.
[0014] In further features, the fiber is coated with a resin.
[0015] In further features, the fiber has a circular cross-section.
[0016] In further features, the fiber is selected from a group consisting of
steel,
titanium, aluminum, copper, tungsten, and an alloy of one of steel, titanium,
aluminum,
copper, tungsten.
[0017] In further features, adjacent ones of the coils contact each other.
[0018] In further features, the golf club shaft is hollow inside of the coils
of fiber.
[0019] In a feature, a tubular portion of one of a hockey stick, a lacrosse
stick, and a
baseball bat is described. The tubular portion includes: one or more layers of
composite
material; and coils of fiber wound helically relative to an axis of the
tubular portion,
where one of: the one or more layers of composite material are wrapped around
the
coils of fiber and disposed radially outwardly of the coils of fiber; and the
coils of fiber
are wrapped around the one or more layers of composite material and disposed
radially
outwardly of the one or more layers of composite material.
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[0020] In further features, the one or more layers of composite material are
wrapped
around the coils of fiber and disposed radially outwardly of the coils of
fiber, and the
tubular portion further includes a second one or more layers of composite
material,
wherein the coils of fiber are wound helically around the second one or more
layers of
composite material, and the second one or more layers of composite material
are
disposed radially inwardly of the coils of fiber.
[0021] In further features, the coils of fiber are wrapped around the one or
more layers
of composite material and disposed radially outwardly of the one or more
layers of
composite material.
[0022] In further features, at least one of the one or more layers of
composite material
include graphite, an epoxy, and a resin.
[0023] In further features, the fiber is selected from a group consisting of
steel,
titanium, aluminum, copper, tungsten, and an alloy of one of steel, titanium,
aluminum,
copper, tungsten.
[0024] In further features, the fiber has a circular cross-section with a
diameter of less
than 15 microns.
[0025] In a feature, a method of forming tubular sports equipment includes:
winding
coils of fiber helically around a tubular member; and wrapping one or more
layers of
composite material around the coils of fiber such that the one or more layers
of
composite material are disposed radially outwardly of the coils of fiber.
[0026] Further areas of applicability of the present disclosure will become
apparent
from the detailed description, the claims and the drawings. The detailed
description and
specific examples are intended for purposes of illustration only and are not
intended to
limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present disclosure will become more fully understood from the
detailed
description and the accompanying drawings, wherein:
[0028] FIG. 1 includes an example view including two pieces of (uncured)
composite
material and a mandrel used to manufacture sports equipment;
[0029] FIG. 2A includes a cross-sectional view of composite material;
[0030] FIG. 2B includes a cross-sectional view of composite material;
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[0031] FIG. 3 includes an example perspective view of a mandrel placed on top
of
composite material;
[0032] FIG. 4 is a cross-sectional view illustrating the composite material
wrapped
around the mandrel;
[0033] FIG. 5 is a perspective view of fiber wound (coiled) around the
composite
material;
[0034] FIG. 6 is a cross-sectional view of a fiber is wound (coiled) around
the
composite material;
[0035] FIGs. 7-9 include perspective views of fiber wound around portions of
the
composite material;
[0036] FIG. 10 is a perspective view including an example of the fiber 504
wound
around the composite material placed on top of composite material;
[0037] FIG. 11 is a perspective view illustrating an example of the composite
material
wrapped around the fiber;
[0038] FIG. 12 is a cross-sectional view illustrating an example of the
composite
material wrapped around the fiber;
[0039] FIGS. 13 and 14 include example views of composite material including a
cut
out;
[0040] FIG. 15 is a cross-sectional view of the fiber being wound around the
mandrel
and located radially inwardly of composite material;
[0041] FIG. 16 is a perspective view of an example hockey stick including the
fiber;
[0042] FIG. 17 is a perspective view of an example lacrosse stick including
the fiber;
[0043] FIG. 18 is a perspective view of an example baseball bat including the
fiber;
[0044] FIG. 19 includes an example method of manufacturing a piece of sporting
equipment;
[0045] FIG. 20 includes an example method of manufacturing a piece of sporting
equipment;
[0046] FIGS. 21 and 22 include different example orientations of fiber
windings;
[0047] FIG. 23 includes a cross-sectional view of an example handle portion of
a
tubular portion, such as of a lacrosse stick;
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[0048] FIG. 24 includes a cross-sectional view of an example handle portion of
a
tubular portion, such as of a hockey stick;
[0049] FIG. 25 includes a cross-sectional view of an example handle portion of
a
tubular portion, such as of a lacrosse stick;
[0050] FIG. 26 includes a cross-sectional view of an example handle portion of
a
tubular portion, such as of a hockey stick;
[0051] FIGS. 27 and 28 include cross-sectional views of an example handle
portion of
a tubular portion, such as of a lacrosse stick;
[0052] FIGS. 29 and 30 includes cross-sectional views of an example blade
portion of
a tubular portion, such as of a hockey stick; and
[0053] FIG. 31 includes a cross-sectional view of an example implementation of
multiple layers of wound fiber.
[0054] In the drawings, reference numbers may be reused to identify similar
and/or
identical elements.
DETAILED DESCRIPTION
[0055] FIG. 1 includes an example view including two pieces of (uncured)
composite
material 100 and 102 and a mandrel 104 used to manufacture sports equipment,
such
as a golf club shaft. Each piece of the composite material 100 and 102
includes one or
more layers of the composite material. The composite material may also include
a resin
that can later be cured.
[0056] FIG. 2A includes a cross-sectional view of the composite material 100.
The
composite material 100 includes at least one layer 204 of the composite
material. The
composite material 100 may include one or more additional layers of the
composite
material, such as layers 208, 212, 216, 220, and 224. While the example of six
layers is
provided, the composite material 100 may have one layer or more than one layer
of the
composite material.
[0057] FIG. 2B includes a cross-sectional view of the composite material 102.
The
composite material 102 includes at least one layer 240 of the composite
material. The
composite material 102 may include one or more additional layers of the
composite
material, such as layers 244, 248, 252, 256, and 260. While the example of six
layers is
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provided, the composite material 102 may have one layer or more than one layer
of the
composite material.
[0058] Each of the layers of the composite material 100 and 102 includes
fibers of the
composite material, an epoxy, and a resin. For example, each of the layers may
include
graphite fibers, an epoxy, and a resin. While the example of graphite is
provided,
another suitable aramid may be used. Directions of the fibers of the composite
material
of one layer may be different than the directions of the fibers of the
composite material
of adjacent layers. For example, the fibers of the composite material of the
layer 204
may be arranged in a first direction, the fibers of the composite material of
the layer 208
may be arranged in a second direction that is different than the first
direction, and the
fibers of the composite material of the layer 212 may be arranged in a third
direction
that is different than the second direction, and so on. The fibers of the
composite
material of the layer 240 may be arranged in a fourth direction, the fibers of
the
composite material of the layer 244 may be arranged in a fifth direction that
is different
than the fourth direction, and the fibers of the composite material of the
layer 248 may
be arranged in a sixth direction that is different than the fifth direction,
and so on. The
directions of the fibers may be selected, for example, such that the shaft has
target
structural (e.g., torsional, bending, stiffness, etc.) characteristics. The
fourth direction
may also be different than the third direction.
[0059] The mandrel 104 may be solid (e.g., metal) or hollow and be tubular.
The
mandrel 104 may be, for example, frustoconical or conical (e.g., in the
example of the
shaft being a golf shaft). While the example of a mandrel having a circular
cross-section
is provided, the present application is also applicable to mandrels having
cross-sections
of other shapes, such as mandrels and sports shafts having a cross-section of
a
rectangle, a square, a triangle, a hexagon, an octagon, a pentagon, a
heptagon, an
oval, etc. The sports shaft may have one or more rounded sections in various
implementations. In various implementations, the composite material 100 may
extend
past ends of the mandrel 104.
[0060] As shown in FIG. 3, the mandrel 104 is placed on top of the composite
material
100. The composite material 100 is wrapped (rolled) around the mandrel 104.
FIG. 4
illustrates the composite material 100 wrapped around the mandrel 104. Once
the
composite material 100 is wrapped around the mandrel 104, the composite
material
100 and the mandrel 104 may be pressed and rolled, for example, using a platen
(heat)
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press. The composite material 100 may also be heated using the platen press or
in
another suitable manner. The heating and/or application of pressure may at
least
partially cure the composite material 100 and may completely cure the
composite
material.
[0061] As shown in FIG. 5, a fiber 504 is wound (coiled) around the composite
material 100. The fiber 504 may be a continuous length of fiber having at
least a
predetermined length after being wound around the composite material 100. The
predetermined length may be, for example, at least 25 miles, at least 35
miles, at least
40 miles, at least 45 miles, at least 50 miles, or at least 55 miles.
[0062] The fiber 504 may include, for example, steel, titanium, aluminum,
copper,
tungsten, an alloy of the above, an aramid, or another suitable material. The
fiber 504
may have a round cross-section or another suitable shape of cross-section,
such as
square, ovular, or another suitable shape. The diameter of the fiber 504 is
less than 15
microns, may be less than 12 microns, may be less than 10 microns, and may be,
for
example, approximately 8 microns. The fiber 504 is wound completely around
(360
degrees) at least a predetermined number of times, such as 5,000, 10,000,
15,000,
20,000, 25,000, or more. The fiber 504 may be coated with a resin, such as for
later
curing. For example, the fiber 504 may be fed through a bath of liquid resin
prior to the
wrapping described herein.
[0063] FIG. 6 is a cross-sectional view taken along A of FIG. 5. The winding
of the
fiber 504 around the composite material 100 creates a layer of the fiber 504
around the
composite material 100. Features of the drawings may not be to scale. The
fiber 504
may improve one or more structural characteristics of the sports shaft, such
as
stiffness, flex, weight, moment of inertial (M01), torsion, etc.
[0064] As shown in FIG. 5, the fiber 504 may be wound around the entire length
of the
composite material 100. Alternatively, the fiber 504 may be wound around only
one or
more portions of the composite material 100. This may modify local structural
characteristics, such as flex, weight, torsion, etc. at the location(s) of the
fiber 504.
[0065] FIGs. 7-9 include example perspective views where the fiber 504 is
wound
around less than all of the composite material 100. For example, FIG. 7 is an
example
where the fiber 504 is wound only around a middle portion of between a butt
end and a
tip end. FIG. 8 illustrates an example where the fiber 504 is wound only
around near the
butt end and the tip end (not in the middle portion). FIG. 9 is an example
where the fiber
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504 is wound around the middle portion, the butt end, and the tip end, but
with locations
without fiber between each section.
[0066] Once the fiber 504 is wound around the composite material 100, the
mandrel
104 (covered with the composite material 100 and the fiber 504) is placed on
top of the
composite material 102, such as shown in FIG. 10. The composite material 102
is
wrapped (rolled) around the mandrel 104. FIG. 11 illustrates the composite
material 102
wrapped around the fiber 504 and the composite material 100.
[0067] Once the composite material 102 is wrapped around the fiber 504 and the
composite material 100, the composite material 102, the fiber 504, the
composite
material 100, and the mandrel 104 may be pressed and rolled, for example,
using the
platen (heat) press. The composite material 102 may also be heated using the
platen
press or in another suitable manner. The heating and/or application of
pressure may
completely cure the resin of the fiber 504 and/or the composite material 102
and may
cure the composite material 100 if not already completely cured.
[0068] FIG. 12 is a cross-sectional view taken along A of FIG. 11. As shown in
FIG.
11, the composite material 102 covers the fiber 504 and the composite material
100.
Example thicknesses of the composite material 100, the fiber 504, and the
composite
material 102 are shown in FIG. 12. Other suitable thicknesses may be used, for
example, by the composite material 100 and/or the composite material 102
including
different numbers of layers.
[0069] In various implementations, the composite material 102 may include only
one
layer of the composite material. In various implementations, the composite
material 100
may be omitted. In such implementations, the fiber 504 may be wound directly
around
the mandrel 104, and the composite material 102 may be applied around the
fiber 504.
[0070] As shown in FIG. 13, a portion of (e.g., an interior of) the composite
material
102 may be cut away as to form one or more apertures through the composite
material
102. In other words, one or more apertures may be formed through the composite
material 102. For example, the example of FIG. 13 illustrates a cut out 1304
of the
composite material 102. Other things can be cut out of the composite material
102,
such as words, letters, logos (trademarked or non-trademarked), images,
patterns, etc.
In various implementations, a cutting device (e.g., a computer numerical
control (CNC)
cutting machine, such as a CNC router) may cut out the composite material 102
in
response to user input indicative of one or more items to cut out of the
composite
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material 102. The aperture(s) may be located where the fiber 504 is wound
around the
composite material 100 such that the fiber 504 is visible through the
apertures, such as
shown in the example of FIG. 14.
[0071] The composite material 102 and the aperture(s) may improve one or more
.. structural (e.g., torsional, bending, weight, etc.) characteristics of the
sports equipment.
The composite material 102 and the aperture(s) may additionally or
alternatively
improve one or more aesthetic characteristics of the sports equipment.
[0072] After the composite material 102 is cured, the mandrel 104 can be
removed.
The sports equipment (e.g., golf shaft) may be trimmed to a target length
after the
.. curing. One or more layers of paint may be applied over the composite
material 102
after curing. The paint may be a clear paint or a translucent paint to
maintain the
visibility of the composite material 102 or the fiber 504 through the
aperture(s) in the
composite material 102.
[0073] While the fiber 504 is shown as being between the composite material
100 and
.. the composite material 102, the fiber 504 could alternatively be wound
around the
mandrel 104 and located radially inwardly of the composite material 100. A
cross-
sectional view of such an arrangement is provided in the example of FIG. 15.
While the
example of the inclusion of the composite material 100 is provided, the
composite
material 100 may be omitted.
.. [0074] As stated above, the sports equipment could be a golf club shaft,
where a golf
club head is attached to the tip end of the golf club shaft, and a golf grip
is attached to
the butt end of the golf club shaft. The fiber 504 could be included in other
types of
sports equipment, however.
[0075] For example, FIG. 16 includes an example illustration including a
hockey stick
.. 10 including the fiber 504. The hockey stick 10 includes a handle portion
12 (i.e., shaft),
which a player 14 holds, and a blade portion 16 (i.e., blade), which is used
for
controlling a hockey puck 18 or a ball. The hockey stick 10 can be adapted for
any
position on a hockey team, including that of a goalie. In other words, the
hockey stick
10 may be a goalkeeper hockey stick or a hockey stick configured to be used by
other
.. positions in hockey. While the example of an ice hockey stick will be
provided, the
present application is also applicable field hockey sticks, roller hockey
sticks, and other
types of sports equipment.
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[0076] The handle portion 12 can be elongated and longitudinally straight. In
some
embodiments, the handle portion 12 can include a hollow core that is embedded
and
wrapped within a covering (e.g., composite material with carbon fibers). The
fiber 504
may be, for example, an inner layer of the handle portion 12 (e.g., similar to
the
example of FIG. 15) or between layers of composite material of the handle
portion 12
(e.g., similar to the example of FIG. 12).
[0077] Cross sectional views of an example of the handle portion 12 are
provided in
FIGs. 24 and 26. As shown in FIG. 26, one or more corners of may be rounded.
As
discussed above, in various implementations, the fiber 504 may be located
radially
inwardly of the composite material 100, or the composite material 100 may be
omitted.
In various implementations, the fiber 504 may be wound around the composite
material
100, and the composite material 102 may be omitted. In this implementation,
the fiber
504 may be visible on an exterior of handle portion 12. While example shapes
of the
handle portion 12 are provided in FIG. 26, the present application is also
applicable to
other shapes of handle portions.
[0078] Referring back to FIG. 16, the handle portion 12 includes a blade
connecting
end 13. The blade portion 16 is fixed to the blade connecting end 13 of the
handle
portion 12. The blade portion 16 can be fixed to the blade connecting end 13
in any
suitable manner. The handle portion 12 and the blade portion 16 can be
manufactured
separately and subsequently attached together. Alternatively, the handle
portion 12 and
the blade portion 16 may be manufactured together.
[0079] The blade portion 16 generally includes a front face 20, which can be
used for
receiving and moving the hockey puck 18 (e.g., passing, shooting, etc.), and a
rear face
22, which can also be used for receiving and moving the hockey puck 18. The
blade
portion 16 also includes a first end 28 that is connected to the blade
connecting end 13
of the handle portion 12. The blade portion 16 also includes a second end 30
that is
opposite to the first end 28.
[0080] The blade portion 16 also includes an upper edge 24 and a lower edge 26
that
is opposite the upper edge 24. The upper edge 24 is typically spaced away from
a
playing surface (e.g., ice). The lower edge 26 may contact the playing
surface.
[0081] Both the upper and lower edges 24 and 26 extend between the first and
second ends 28 and 30 of the blade portion 16. The upper and lower edges 24
and 26
and the front and rear faces 20 and 22 can have a curvature between the first
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second ends 28 and 30 such that the front face 20 is concave while the rear
face 22 is
convex.
[0082] FIGs. 29 and 30 include cross-sectional views of an example of the
blade
portion 16. The blade portion 16 may include a covering 2904 that is wrapped
around
one or more core members 2908. The covering 2904 includes one or more layers
of
composite material, similar to the golf club shaft described above (e.g.,
102). The fiber
504 may be, for example, an inner layer of the blade portion 16 (e.g., similar
to the
example of FIG. 15) or between layers of composite material of the blade
portion 16
(e.g., similar to the example of FIG. 12). For example, FIG. 29 illustrates
the fiber 504
being wound around the core member(s) 2908, and the covering including one or
more
layers of composite material covering the fiber 504. Alternatively, the fiber
504 may be
wound around the covering 2904 such that the fiber 504 is visible on an
exterior of the
blade portion 16.
[0083] FIG. 30 illustrates an example where the fiber 504 is disposed along
the lower
edge 26 of the blade portion 16. The blade portion 16 including the fiber 504
may
improve one or more structural characteristics, such as stiffness, flex,
weight, moment
of inertial (M01), torsion, shot speed, feel, etc.
[0084] As another example, a lacrosse stick may include the fiber 504. FIG. 17
includes an example illustration including a lacrosse stick 1704 including the
fiber 504.
The lacrosse stick 1704 includes a handle portion 1708, which a player holds,
and a
head portion 1712, which is used for controlling, passing, and shooting a
lacrosse ball.
The handle portion 1708 can be elongated and longitudinally straight. The
handle
portion 1708 may include an offset where the handle portion 1708 deviates from
being
longitudinally straight near the portion where the handle portion 1708
connects to the
head portion 1712. The fiber 504 may be, for example, an inner layer of the
handle
portion 1708 (e.g., similar to the example of FIG. 15) or between layers of
composite
material of the handle portion 1708 (e.g., similar to the example of FIG. 12).
[0085] For example, FIGs. 23, 25, and 27 include cross-sectional views of
example
implementations of the handle portion 1708. The handle portion 1708 may
include, for
example, 6 sides, such as shown in the examples of 23 and 27. In various
implementations, one or more of the sides may be concave and/or one or more of
the
sides may be convex. Additionally or alternatively, corners where two sides
meet may
be rounded, square, or a combination of round and square. While example shapes
are
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shown, the present application is also applicable to handle portions of other
cross-
sectional shapes. The fiber 504 may be disposed between the composite material
100
and the composite material 102, such as shown in the examples of FIGS. 23 and
25.
Alternatively, the fiber 504 may be an inner-most layer, such as shown in the
example
of FIG. 27 or an outer-most layer, such as in the example of FIG. 28. The
examples of
FIGS. 27 and 28 are also applicable to the handle portion of a hockey stick.
[0086] As another example, a baseball bat may include the fiber 504. FIG. 18
includes
an example illustration including a baseball bat 1804 including the fiber 504.
The
baseball bat 1804 includes a handle portion 1808, which a player holds, and a
head or
barrel portion 1812, which is used to bat a ball. The fiber 504 may be, for
example, an
inner layer of the handle portion 1808 (e.g., similar to the example of FIG.
15) or
between layers of composite material of the handle portion 1808 (e.g., similar
to the
example of FIG. 12). Additionally or alternatively, the fiber 504 may be an
inner layer of
the barrel portion 1812 (e.g., similar to the example of FIG. 15) or between
layers of
composite material of the barrel portion 1812 (e.g., similar to the example of
FIG. 12).
In the example of a baseball bat, the fiber 504 may, for example, detune
ringing of the
baseball bat, for example, to comply with one or more regulations of a
baseball
association. The fiber 504 may be used in the baseball bat 1804 to add mass.
The fiber
504 being located at one or more specific areas may adjust performance
characteristics
of the baseball bat.
[0087] FIG. 19 includes an example method of manufacturing a piece of sporting
equipment, such as a golf club shaft, a hockey stick shaft, a hockey stick
blade, a
lacrosse stick, a baseball bat, or another type of sporting equipment. The
method
begins with 1904 where the composite material 100 is wrapped around one or
more
tubular core members (e.g., the mandrel 104, the cores used to form a hockey
stick
shaft, hockey stick blade, baseball bat, lacrosse stick, etc.).
[0088] At 1908, the composite material 100 is pressed toward the core
member(s),
such as using a platen press. The pressing may involve rolling (e.g., in the
example of a
baseball bat or a golf club shaft). Heat may also be applied.
[0089] At 1910, the fiber 504 is wound (coiled) around the composite material
such
that a top portion of a coil of the fiber 504 contacts a bottom portion of a
next adjacent
coil of the fiber 504 above the coil and a bottom portion of the coil of the
fiber 504
contacts the top portion of the next adjacent coil of the fiber 504 below the
coil. The
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fiber 504 may be wound around the composite material, for example, by rotating
the
tubular core member(s) axially and moving a bobbin (or spool) including the
fiber 504
lengthwise (e.g., from tip end to butt end in the example of a golf club
shaft).
[0090] At 1912, the composite material 102 is wrapped around the fiber 504,
the
composite material 100, and the core member(s). At 1916, the composite
material 102
is pressed toward the core member(s), such as using a platen press. The
pressing may
involve rolling (e.g., in the example of a baseball bat or a golf club shaft).
Heat may also
be applied.
[0091] At 1920, the composite materials 100 and 102 may be cured. Optionally
(e.g.,
in the example of the golf club shaft), trimming and paint may be applied over
the outer
layer at 1924.
[0092] FIG. 20 includes an example method of manufacturing a piece of sporting
equipment, such as a golf club shaft, a hockey stick shaft, a hockey stick
blade, a
lacrosse stick, a baseball bat, or another suitable type of sporting
equipment. The
method begins with 2004 where the fiber 504 is wound (coiled) around one or
more
tubular core members (e.g., the mandrel 104, the cores used to form a hockey
stick
shaft, hockey stick blade, baseball bat, lacrosse stick, etc.). The fiber 504
may be
wound around the composite material, for example, by rotating the tubular core
member(s) axially and moving a bobbin (or spool) including the fiber 504
lengthwise
(e.g., from tip end to butt end). The fiber 504 is wound (coiled) such that a
top portion of
a coil of the fiber 504 contacts a bottom portion of a next adjacent coil of
the fiber 504
above the coil and a bottom portion of the coil of the fiber 504 contacts the
top portion
of the next adjacent coil of the fiber 504 below the coil.
[0093] At 2008, the composite material 100 is wrapped around the fiber 504 and
the
tubular core member(s). At 2010, the composite material 100 is pressed toward
the
core member(s), such as using a platen press. The pressing may involve rolling
(e.g., in
the example of a baseball bat or a golf club shaft).
[0094] At 2012, the composite material 102 may be wrapped around the composite
material 100, the fiber 504, and the core member(s). At 2016, the composite
material
102 is pressed toward the core member(s), such as using a platen press. The
pressing
may involve rolling (e.g., in the example of a baseball bat or a golf club
shaft).
Alternatively, 2012 and 2016 may be omitted, and the wrapping of composite
material
may be performed in one step using multiple layers of the composite material.
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[0095] At 2020, the composite materials 100 and 102 may be cured. Optionally
(e.g.,
in the example of the golf club shaft), trimming and paint is applied over the
outer layer
at 2024.
[0096] The example of FIG. 5 illustrates the coils of the fiber 504 being
arranged
approximately perpendicularly (90 degrees) to a longitudinal axis of the
mandrel 104
and the resulting golf shaft. Approximately may mean +/-1 degree or less as to
allow for
the helical winding of the fiber 504. The present application, however, is
also applicable
to winding of the fiber 504 in other directions relative to the longitudinal
axis. For
example, FIG. 21 includes an example perspective view of the fiber 504 wound
or
arranged approximately parallel to the longitudinal axis (0 degrees). FIG. 22
includes a
perspective view of an example where the fiber 504 is wound or arranged such
that the
coils are not approximately perpendicular to the longitudinal axis and not
approximately
parallel to the longitudinal axis. In this example, the coils may each form an
angle of
between 0 and 90 degrees relative to the longitudinal axis.
[0097] In various implementations, the sports equipment may include one or
more
layers of the fiber 504. For example, FIG. 31 includes a cross-sectional view
of an
example portion of sports equipment (e.g., a golf shaft, a hockey stick
handle, a hockey
stick blade, a lacrosse stick handle, a baseball bat, etc.) including multiple
layers of the
fiber 504. For example, the sports equipment may include a first layer 3104 of
the fiber
504, a second layer 3108 of the fiber 504 wound around the first layer 3104, a
third
layer 3112 of the fiber 504 wound around the second layer 3108, and a fourth
layer
3116 of the fiber 504 wound around the third layer 3112. The coils of one or
more of the
layers may be arranged in different directions relative to the longitudinal
axis. While the
example of four layers of the fiber 504 is provided in the example of FIG. 31,
the
present application is applicable to N layers of the fiber 504 where N is an
integer
greater than zero.
[0098] Multiple layers of the fiber 504 may be disposed in an area of the
sports
equipment, for example, to create a knob on the sports equipment. For example,
the
hockey stick may include a knob at the end of the handle portion 12 that is
opposite to
the blade connecting end 13. The lacrosse stick 1704 may include a knob at the
end of
the handle portion 1708 that is opposite to where the handle portion 1708
connects to
the head portion 1712. The baseball bat 1804 may include a knob 1816 formed at
an
end of the handle portion 1808, such as shown in the example of FIG. 18.
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[0099] The foregoing description is merely illustrative in nature and is in no
way
intended to limit the disclosure, its application, or uses. The broad
teachings of the
disclosure can be implemented in a variety of forms. Therefore, while this
disclosure
includes particular examples, the true scope of the disclosure should not be
so limited
since other modifications will become apparent upon a study of the drawings,
the
specification, and the following claims. It should be understood that one or
more steps
within a method may be executed in different order (or concurrently) without
altering the
principles of the present disclosure. Further, although each of the
embodiments is
described above as having certain features, any one or more of those features
described with respect to any embodiment of the disclosure can be implemented
in
and/or combined with features of any of the other embodiments, even if that
combination is not explicitly described. In other words, the described
embodiments are
not mutually exclusive, and permutations of one or more embodiments with one
another
remain within the scope of this disclosure.
[0100] Spatial and functional relationships between elements are described
using
various terms, including "connected," "engaged," "coupled," "adjacent," "next
to," on top
of," "above," "below," and "disposed." Unless explicitly described as being
"direct," when
a relationship between first and second elements is described in the above
disclosure,
that relationship can be a direct relationship where no other intervening
elements are
present between the first and second elements, but can also be an indirect
relationship
where one or more intervening elements are present (either spatially or
functionally)
between the first and second elements. As used herein, the phrase at least one
of A, B,
and C should be construed to mean a logical (A OR B OR C), using a non-
exclusive
logical OR, and should not be construed to mean at least one of A, at least
one of B,
and at least one of C."
