Flexible Shaft for Hockey Stick

The present invention relates generally to the field of ice hockey equipment, and more particularly to ice hockey sticks.

Traditionally, ice hockey sticks have been made from wood. These solid wood sticks often lacked durability and adequate stiffness, amongst other limitations. In an attempt to address these shortcomings, ice hockey stick construction moved from using solid wood for the shaft to laminated wood, aluminium, and eventually carbon fiber composites.

Carbon fiber composites can reduce the weight of the stick. For example, a solid wood hockey stick can weigh between 650-700 g as compared to an equivalently sized carbon fiber stick, which can weigh less than 400 g. Having a lighter stick for a player is advantageous as it can facilitate more nimble, faster play. Carbon fiber composites can also increase the strength of the stick as compared to solid wood sticks, and permit a greater variety of shapes for the stick along the shaft.

For example, traditional wooden sticks had a generally rectangular cross-section with square corners as a result of common woodworking practices (and limitations). Carbon fiber composites allow for the geometry along the length of the shaft to be varied. This has led to the development of shafts with rounder, asymmetric shapes that are considered to be more ergonomic as compared to a rectangle shaft with square corners.

The evolving technology has led to the development of more flexible shafts with engineered bend points that allow the shaft to store and release energy more efficiently as compared to traditional ice hockey sticks. Zones of higher stiffness relative to the rest of the shaft have typically been created by adding supplemental layers of material to specific areas of hockey sticks. However, adding material to create stiffness can result in the non-supplemented portions that sit adjacent being relatively thinner. As a result, such non-supplemented sections of the shaft can result in structural weaknesses. Because non-supplemented areas are relatively soft compared to the stiffer supplemented parts, more strain occurs in this area and they become more susceptible to damage and breakage.

In addition to the changes in hockey stick construction, shooting mechanics have evolved over time, particularly in the last two decades. Due to an increase in the speed of the game, players no longer have the same amount of time they once did to use long wind-ups and traditional slap shots. In particular, typical players used to hold the stick during skating with their upper, driving hand close to the butt or handle end, and their lower hand positioned along the shaft below the upper hand. Players were coached to shift their lower hand down to the midpoint area of the shaft when preparing for a shot. This practice added power and accuracy to the shot, but shifting the lower hand was time consuming in the context of a fast-moving game.

In modern playing, due to the increased speed of the game, players are now being coached to shoot with their lower hand remaining higher up the shaft of their stick. This produces shorter, quicker-release shots that can be taken from the skating hand position. While this can allow for a quicker release of the puck, the higher hand position can provide less leverage to the stick blade and puck. There have not been any sticks commercially available that have been engineered for maximal performance when used in this new style of play.

Therefore, despite advances made to date in the development of ice hockey sticks, there is room for improvement to address the above-mentioned problems and shortcomings of the prior art.

It is an object of the present invention to obviate or mitigate at least one of the above-mentioned disadvantages of the prior art.

It is another object of the present invention to provide a novel hockey stick shaft.

Accordingly, in one of its aspects, the present invention provides a hockey stick shaft comprising along its longitudinal axis, (a) an upper section comprising four walls, each of which comprises a cross-sectional convex surface; (b) a middle section comprising four walls, three of which comprise a cross-sectional convex surface and one of which comprises a cross-sectional concave surface; and (c) a lower section comprising four walls, each of which comprises a cross-sectional convex surface.

In a further aspect, the present invention provides a hockey stick shaft that is hollow, and preferably formed from a carbon fibre composite consisting of carbon fiber and resin, such as epoxy resin. However, other materials such as urethane, acrylics, and other forms of resin may be used. Likewise, it is possible to substitute one or more layers of carbon fiber with other technical fibers such as aramid, PBO, or others. Such construction results in a lightweight stick that can effectively be used in fast play.

In a still further aspect, the present invention relates to a hockey stick shaft that is formed without sharp or squared corners along the length of the shaft, thus improving the ergonomic comfort of the shaft when held during active play.

In a still further aspect, the present invention relates to a hockey stick shaft that is formed by wrapping sheets of carbon fibre composite around an expandable membrane, which is used to press the material outwardly into the internal cavity of a mold consisting of a shape without sharp or squared corners. This also obviates the need for the fibres to create sharp corners, which results in a stronger fibre-based structure.

In a still further aspect, the present invention relates to a hockey stick shaft having at least three sections: a lower section that terminates in the heel of the blade, a middle section that connects with the lower section, and an upper section that terminates in the butt end or handle end of the stick, that features a uniform wall thickness of carbon fibre composite along at least the lower section. In other words, there are no areas of the lower section in which additional material has been added to strengthen it, and there are no areas of the lower section in which material has been removed in order to render the lower section more flexible. This results in a stronger structure for the lower section, lowering the risk of over-flexure and breakage.

In a still further aspect, the present invention relates to a hockey stick shaft having at least five sections: a lower section that terminates in the heel of the blade, a middle section that connects with the lower section, and an upper section that terminates in the butt end or handle end of the stick, with transitional zones between the lower and middle sections and between the middle and upper sections, and that may further feature a uniform wall thickness of carbon fibre composite along at least the lower region, transitional zone between the lower and middle sections, and middle section. The same benefits in terms of increased strength along the uniform wall sections as described above apply to this alternate embodiment.

In a still further aspect, the present invention relates to a hockey stick shaft that features a uniform wall thickness of carbon fibre composite along its entire length. This results in a stronger structure for the shaft overall, lowering the risk of over-flexure and breakage. The same benefits in terms of increased strength for a uniformly walled structure as described above apply to this alternate embodiment.

Thus, the present inventor has developed a hockey stick that permits a player using a modern grip, with the lower hand higher up the shaft of the stick, to load the shaft of the stick more easily and allow for more energy to be stored and released during a shot, as compared to traditional hockey sticks. The present hockey stick provides a more ergonomic and lightweight design, allowing the player to quickly make adjustments to their grip position without compromising the fit of the stick shaft in their hand, and a preferred mass distribution along the length of the shaft.

To the knowledge of the inventor, a hockey stick having such a combination of features is heretofore unknown.

Other advantages of the invention will become apparent to those of skill in the art upon reviewing the present specification.

The present invention relates to a hockey stick shaft comprising along its longitudinal axis, (a) an upper section comprising four walls, each of which comprises a cross-sectional convex surface; (b) a middle section comprising four walls, three of which comprise a cross-sectional convex surface and one of which comprises a cross-sectional concave surface; and (c) a lower section comprising four walls, each of which comprises a cross-sectional convex surface.

Preferred embodiments of the present invention will be described with reference to the following exemplary information which should not be used to limit or construe the invention.

The present hockey stick comprises three main sections along the longitudinal axis of the stick. The three sections have varying cross-sectional shapes, which creates dual points of flexure in the shaft, as described herein. There are also two intervening connecting, transitional zones that act to transition between the three main sections. The hockey stick is preferably comprised of carbon fiber composite, but can be made from any suitable material.

is a side view of a schematic of an embodiment of the present hockey stick. The hockey stick shaftis preferably hollow and in this embodiment, comprises a uniform wall thickness throughout.

The hockey stick shaftcomprises an upper section, which is held by the upper hand of the player, and is on the opposite end of the shaft to the hockey blade (not shown). Upper sectioncomprises a first upper section endthat is opposite a second upper section endalong the longitudinal axis of the stick. The second upper section endis connected to a connecting zonewhich in turn connects to a middle sectionat its first middle section end. In some preferred embodiments, the first connecting zonewill have the same perimeter measurement as the second upper section endto the first middle section end. This will allow a more seamless transition from shape to shape.

The upper sectioncomprises a convex-convex cross-sectional shape, as illustrated in, comprising a top wall, a front wall, a bottom wall, and a back wall, each of which comprises a convex surface. While not wishing to be bound by any particular theory or mode of action, the resulting round shape of the upper sectioncan fit into the palm of a player's upper hand, maximizing surface contact with the player's hand and allowing the player to efficiently control the stick. Furthermore, the round shape allows the player to make adjustments to their grip position without compromising the fit of the shaft in their hand.

The hockey stick shaftfurther comprises a middle sectioncomprising a first middle section endthat is opposite a second middle section endalong the longitudinal axis of the stick.

The middle sectioncomprises a convex-concave cross-sectional shape, as illustrated in. Specifically, middle sectioncomprises a top wall, a bottom wall, and a back walleach of which comprise convex surfaces, and a front wallwhich comprises a concave surface. While not wishing to be bound by any particular theory or mode of action, the resulting shape of the top wall, bottom wall, and back wallpermit the stick to fit comfortably in the palm of the player's lower hand and maximize contact between the player's hand and the stick. The concave surface of the front wallalso reduces the Moment of Inertia (I) for the middle section, creating a more flexible zone in the middle of the stick's shaft. The shape and location of the middle sectioncreates an upper area of flexure, or a “kick point”, when using the stick to perform a shot. The precise location of the upper kick point will depend on where the player's lower hand is placed along the shaft. However, as mentioned above, in the modern style of play, the player's lower hand is placed higher up the shaftthan has traditionally been taught. The player's lower hand will likely land in the area between first middle section endand second middle section end. The concave wallthen provides a convenient and secure grip for the player's fingers. Thus, if the player uses a higher position for the hand as is typical of the modern style of play, the upper kick point will be located in the middle sectionand near the player's lower hand, which is preferred.

The hockey stick shaftfurther comprises a lower sectioncomprising a first lower section endthat is opposite a second lower section endalong the longitudinal axis of the stick. The second lower section endof the lower sectionis configured to connect to a hockey stick blade (not shown). In some embodiments, the blade is replaceable. The blade can comprise any suitable material, including, but not limited to, wood, plastic, or composite materials.

The lower section comprises a convex-convex cross-sectional shape, as illustrated in, comprising a top wall, a front wall, a bottom wall, and a back wall, each of which comprises a convex surface. While not wishing to be bound by any particular theory or mode of action, the convex surface of the front wallincreases the overall Moment of Inertia (I), creating a more rigid zone in the stick's shaft. The relative stiffness compared to the middle sectionassists in creating the upper kick-point in the middle section, which is described above.

In some embodiments, the lower section is preferably tapered from the first lower section endto the second lower section end. While not wishing to be bound by any particular theory or mode of action, the associated reduction in Moment of Inertia towards lower endcreates an area of relative low stiffness. This creates a lower “kick point”. Taken together with the upper kick point, what results when using a stick incorporating the shaft of the invention is a dual firing profile, in which there are two kick points which cooperate to transfer an enhanced force to the puck when performing a slap shot.

As mentioned, the upper sectionis separated from the middle sectionby a first connecting zone. The upper sectionis connected at the second upper section endto one end of the first connecting zoneand the middle sectionis connected at the first middle sectionto the opposing end of the first connecting zone.

Similarly, the lower sectionis separated from the middle sectionby a second connecting zone. The lower sectionis connected at the first lower section endto one end of the second connecting zoneand the middle sectionis connected at the second middle sectionto the opposing end of the second connecting zone.

As expressed above, the hockey stick shaftof the invention is designed to suit styles of modern, faster play, in which the lower hand of the player remains higher on the stick during shots, so that time is not lost by shifting the lower hand. Some hockey sticks of the prior art were also designed to have along their shafts multiple zones of flexibility, such as lower, middle, and upper zones with transitional zones. However, the proportions between their zones differed. The following Table 1 illustrates the percentages of shaft length accorded to sticks of the prior art as compared to the invention.

As can be seen by comparing the proportions above, prior art sticks had approximately equal length allocated to the upper, middle and lower sections. In the stick of the invention, more of the length of the shaft is concentrated in the lower section and middle section. This is because when using sticks of the prior art, in order to maximize force on the puck, the player's lower hand would need to slide down the shaft, essentially creating a cantilever that contributed to the force transmitted to the puck through the flexible shaft. There was no strategic benefit in departing from a default construction of three approximately equally sized sections. However, in the stick of the invention, the player's hands remain high on the shaft, and it is not necessary to perform the time consuming shift of hand position. Rather, through the engineering of the shaft to have different cross-sectional profiles across different regions, the stick of the invention allows for the above-described dual kickpoint to be created, and a sharp force transmitted to the puck even when both of the player's hands remain relatively high on the shaft.

It is noted that the transitional zones of the invention are allocated about 10% each of the shaft length. This allows for a gradual transition between the different primary lower, middle and upper sections. Particularly when using carbon fibre to create the stick, gradual transitions prevent abrupt changes in cross-sectional profile and avoid associated structural stresses which can lead to weak points along the shaft.

It is also noted that the percentages allocated to each of the three main sections of the shaftmay be varied within up to 20% of the percentages shown. The advantages of the invention are maintained even with such variances.

The following Tables 2-9 further illustrate examples of the lengths of each component zone for a hockey stick for adult male players, which is 1544.3 mm in length. Also outlined are additional effective ranges for the lengths of the sections.

Different sizes of stick are designed for players depending on height, ranging from children to senior players. However, the above proportions in terms of percentage of shaft length corresponding to each of the three main sections and the two connecting zones are consistent between different sizes of stick.

It is further advantageous that the shaftmay have consistent wall thickness and mass along its length. In prior art sticks, areas of flexure were made by shaving away or otherwise subtracting material or with thinner walls. Areas designed to have greater strength and reduced flexure were reinforced by increasing the amount of material in those areas, or by introducing additional structure such as bracing made from metals or wood and other similar reinforcements. This non-uniformity along the length of hockey stick shafts made for larger contrasts between flexible and non-flexible regions, increasing the likelihood of over-flexure and breakage of the shaft during play. Advantageously, shaftof the invention has areas of increased flexibility that are engineered using differing geometry rather than manipulating the amount of material used for those regions of the shaft. The result is that the shaft is uniformly strong and less prone to breakage, while offering the dual flex points that translate into sharp and enhanced force on the puck during play.

Alternative embodiments of stick shaft may also be prepared in which the wall thickness is uniform only across regions of the stick that are subject to the most flex and strain, for example, the lower section, second connecting zone, and middle section. It may be desired to use less carbon fibre material in portions of the shaft that are not typically subjected to significant impact, flexing or strain, such as upper region. Having a thinner wall in regionwould reduce the weight of the stick and could allow for manufacture of the stick at less expense, due to the savings in carbon fibre material in this region. Such a reduction in wall thickness in upper regionwould not have significant negative consequences for overall strength of the shaft. Such alternate embodiments are within the scope of this invention.

As mentioned above, in a preferred embodiment, the hockey stick shaftis hollow and formed from carbon fibre composite. When manufacturing a hollow shaft using carbon fibre composite, sheets of carbon fibres embedded in epoxy resin “prepreg” may be wrapped around a cylindrical mandrel. The mandrel is then removed and an expandable membrane is placed inside the uncured form. This assembly is then placed inside a heated mold which is formed in the desired external shape of the stick. The membrane is then expanded, pushing the carbon fiber composite against the internal cavity of the mold to form the cured composite structure. Sharp cornered shafts of the prior art, when made such a method, have reduced strength as the fibres are stressed when used to form sharp corners. A further advantage of this embodiment of the invention is that the shaft corners are rounded, resulting in better structural integrity for a structure made from carbon fibre composite.