CA3168839A1 - Sports equipment with wound fiber - Google Patents

Abstract

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.

Description

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.

[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.

20 [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;

[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;

[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 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) 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 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 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.

[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 and 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 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 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 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.

[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.

[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."

Claims (20)

PCT/US2021/017360What is claimed is:

1. A golf club shaft, comprising:
a butt end;
a tip end, wherein 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.

2. The golf club shaft of claim 1 further comprising 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.

3. The golf club shaft of claim 1 wherein at least one of the one or more layers of composite material include graphite, an epoxy, and a resin.

4. The golf club shaft of claim 1 wherein a diameter of the fiber is less than 15 microns.

5. The golf club shaft of claim 1 wherein 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.

6. The golf club shaft of claim 1 wherein each of the coils is disposed approximately perpendicular to the axis.

7. The golf club shaft of claim 1 wherein each of the coils is disposed approximately parallel to the axis.

8. The golf club shaft of claim 1 wherein each of the coils is disposed at an angle of __ between 1 degree and 89 degrees relative to the axis.

9. The golf club shaft of claim 1 wherein the fiber is coated with a resin.

10. The golf club shaft of claim 1 wherein the fiber has a circular cross-section.

11. The golf club shaft of claim 1 wherein 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.

12. The golf club shaft of claim 1 wherein adjacent ones of the coils contact each other.

13. The golf club shaft of claim 1 wherein the golf club shaft is hollow inside of the coils of fiber.

14. A tubular portion of one of a hockey stick, a lacrosse stick, and a baseball bat, the tubular portion comprising:
one or more layers of composite material; and coils of fiber wound helically relative to an axis of the tubular portion, wherein 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.

15. The tubular portion of claim 14 wherein 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 wherein 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.

16. The tubular portion of claim 14 wherein 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.

17. The tubular portion of claim 14 wherein at least one of the one or more layers of composite material include graphite, an epoxy, and a resin.

18. The tubular portion of claim 14 wherein 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.

19. The tubular portion of claim 14 wherein the fiber has a circular cross-section with a diameter of less than 15 microns.

20. A method of forming tubular sports equipment, the method comprising:
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.