TW201529129A - Ball bat with a fused end cap - Google Patents

Abstract

A ball bat includes an end cap that is fused directly or indirectly to an inner or outer surface of the bat barrel. In one embodiment, a sleeve is molded or bonded to an inner surface or an outer surface of the bat barrel. The end cap is then fused to the sleeve, optionally via a spin-welding process. If removal of the end cap is attempted, a fracture zone results that damages the end cap and makes it unusable and effectively irreplaceable.

Description

Bat with fusion end cap

This case relates to a bat with a fusion end cap.

Many modern bats include a plastic end cap that is mechanically secured to the end of the bat barrel or bonded in place. The plastic end cap provides a lightweight closure for the end of the bat barrel. Because the impact of the bat is strong, the end cap and its attachment mechanism must be able to withstand multiple impacts while remaining in place. A common problem is that plastics do not easily bond to fiber composites or other commonly used bat materials, and the bonding process itself may be unreliable. The mechanical mechanism of fixing the end cap to the bat barrel is also often unreliable.

FIG. 1 illustrates an example of a prior art end cap 10 that is mechanically coupled to the bat barrel 12. The end cap 10 can be made of an injection molded thermoplastic material or another suitable material. Such an end cap 10 generally covers the end 14 of the barrel 12 and the outer edge 16 of the end cap 10 has a diameter substantially equal to the outer diameter 18 of the bat barrel 12. In the illustrated example, the bat barrel 12 includes an inwardly facing recess 26 and an inwardly projecting ridge 22 which are respectively formed by an outwardly projecting ring 24 and an outwardly facing recess 20 of the end cap 10. Engage. The end cap may additionally or alternatively be bonded to the inner surface of the barrel 12 with an adhesive.

An end cap 10 as shown in Figure 1 can typically be removed without damaging the bat. This removal can be accomplished by applying heat or steam to soften the end cap to any adhesive and then pulling the end cap 10 from the barrel 12 using a clamping device. Once the end cap is removed, the aftermarket bat modifier can thin the barrel 12 from the interior, which will create a more reactive bat barrel (i.e., increase the potential power of the bat). Such a modified bat is generally not approved by the Confederate game and may be dangerous to the fielder because it may increase the speed at which the ball leaves the bat.

With such unauthorised modifications, the end cap 10 can typically be reattached to the bat barrel 12 such that internal modifications become undetectable. Also, in the event that the end cap 10 is just damaged, a new end cap can be used in place of the original end cap. This type of unapproved modification has become so common that replacement end caps are now available from third-party vendors. Therefore, there is a need for a bat constructed in a manner that makes it impossible to detect the modification of the cylinder or to achieve it.

A bat comprising an end cap that is fused directly or indirectly to an inner or outer surface of the bat barrel. In one embodiment, a sleeve is molded or bonded to an inner or outer surface of the bat barrel. The end cap is then fused to the sleeve, optionally through a spin welding procedure. If an attempt is made to remove the end cap, a broken area will be created which will damage the end cap and render it unusable and substantially non-replaceable. Other features and advantages will appear below. The features described above may be used alone or together, or in various combinations of one or more of the features.

1‧‧‧ bat

2‧‧‧handle

4‧‧‧Cylinder

6‧‧‧Cone section

8‧‧‧ knob

9‧‧‧End cover

10‧‧‧End cover

12‧‧‧Cylinder

14‧‧‧ End

16‧‧‧ outer edge

18‧‧‧ outside diameter

20‧‧‧ Groove

22‧‧‧ Ridge

24‧‧‧ Ring

26‧‧‧ Groove

28‧‧‧ Ring

29‧‧‧End cover

30‧‧‧ sleeve

31‧‧‧ slot area

32‧‧‧ inner surface

34‧‧‧ Ridge

36‧‧‧Shoulder

38‧‧‧ melting zone

40‧‧‧Inner sleeve

42‧‧‧Aluminum cylinder

44‧‧‧ Ring

46‧‧‧ Groove

48‧‧‧External part

50‧‧‧ outer surface

52‧‧‧ core heart

53‧‧‧ Space

54‧‧‧ inner surface

55‧‧‧End

56‧‧‧ outer surface

60‧‧‧Aluminum cylinder

62‧‧‧Flange

64‧‧‧ Forming part

66‧‧‧ inner edge

68‧‧‧ inner surface

70‧‧‧Bend section

72‧‧‧ inner edge

74‧‧‧End cover

76‧‧‧Extension

78‧‧‧ Cavity

80‧‧‧Extension

90‧‧‧Cylinder

92‧‧‧ Groove

94‧‧‧ edge

96‧‧‧ hole

98‧‧‧ wall

100‧‧‧Outer sleeve

102‧‧‧ bottom

104‧‧‧Protruding

106‧‧‧ inner wall

110‧‧‧End cover

112‧‧‧ welding area

In the figures, the same reference numerals are used throughout the drawings to refer to the same elements: FIG. 1 is a cross-sectional view of an existing end cap mechanically attached to a bat.

Figure 2 is a side view of a bat with an end cap.

3 is an exploded cross-sectional view of a fusible end cap separated from a bat barrel, in accordance with an embodiment.

4 is a cross-sectional view of the inner sleeve of FIG. 3 fused to an inner sleeve in a bat barrel.

Figure 5 is a cross-sectional view of an inner sleeve being injection molded into the inner surface of a bat barrel, in accordance with an embodiment.

Figure 6 is a cross-sectional view of the inner sleeve that is injection molded into the inner surface of a bat barrel as produced by the process of Figure 5.

Figure 7 is an exploded cross-sectional view of an end cap separated from a bat barrel in accordance with another embodiment.

Figure 8 is a cross-sectional view of the end cap of Figure 7 as being rotationally welded to the inner surface of a bat barrel.

9 is a cross-sectional view of one end of a bat barrel configured to receive an outer sleeve.

Figure 10 is a cross-sectional view of a bat barrel of Figure 9 with an outer sleeve attached to the barrel.

Figure 11 is a cross-sectional view of a bat barrel having an end cap fused to the outer sleeve of Figures 9 and 10.

Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling the description of the embodiments. However, it will be understood by those skilled in the art that the present invention may be practiced without many of these details. In addition, some well-known structures or functions may not be shown or described in detail in order to avoid unnecessarily obscuring the description of the various embodiments.

The terms used in the description below are intended to be interpreted in their broadest reasonable manner, although the terms are used in conjunction with the detailed description of certain specific embodiments of the invention. Certain terms may be even emphasized below; however, any term that is intended to be interpreted in any manner that is unconstrained is also disclosed and specifically defined in the Detailed Description section.

Where the context permits, singular or plural terms may also include the plural or singular. In addition, the use of "or" in this list is interpreted as containing unless the word "or" is expressly limited to the meaning of a single item that excludes other items from the list of two or more items. Any single project in the list, (b) all the projects in the list, or (c) any combination of the projects in the list. In addition, terms such as "attached" or "connected" are intended to encompass an integral connection, as well as a connection between physically separate elements, unless otherwise specified.

Turning now to the details in the drawings, as shown in Figure 2, a baseball or softball bat 1, hereinafter collectively referred to as a "bat", will be depicted and described. The bat 1 includes a handle 2, a barrel 4 and a tapered section 6 for engaging the handle 2 to the barrel 4. The free end of the handle 2 includes a knob 8 or similar structure. The barrel 4 is closed by an end cap 9, as detailed below. The inside of the bat 1 is preferably hollow. It allows the bat 1 to be lighter, allowing the player to produce a considerable blow speed when swinging the bat 1.

The bat 1 may be a one-piece construction, or may include two or more separate attachments (e.g., a single handle and barrel), such as described in U.S. Patent 5,593,158, incorporated herein by reference. . The cylinder 4 may be made of a composite material such as carbon or glass, or made of a metal material such as aluminum. The bat handle 2 can be made of the same material or different materials as the cylinder 4. In a two-piece bat construction, for example, the handle 2 can also be made of a composite material (and the same or a different material used to form the cylinder), a metallic material, or any other suitable material.

The bat barrel 4 can comprise a single wall or multi-wall construction. The multi-walled cylinder may comprise, for example, one or more interface shear control zones ("ISCZ"), as described in detail in U.S. Patent No. 7,115,054, the disclosure of which is incorporated herein by reference. Separate wall of the tube.

The bat 1 can have any suitable size. The total length of the bat 1 can be 20 to 40 inches or 26 to 34 inches. The overall diameter of the barrel can be 2.0 to 3.0 inches or 2.25 to 2.75 inches. Typical bats have a diameter of 2.25, 2.625, or 2.75 inches. Various combinations of such total lengths and barrel diameters or any other suitable size rods are contemplated herein. The particular preferred combination of rod sizes is typically determined by the user of the stick 1 and can vary widely from user to user.

The embodiments described below generally relate to a bat comprising an end cap that is fused directly or indirectly to the inner surface of the bat barrel. For example, a sleeve that allows the end cap to fuse therewith can be bonded or molded to the inner surface of the bat barrel. "Fusing" as used herein generally means passing two compatible elements The solid state connections achieved by melting together, such as two components made of thermoplastic or composite materials. Polyester is a particularly suitable thermoplastic material because the polyester can be combined with an epoxy resin to form a typical composite bat barrel. Other suitable materials include polyurethane, polycarbonate, polyamide, polypropylene or similar materials.

In one embodiment, an inner sleeve is formed in the composite bat barrel and attached to the barrel during the barrel forming process. This allows the outer surface of the sleeve to be welded to the inner surface of the composite barrel by applying heat and pressure during molding. The composite bat cylinder is usually formed by winding a multilayer fiber-reinforced prepreg into a cylindrical shape. A pouch is placed in the prepreg tube and the component is placed in a mold. Air fittings can be applied to the end of the pouch. The mold is then closed and heated so that air pressure is applied to the bladder to pre-impregnate the mold to the mold, thereby compacting and curing the plies.

The sleeve can be placed between the bladder and the innermost ply such that when pressure is applied during the molding process, the sleeve is pressed against the innermost ply and bonded to the epoxy flowing along the sleeve. Once the epoxy is crosslinked and cured, the sleeve is molded onto the inner surface of the barrel.

Alternatively, the sleeve can be bonded to the inner surface of an already cured bat barrel via an adhesive. This may be preferred when the barrel material is aluminum or other metal, or the bat material requires an adhesive for bonding the inner surface of the barrel to the sleeve. In one embodiment, the adhesive is placed between the inner surface of the bat barrel and the outer surface of the sleeve. Pressure can then be applied to the inner sleeve to squeeze the bond and complete the bonding procedure.

The sleeve can also be made of plastic or similar material and rolled into a cylindrical shape. The sheet is then placed on the inside of the pre-impregnated ply of the rolled bat barrel. When the barrel is formed, the heat and consolidation pressure will force the rolled sheet to bond to the thermosetting resin of the prepreg sheet, permanently securing the inner sleeve to the inner surface of the bat barrel.

In another embodiment, the sleeve can be injection molded onto the inner surface of the bat barrel. Such a method includes placing the barrel into an injection mold that seals the outer surface of the barrel. A sliding core can then be placed adjacent to or against the inner surface of the barrel. Plastic is then injected between the inner surface of the barrel and the sliding core to form the sleeve.

The inner sleeve may additionally or alternatively include ridges, grooves, holes or other surface effects for mechanically locking the sleeve to or corresponding to features in the bat barrel.

The inner sleeve can have any suitable size when in use. In one embodiment, the inner sleeve has a thickness of from about 0.03 to 0.07 inches and a length of from about 0.25 to 0.75 inches. The inner sleeve can form a complete cylinder or can optionally have a gap along its length to allow expansion of the prepreg ply during formation of the sleeve. The inner sleeve is preferably made of the same material as the end cap or a similar material to allow it to be thermally bonded to the end cap. The inner sleeve is also preferably a resin that can be bonded or molded into the composite cylinder.

In another embodiment, the barrel itself may be formed from a thermoplastic material or the like such that the material of the end cap is a resin that is compatible with and fused to the bat barrel. In this embodiment, the end cap can be directly fused to the inner or outer surface of the barrel such that the sleeve becomes unnecessary.

In one embodiment, the end cap is fused to the inner sleeve by spin welding On the inner surface of the barrel or bat barrel. Spin welding is a process in which friction is generated by rotating another element relative to one element, such as two thermoplastic elements, and forcing them together. The heat from the friction melts the two materials and creates a solid state connection between the two. The end cap is preferably slightly flexible and has an outer diameter that is slightly larger than the inner diameter of the bat mating surface, such as the inner surface of the barrel or inner sleeve, to create the necessary obstruction and friction.

The spin welding procedure fuses the end cap to the inner surface of the inner sleeve or bat barrel. Removing such a fusion end cap would be very difficult and would result in significant damage or damage to the end cap itself. In addition, any "successful" end cap removal can result in a broken band in the bat barrel or on the inner sleeve, making it virtually impossible to successfully attach or adhere the other end cap to the rupture zone.

Various specific embodiments will now be described. Of course, it should be understood that other embodiments utilizing the inventive concepts described herein may be used instead.

Turning to Figures 3 and 4, in one embodiment, a sleeve 30 is permanently bonded, molded or otherwise attached to the inner surface of a bat barrel 12. A flexible end cap 29 includes a ridge or raised ring 28 and has an outer diameter that is greater than the inner diameter of the inner sleeve 30 prior to insertion of the end cap 29 into the barrel 12. End cap 29 and inner sleeve 30 are formed from similar or identical materials, such as thermoplastic or other suitable materials, such that when they are ground together in a, for example, a spin welding procedure, a solid bond can be formed therebetween. At a minimum, the end caps 29 are made of a material that is compatible with the resin of the barrel such that thermal bonding between them can be achieved in a spin welding or similar procedure.

In one embodiment, the inner sleeve 30 can be formed into a cylindrical shape by injection molding before it is fused to the barrel 12, which includes a substantially The inner diameter of the bat barrel 12 matches the outer diameter. The sleeve 30 may additionally or alternatively include one or more grooves in which the epoxy may flow, or one or more ridges 34 that may be corresponding to the recesses on the inner surface of the bat barrel 12. The slots or channels engage to provide a mechanical lock to the barrel 12. The inner sleeve 30 can optionally include a gap along its length that allows the inner sleeve 30 to expand during the molding process.

In one embodiment, the inner sleeve 30 can be bonded to the inner surface 32 of the barrel 12 in a molding process. The inner sleeve 30 can be placed in a preformed barrel during mold filling. When the mold is heated and air pressure is applied to compact the prepreg cylinder plies, the inner sleeve 30 is pressed against the plies to bond them to the epoxy.

The inner sleeve 30 effectively forms at least a portion of the inner material of the barrel 12. Fusing the end cap 29 to the inner sleeve 30 can occur at any time during the manufacturing process, but typically occurs after the barrel 12 is completed and modified. The spin welding process is well suited for fusing the end cap 29 to the inner sleeve 30. This procedure involves clamping or otherwise securing the bat barrel 12 in place when the end cap 29 is rotated and inserted into the bat barrel 12 at a high rotational speed. To rotationally weld the end cap 29 to the inner sleeve 30 or inner surface of the bat barrel 12, the end cap 29 is rotated at a speed of about 2500-3500 rpm or about 3000 rpm.

In the embodiment illustrated in Figures 3 and 4, the protruding ring 28 of the end cap 29 comes into contact with the inner sleeve 30 and its thermoplastic (or other similar) material is welded together by heat generated by friction between them. . The end cap 29 continues to be inserted into the barrel 12 until a shoulder 36 on the end cap 29 contacts the end of the bat barrel 12. The two component melt zones 38 are then solidified such that the end cap 29 It becomes permanently fused to the bat barrel 12. Any excess resin or flash may optionally be collected in a slot region 31. A second slot region can optionally be included at the handle end of the melt zone 38.

Figure 4 illustrates the end cap 29 being fused to the bat barrel 12 in the finished state. The protruding ring 28 of the end cap 29 has melted and is fused to the inner sleeve 30 in the melt zone 38. Excess flash is provided in the slot region 31. The volume of the melt zone 38 can vary based on the materials used, the strength of the attachment required, and the desired weight of the bat. If such a fusion end cap 29 is removed, the melt zone 38 will rupture. The resulting rupture zone will have a rough and inconsistent surface such that it does not effectively reattach the end cap 29 or attach a replacement end cap. In addition, there are no mechanical mechanisms available to attach the end caps.

Figures 5 and 6 illustrate an embodiment in which the inner sleeve 40 is injection molded onto the inner surface of a metal cylinder, such as an aluminum cylinder 42. The aluminum cylinder 42 includes a ridge or inwardly projecting ring 44 and a recess 46. Other mechanical devices can be used to lock the inner sleeve 40 and the aluminum cylinder 42. For example, additional grooves or collars can be utilized. Additionally or alternatively, the apertures may be drilled into the wall of the barrel for receiving a protruding configuration on the inner sleeve.

The barrel 42 is placed in an injection mold with the outer portion 48 of the mold compressed and sealed to the outer surface 50 of the barrel 42. A core core 52 is then inserted into the barrel to compress and seal the protruding ring 44 and end 55 of the barrel 42. The polymer resin is injected into the space 53 formed between the inner surface 54 of the cylinder 42 and the outer surface 56 of the core 52 to form the inner sleeve 40. The injected polymer flows into the recess 46 to provide a mechanical lock.

Figure 6 depicts the molding to the injection molding process shown in Figure 5 The inner sleeve 40 of the barrel 42. The polymer has been formed in the recess 46 to provide a mechanical lock that prevents the inner sleeve 40 from being removed. A weld zone between a subsequently added end cap and inner sleeve 40 can be located anywhere along the length of the inner sleeve 40. Removing such end caps will result in rough and inconsistent break zones, making replacement of the end caps virtually impossible.

Figures 7 and 8 illustrate another embodiment in which the end cap 74 is attached to a metal cylinder, such as an aluminum cylinder 60. The aluminum cylinder 60 includes an inwardly projecting ridge or flange 62 and an inwardly projecting receiving portion or forming portion 64. The flange 62 includes an inner edge 66 having a smaller diameter than the inner surface 68 of the barrel 60. The shaped portion 64 includes a curved portion 70 and an inner edge 72. The inner edge 72 has a diameter that is less than the inner diameter of the inner edge 66 of the flange.

End cap 74 includes a cylindrical or substantially cylindrical extension 76. The end cap 74 is rotated at a high speed of about 2500-3500 rpm or about 3000 rpm and is inserted into the barrel 60. When the end cap extension 76 is in contact with the curved portion 70 of the barrel 60, the thermoplastic (or similar) material of the end cap 74 begins to soften and deform. The deformed extension 76 is then guided by the curved portion 70 into the cavity 78 below the flange 62 such that the end cap 74 is secured in place. Figure 8 illustrates the installed end cap 74 and the deformed extension 80 that fills the cavity 78 and locks the end cap 74 in place.

In another embodiment, the bat barrel may include an outer recess or region for receiving a sleeve that may be fused or otherwise attached by the inner surface of one end cap. This construction is particularly suitable for metal bat barrels, but can also be used with a composite bat barrel. The end of the bat barrel can be formed by machining in the case of a metal bat or in the case of a composite bat Forming.

An example of such an embodiment is illustrated in Figures 9-11. A bat barrel 90 includes recessed channels or grooves 92 that are joined by edges 94 or other outward projections. The sleeve 100 is molded or otherwise attached to the outer surface of the groove 92. End cap 110 is fused or otherwise attached to weld zone 112 formed by outer sleeve 100 between an inner surface of end cap 110 and an outer surface of sleeve 100.

The outer sleeve 100 can be a conformal C-ring such as a thermoplastic ring that can be pulled apart to clear the edge 94 and seat on the bottom 102 of the recess 92. On the other hand, the sleeve 100 may be made of two or more separate members disposed along the outer circumference of the groove 92. A spin welding or similar method desirably fuses any slits to form a single piece that is fused to the end cap 110.

In the illustrated embodiment, the optional apertures 96 or openings are drilled through the wall 98 of the bat barrel 90 at the recessed region. The outer sleeve 100 includes one or more protrusions 104 that are adapted to one or more apertures 96. Such protrusions 104 help prevent rotation of the outer sleeve 100 when the end cap 110 is rotationally welded or otherwise attached to the outer sleeve 100. The free end of the protrusion 104 can optionally be thermally riveted to the inner wall 106 of the bat barrel 90.

Any of the above embodiments may be used alone or in combination with the other. Moreover, the end caps and associated attachment mechanisms can include additional features not described herein. While a number of embodiments have been shown and described, various modifications and changes may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, but limited by the scope of the following claims and their equivalents.

12‧‧‧Cylinder

28‧‧‧ Ring

29‧‧‧End cover

30‧‧‧ sleeve

31‧‧‧ slot area

38‧‧‧ melting zone

Claims (20)

A bat comprising: a handle; a barrel attached to or integral with the handle; a sleeve attached to a surface of the barrel or to the barrel One surface of the body is combined into a unitary body; and an end cap is disposed at one end of the barrel and fused with the sleeve. The bat of claim 1 wherein the end cap and the sleeve comprise substantially similar materials such that they are fused to each other. The bat of claim 2, wherein each of the end cap and the sleeve comprises a thermoplastic material. The bat of claim 3, wherein the barrel comprises a composite material and the thermoplastic sleeve is molded or bonded to an inner surface of the composite cylinder. The bat of claim 3, wherein the barrel comprises a composite material and the thermoplastic sleeve is molded or bonded to an outer surface of the composite cylinder. The bat of claim 1 wherein the end cap is fused to an inner surface of the sleeve. The bat of claim 1, wherein the end cap is fused to the sleeve An outer surface. The bat of claim 1, wherein the sleeve is injection molded onto the inner surface of the barrel. The bat of claim 8, wherein one of the sleeve and the inner surface of the barrel includes a protrusion, and the other of the sleeve and the inner surface of the barrel includes a corresponding one A recess for receiving the projection therein to mechanically secure the sleeve to the inner surface of the barrel. The bat of claim 1, wherein one of the sleeve and the surface of the barrel includes a protrusion, and the other of the sleeve and the surface of the barrel includes a corresponding groove Providing the projection therein for mechanically securing the sleeve to the surface of the barrel. A bat comprising: a handle; a barrel comprising a first end attached to or integral with the handle and a second distal end, the barrel being at the second end The end includes an inwardly projecting edge and an inwardly projecting formation spaced from the edge to define a cavity between the edge and the formation; and an end cap comprising a deformable An extension is disposed below the edge in the cavity such that the end cap is secured to the barrel. The bat of claim 11, wherein the barrel comprises a metallic material and the end cap comprises a deformable material. The bat of claim 12, wherein the end cap comprises a thermoplastic material. The bat of claim 11, wherein the forming portion includes a bend that positions the deformable extension in the cavity. A method of attaching an end cap to a barrel of a bat, comprising the steps of attaching a sleeve to an inner surface of the barrel; rotating the end cap at a high speed; An end cap is inserted into the barrel such that an outer region of the end cap rotates an inner surface of the sleeve; and the outer region of the end cap is welded to the sleeve by heat and friction generated therebetween . The method of claim 15, wherein the attaching step comprises the step of molding the sleeve onto the inner surface of the barrel. The method of claim 15 wherein the attaching step comprises the step of bonding the sleeve to the inner surface of the barrel. The method of claim 15, wherein the rotating step comprises the following steps Step: The end cap is rotated at a high speed of about 3000 rpm. The method of claim 15 wherein the inserting step continues until a shoulder on the end cap contacts one end of the barrel. A bat comprising: a handle; a barrel attached to or integral with the handle, the barrel comprising a first fusible material; and an end cover comprising a second A fusible material that is compatible with the first fusible material and that is fused directly to the barrel.