WO2008149183A1 - Composite lacrosse head having a multiple tube structure - Google Patents

Abstract

A structure for a lacrosse head is described by using multiple composite tubes bonded to one another, wherein apertures, or 'ports,' are molded between the tubes to improve the stiffness, strength, ball control, netting attachment and aerodynamics of the lacrosse head. Further aspects of the present invention relate also to a lacrosse stick and a lacrosse handle component having a multi-tube structure.

Description

COMPOSITE LACROSSE HEAD HAVING A MULTIPLE TUBE STRUCTURE

DESCRIPTION

BACKGROUND OF THE INVENTION

The present invention relates to a composite structure for a lacrosse head. Further aspects of the present invention relate also to a lacrosse stick and a lacrosse handle component having a multi-tube structure.

The performance of a lacrosse stick is determined by a number of factors such as weight, swing weight, strength, ball catching, ball control, ball throwing, and aerodynamics. The traditional lacrosse stick is comprised of a single tubular handle connected to a head with a strung netting for handling the ball. The handle portion may be made from a number of materials such as aluminum, steel, titanium, and light weight composite materials. The head is traditionally made from injection molded polymers such as polyamide, polycarbonate and abs. The weight of a lacrosse stick is a critical feature in determining performance. The lighter the stick weight, the easier it is to swing the stick resulting in higher swing speeds. Therefore, the lightest materials and designs are used to achieve these performance goals. A popular high performance material for modern lacrosse handles is Carbon Fiber reinforced Epoxy resin (CFE) because it has the highest strength and stiffhess-to -weight ratio of any realistically affordable material. As a result, CFE can produce a very light weight lacrosse handle with excellent strength as well as providing a variety of stiffnesses. CFE has been used in limited applications for the head because it is preferred the head have more flexibility to accommodate the various skills needed in lacrosse. A stiffer head tends to have a trampoline effect making catching the ball difficult. It is also more difficult to catch the ball if the strung netting is too tight, meaning that the string tension in the netting is too high. It is generally desirable to have a flexible upper portion of the lacrosse head for catching balls and scooping balls off the ground. The lower portion of the head needs to be stiffer to contain the ball in the pocket. A certain amount of stiffness of the head is desired when throwing the ball. This largely depends on the type of motion to throw the ball.

The modern lacrosse head is a one piece injection molded polymeric frame that attaches to the handle portion of the stick. The typical lacrosse head has a pair of curved sidewalls diverging from a "U" shaped throat area, a top scoop portion joining the side walls, a means to attach to a handle portion, and a net strung to the frame of the lacrosse head. The conventional netting used in a lacrosse head comprises four longitudinally extending thongs which are connected to the head by means of holes formed in the scoop portion and holes in the region of the throat. Lacing or cord is intertwined between these thongs and is connected to the sidewall by holes formed therein.

Some examples of injection molded polymer lacrosse heads are: U.S. Pat. Nos. 5,494,297 and RE37,894 to MacNeil; U.S. Pat. No. 5,568,925 and RE38,216 to Morrow and Naumburg; U.S. Pat. Nos. 5,651,549 and 5,935,026 to Dill and Brine; U.S. Pat. No. 5,651,744 to Millon and Fream; U.S. Pat. No. 5,674,140 to Tucker, et. al.; U.S. Pat. No. 5,938,550 to Hexemer et. al.; and U.S. Pat. Nos. 6,561,932, 6,902,501, and 6,926,628 to Morrow and Hubbard. Many of the injection molded lacrosse head designs have features to enhance ball control. Some examples are U.S. Pat. No. 5,067,726 to Brine and Brine which describes a ball stop member attached to the throat area of the lacrosse head. U. S. Pat. No. 6,066,056 to Morrow describes ball retaining ridges that extend along the interior surface of the sidewalls to retain the ball in the pocket. U. S. Pat. No. 6,923,739 to Gait and Kohler describes a lacrosse head with edge protrusions to improve ball control. U. S. Pat. No. 7,044,868 to Brine and Lamson describes a lacrosse head with inner projecting sidewalls to improve ball control. U.S. Pat. Nos. 6,723,134, 6,910,976, and 7,101,294 to Tucker describe multiple component lacrosse head made of at least two materials to improve ball control.

Another important characteristic of a lacrosse head is catching the ball. It is desirable to have a soft pocket to absorb the velocity of the ball and eliminate bouncing or rebound. U.S. Pat. No. 5,957,791 to Nichols and Johnson describes a lacrosse head provided with stringing holes located on the upper edge of the sidewalls to create a deeper, narrower pocket for improved ball catching. U.S. Pat. No. 6,852,047 to Tucker describes a lacrosse head frame having a thread hole and an aperture proximate to the thread hole. The aperture creates a moveable structure of the frame to absorb the ball velocity for improved ball catching. The features of a lacrosse head that improve ball catching may be the opposite of those needed for ball throwing. When throwing the ball, the handle is accelerated which causes the head of the lacrosse stick to flex. Some flexure is desirable, but too much will result in a loss of energy and throwing velocity. In addition, because the lacrosse heads are constructed of a homogeneous polymeric material, they are susceptible to fatigue and become more flexible with use. Furthermore, the polymeric materials are hygroscopic, meaning that moisture is absorbed from the atmosphere, which can degrade the properties based on the environment. An improvement in performance for the lacrosse head is possible with different materials. Fiber reinforced composites offer an excellent alternative to injection molded polymers because they are stiffer, stronger, and can provide different stiffness in different areas by using different fibers, resins, and fiber angles. U.S. Pat. No. 5,685,791 to Feeney describes a composite lacrosse stick head comprised of a fiber reinforced resin tubular structure molded to create a closed loop configuration. Holes are then drilled to accommodate the strings and netting. This process is similar to that used to produce hollow composite tennis racquets and will produce a stiff and strong structure. However, the disadvantage is the lacrosse head structure will be too stiff for ball catching, resulting in a trampoline effect.

U.S. Patent Applications US2006/0025247 and US2006/0025248 to Hayden and Wittman describe a single body lacrosse stick where the head and handle are molded as one piece. The preferred material is fiber reinforced composites. As mentioned previously, this will result in a stiffer and stronger structure for ball throwing. There is no mention of how to make this composite structure more flexible, so ball catching will likely suffer.

U.S. Patent Application US2005/0043123 to Harvey describes a lacrosse stick where the head and handle are connected by an external sheath to form a unitary structure. The inventor teaches that a head which is more flexible than the handle is desirable. To achieve the flexible head, the inventor teaches the use of a polymer material. The connection to the handle may be improved with the external sheath, but the polymer head is still susceptible to fatigue and environmental conditions. The inventor mentions the option of molding the exterior of the head out of fiber reinforced composites, but does not provide details on how to optimize the stiffness of the head.

U.S. Patent Application Number US2006/0019777 to Rogers et. al. describes a flexible head frame over molded onto a forked end of a composite handle. This may provide a more secure connection between the flexible head and stiffer handle. However, the flexible head is still subject to fatigue and environmental conditions. In addition, once the flexible head is no longer useable, it cannot be replaced. The entire lacrosse stick must be replaced. There exists a continuing need for an improved lacrosse stick head which has improved strength and stiffness options while providing an improved pocket attachment means. In this regard, the present invention substantially fulfills this need. SUMMARY OF THE INVENTION

The present invention relates to a composite structure for a lacrosse head, and more particularly, where the structure is generally tubular and the traditional solid polymeric structure is replaced with multiple continuous tubes, preferably a pair of tubes fused together along their facing surfaces to provide an internal reinforcing wall as well as apertures, or "ports," between the tubes to provide specific performance advantages.

In particular, a multiple tube design is adopted, which maintains the same or similar geometric exterior shape of the original lacrosse head design. This provides a structure with an internal wall between the tubes which has strength and stiffness advantages. In addition, the tubes can be separated at various locations to form apertures or ports between the tubes which act as opposing arches which provide advantages in strength, flexibility, ball control, pocket attachment, and aerodynamics.

The lacrosse head according to the present invention substantially departs from the conventional concepts and designs of the prior art and in doing so it provides a structure primarily developed for the purpose of improved strength, flexibility, ball control, pocket attachment, aerodynamics, and appearance.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.

For example, further aspects of a present invention relate to the use of a multiple structure for a lacrosse stick and a lacrosse handle, which may be metal and produced using a multiple tube construction in which the tubes have facing surfaces which are bonded to one another along at least much of their lengths.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

The present invention provides a new and improved lacrosse head which may be easily and efficiently manufactured. The present invention provides a new and improved lacrosse head which is of durable and reliable construction.

The present invention provides a new and improved lacrosse head which may be manufactured at a low cost with regard to both materials and labor

The present invention further provides a lacrosse head that can provide specific stiffness zones at various orientations and locations along the length of the lacrosse head.

The present invention provides an improved lacrosse head that has superior strength and fatigue resistance.

The present invention provides an improved lacrosse head that has improved netting attachment means.

The present invention provides an improved lacrosse head that has improved aerodynamics.

The present invention provides an improved lacrosse head that has a unique look and improved aesthetics.

Lastly, the present invention provides a new and improved lacrosse head made with a multiple tube design, where the tubes, which are fused together along much of their lengths, are preferably separated from one another at selected locations to form apertures that act as double opposing arches, providing improved means of adjusting stiffness, resiliency, strength, ball control, netting attachment, and aerodynamics.

For a better understanding of the invention and its advantages, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an isometric view of a lacrosse head constructed in accordance with an embodiment of the present invention.

Figure 2 is a side view of the lacrosse head shown in Figure 1.

Figure 2 A is a cross sectional view of the lacrosse head taken along lines 2A-2A of Figure 2.

Figure 2B is a cross sectional view of the lacrosse head taken along lines 2B-2B of Figure 2.

Figure 2B is a cross sectional view of the lacrosse head taken along lines 2C-2C of Figure 2.

Figure 2D is a longitudinal sectional view of a portion of the lacrosse head taken along lines

2D-2D in Figure 2.

Figure 3 is a side view of lacrosse head constructed with a multiple tube design.

Figure 3 A is a cross section of the lacrosse head taken along lines 3A-3A of Figure 3.

Figure 3B is a cross section of the lacrosse head taken along lines 3B-3B of Figure 3. Figure 4 shows a means of attaching the strung pocket to the molded ports.

Figure 4A is a cross section of the attachment means shown in Figure 4 taken along the lines

4A-4A.

Figure 4B is a cross section of an alternative netting attachment means.

Figure 4C is a cross section of an alternative netting attachment means.

Figure 5 is a view of an alternative netting attachment means.

Figure 6 is a view of an alternative netting attachment means.

Figure 7 is a view of an alternative netting attachment means.

Figure 8 shows an alternative example of a multiple tube lacrosse head.

Figure 8 A is a cross sectional view taken along the lines 8A-8A of Figure 8.

Figure 8B is a cross sectional view of an alternative design of Figure 8 A.

Figure 8 C is a cross sectional view of an alternative design of Figure 8 A.

Figures 9-9C show various shapes of ports.

Figures 10-11 are perspective views illustrating a process for forming a frame member of two different materials.

The same reference numerals refer to the same parts throughout the various Figures.

DETAILED DESCRIPTION OF THE INVENTION

As described below, the lacrosse head is formed of two or more tubes which are molded together to form a common wall (or walls, in the case of more than two tubes). However, at selected locations, the facing surfaces of the tubes are kept apart during molding, to form openings. On either side of the openings, the tubes are joined together. The openings so formed are referred to herein as "ports." These ports are formed without drilling any holes or severing any reinforcement fibers.

The resulting structure is found to have superior performance characteristics for several reasons. The ports are in the shape of double opposing arches which allow the structure to deflect which deforms the ports, and return with more resiliency. The ports also allow greater bending flexibility than would traditionally be achieved in a single tube composite design. The internal wall between the internal tubes adds strength to resist compressive buckling loads such as those near high deflection areas such as the scoop region. The structure can also improve attachment of the strung netting to the lacrosse head frame by offering a quick attachment means. Finally, the ports can improve aerodynamics by allowing air to pass through the lacrosse head to reduce the wind resistance and improve maneuverability.

Figure 1 illustrates a lacrosse head, which is referred to generally by the reference numeral 10. The lacrosse head 10 is comprised of a tip or scoop portion 12, a throat portion 14, sidewall portions 16 and 18, and a handle portion 20.

Figure 1 shows one preferred embodiment wherein the lacrosse head 10 contains openings, or

"ports" 30, located in the sidewalls 16,18 and ports 32 located in the scoop portion 12 of the lacrosse head 10. In addition, ports 34 are located in the netting attachment portion 36 which is fixed to the lacrosse head 10.

Ports 30 in the sidewalls 16 and 18 have axes that are generally parallel to the lacrosse head neutral plane, which is a plane which passes through the central axis of the handle 20, and is equidistant from the top edges of the sidewalls 16 and 18. The ports 30 provide increased flexibility of the sidewalls for in-plane deflections, in other words, for the movement of the sidewalls toward or away from each other. Ports 32 in the scoop portion 12 are oriented with axes at an angle to the neutral plane of the lacrosse head 10, and provide increased flexibility for the scoop portion 12. Ports 34 in the pocket attachment portion 36 have axes that are generally parallel to the neutral plane of the lacrosse head 10, and provide a means to attach netting to the lacrosse head frame.

Ports 30 and 32 oriented in this manner provide improved aerodynamics compared to a single tube composite lacrosse head by reducing the exposed frontal area of the lacrosse head to the wind as the lacrosse head is swung. The ports 30 can be located anywhere along the frame of the lacrosse head. An additional port 38 with an axis perpendicular to the neutral plane may be formed below the throat portion 14 to provide even greater aerodynamic advantage.

The handle 20 may be connected to the lacrosse head 10 to form a unitary structure.

Alternatively, the lacrosse head 10 may be formed separately from the handle 20 and later attached by mechanical means.

Figure 2 shows a side view of the lacrosse head 10 shown in Figure 1 and is used to better show the cross sectional cutting planes. With reference to Figure 2A, this cross sectional view along the lines 2A-2A of Figure 2 shows the three tubes 40, 42, 44 which form the structure of the lacrosse head 10. The tubes 40 and 42 are joined together to form an internal wall 46, and tubes 42 and 44 are joined together to form an internal wall 48.

The preferred location of the internal wall 46 is such that tubes 40 and 42 are the same size and, when molded, form a "D" shape. The tube 44 for the pocket attachment portion 36 is much smaller than tube 42, resulting in a smaller internal wall 48.

Figure 2B shows a cross sectional view along the lines 2B-2B of Figure 2 where the internal tubes 40 and 42 are separated from one another to form port 30. It is advisable to have a radius (i.e., rounded edges 50) leading into the port so to reduce the stress concentration and to facilitate the molding process.

Figure 2C shows a cross sectional view along the lines 2C-2C of Figure 2 where in addition to internal tubes 40 and 42 being separated, internal tubes 42 and 44 are separated from one another to form port 34. It is advisable to have a radius (i.e., rounded edges 50) leading into the port so to reduce the stress concentration and to facilitate the molding process. The port

34 may have a particular shape to accommodate netting attachment means.

Figure 2D is a longitudinal cross section of a portion of the lacrosse head 10 taken along the lines 2D-2D in Figure 2. The internal tubes 40 and 42 are positioned side by side and are fused together along much of their lengths to form a common wall 46. At selected locations, e.g., where ports 30 are to be formed, the facing surfaces 40a and 42a of the tubes 40 and 42 are separated during molding to form apertures 30 in the shape of double opposing arches which act as geometric supports to allow deformation and return. In addition, the internal wall 46 provides structural reinforcement to resist deformations and buckling failures.

In a similar manner the internal tubes 42 and 44 are positioned side by side and are fused together along much of their lengths to form a common wall 48. At selected locations, e.g., where ports 34 are to be formed, the facing surfaces 42b and 44a of the tubes 42 and 44 are separated during molding to form apertures 34 in the shape of double opposing arches which act as attachment means for the pocket. In addition, the internal wall 48 provides structural reinforcement to resist deformations and buckling failures.

Figure 3 shows an alternative design using two tubes to form the lacrosse head 10. In this example, a single row of ports 34 are formed. In this example, ports 34 are for attaching the pocket to the lacrosse head. The ports 34 could also provide previously mentioned advantages such as improved bending flexibility and improved strength.

Figure 3 A shows a cross sectional view along the lines 3 A-3 A of Figure 3 where internal tubes

50 and 52 form the internal wall 54. Figure 3B shows a cross sectional view along the lines

3B-3B of Figure 3 where internal tubes 50 and 52 are separated from one another to form port

34. The shape of port 34 will depend on whether it is used for pocket attachment or other performance characteristics.

In a multiple tube design, there can be any number of ports and orientations of ports depending on the number of internal tubes used and how many are separated to form these ports. In addition, for example with a 3 tube design, the axes of the ports would not necessarily have to be parallel to each other. Figure 4 shows a method of attaching the netting to the lacrosse frame. A partial view of a lacrosse head 10 is shown. The lacrosse head 10 is comprised of internal tubes 40 and 42 which are separated at various locations to form ports 34.

It is common for lacrosse netting to be manufactured as a pre-woven mesh resulting in closed ended loops 54 used to tie to the lacrosse head 10. In this particular example, loop ends 54 are inserted through ports 34. A continuous member 56 is inserted through each of the exposed loop ends to secure the netting to the lacrosse frame 10.

Figure 4A shows a cross sectional view taken along lines 4A-4A of Figure 4. The member 56 is positioned inside the loop end 54 and is supported by the surface 58. The member 56 must be stiff and strong enough to not be pulled through the port 34 during ball catching or throwing. The member 56 may be of a flexible multifilament construction similar to a typical stringer used to attach netting to lacrosse frames. The member 56 may also be more rigid plastic material such as extruded polyethylene, polyamide, abs, or similar. Figure 4B shows a cross section of an alternative design to secure the loop end 54 to the port 34 of the lacrosse head 10. A wedge shaped member 60 is placed inside the loop end 54. This assembly is positioned into the port 34. The wedge 60 has a tapered shape so that the more it is forced into the port 34, the more pressure it exerts on the loop end 54 against the wall of the port 34. The wedge 60 is designed so that it largest dimension shall not permit the loop end 54 to pass through the port 34.

Figure 4C shows an alternative wedge design 62 with a cap 64 positioned on top of the tapered portion 66. The cap 64 has a shoulder 68 that rests on the string groove 58 (see Figure 4). In addition, the wedge 62 comprises a string groove 70, which provides a location for the loop end 54 as well as protecting the loop end 54 from impacts and abrasion against foreign matter.

Figure 5 illustrates an alternative design for securing the netting to the lacrosse head. Shown is a portion of a lacrosse head 10 with elongated ports 70. A plastic grommet 72 is shaped with a cap 74 fixed to a male portion 76. The male portion 76 is designed to fit (see the dotted arrow) the port 70 with a slight interference fit so that it will not back out during play. The cap 74 is larger than the port 70 which creates a shoulder 80 which is supported by the frame surface 82. A string groove 78 is formed in the male portion 76 and cap 74 to accommodate the loop end 54. To attach the netting to the lacrosse head, the loop end 54 is threaded through the port 70 and around the grommet 72 using the string groove 78. The grommet 72 is inserted into the port 70 until the shoulder 80 of the grommet 72 rests against the string groove 82 of the lacrosse frame 10. The grommet 72 is sufficiently stiff and strong enough to resist the tension in the loop end 54 resulting from ball catching or throwing. Figure 6 is a cross sectional view illustrating another method of attaching the netting to the lacrosse frame. The cross section of the lacrosse head 10 is in the area of a port 84. The port 84 is formed with a larger diameter 86 on the exterior side and a smaller diameter 88 on the netting side. A cable tie (or wire tie) 90 is positioned with its head 92 supported inside the larger diameter 86 of the port 84. The band 94 of the cable tie 90 is positioned through the smaller diameter area 88 of port 84, through the loop end 54 and returns back through the smaller diameter 88 of port 84 back into the head 92. The band 94 has ridges that engage teeth (not shown) in head 92, and when pulled, brings the loop 54 closer to the lacrosse head 10. This provides some tension adjustment when securing the netting to the lacrosse head and can be an advantage in creating the type of pocket for a particular style of play. Any excess length 94a of band 94 that protrudes on the exterior side of the lacrosse head 10 can be cut off to leave a smooth surface.

Figure 7 illustrates a traditional means of attaching the netting to the lacrosse head 10. In this example, a pre-woven netting is not used. A netting string 96 is strung through the port 98 and continues along the string groove 100 and back through the adjacent port 98'. This is a similar technique to stringing a tennis racquet.

Figure 8 shows an alternative design for the lacrosse head 10. In this example, ports 102 are formed as previously described. A long port 104 is formed in the tip region 12 connecting side 16 to side 18. The port 104 is comprised of tubes 106 and 108 which, because of their long unsupported length, provide more flexibility in the tip region 12.

Figures 8A-8C show cross sectional views (along the line 8A-8A) of the tip area of the lacrosse head 10 in Figure 8. Tubes 106 and 108 can move independently of each other to offer more flexibility in this region. It is also possible to place a spacer 110 between tubes 106 and 108. This spacer can increase the stiffness of the lacrosse head if the spacer is bonded to tubes 106 and 108. The spacer can also be over molded on to tubes 106 and 108. The spacer 110 is preferably an elastomeric material but can also be polymeric. The spacer 110 may also have a port 112 molded in it to provide improved performance or netting attachment means. Figures 9A-9C illustrate some examples of the variety of shapes possible to be used for the ports. Depending on the performance required of the structure at a particular location, more decorative port shapes can be used. In all orientations, the quantity, size, and spacing of the ports can vary according to the performance desired. In addition, ports can be fitted with elastomeric inserts to provide additional cushioning and ball control.

The preferred embodiments of the present invention use multiple continuous composite tubes which are separated to form apertures in the form of double opposing arches at various locations in the lacrosse head.

The single tube, hollow composite lacrosse head must have holes drilled in it to accommodate attaching the netting. This is a disadvantage because moisture and debris can get inside the lacrosse head and affect the weight and performance. In addition, the single tube composite lacrosse head will be too stiff for many playing styles.

When a single hollow tube has a sufficient wall thickness, for example when weight is not critical, the design can sufficiently provide adequate stiffness and strength. However, when the wall thickness becomes thin relative to the diameter of the tube, the tubular part is susceptible to the wall buckling under the impact forces which are always present in lacrosse heads.

In accordance with the present invention, conventional single hollow tubes forming the lacrosse head are replaced with multiple tubes joined with an internal wall in between. The internal wall resists deformation of the cross section under loading which resists the buckling of the wall under compressive forces.

The invention allows the lacrosse head to be custom tuned in terms of its stiffness and resiliency by varying, in addition to the geometry of the lacrosse head itself, the size, number, orientation and spacing of the ports in the lacrosse head.

The process of molding with composite materials facilitates the use of multiple tubes in a structure. The most common method of producing a composite lacrosse head is to start with a raw material in sheet form known as "prepreg" which are reinforcing fibers impregnated with a thermoset resin such as epoxy. The resin is in a "B Stage" liquid form which can be readily cured with the application of heat and pressure. The fibers can be woven like a fabric, or unidirectional, and are of the variety of high performance reinforcement fibers such as carbon, aramid, glass, etc. The prepreg material commonly comes in a continuous roll or can be drum wound which produces shorter sheet length segments. The prepreg is cut at various angles to achieve the correct fiber orientation, and these strips are typically overlapped and positioned in a "lay-up" which allows them to be rolled up over a mandrel to form a pre-form. The mandrel is removed and a thin polymeric bladder in inserted in the pre-form. The pre-form is placed inside a cavity of a mold and the mold is closed. As the mold heats up, air pressure is applied to the bladder which inflates to apply pressure to the prepreg laminates to consolidate and cure the part.

The present invention will require a similar internal inflation molding technique because the use of multiple tubes and forming ports requires internal pressure to consolidate the prepreg plies.

For example when molding the same lacrosse head using two prepreg tubes, each tube should be approximately half the size of the single tube. A polymer bladder is inserted into the middle of each prepreg tube and is used to generate internal pressure to consolidate the plies upon the application of heat. The mold packing process consists of taking each prepreg tube and internal bladder and position into a mold cavity and an air fitting is attached to the bladder. The process is repeated for each tube depending on how many are used. Care should be taken for the position of each tube so that the internal wall formed between the tubes is oriented properly, and that pins can be inserted between the tubes in order to form the ports during pressurization. The pins are secured into portions of the mold and are easily removed.

The mold is pressed closed in a heated platen press and air pressure for each tube should be applied simultaneously to retain the size and position of each tube and the formed wall in between. Simultaneously, the tubes will form around the pins to form the ports, and fuse together to form the internal walls at locations between the ports. As the temperature rises in the mold, the viscosity of the epoxy resin decreases and the tubes expand, pressing against each other until expansion is complete and the epoxy resin is cross linked and cured. The mold is then opened, the pins removed, and the part is removed from the mold.

The internal wall of the molded tubular part adds significantly to improving the structural properties of the tubular part. During bending or local deflections resulting from ball impacts, the shape of the lacrosse head is maintained much better, eliminating the tendency to buckle the cross section.

The orientation of the wall can be positioned to take advantage of the anisotropy it offers. If more bending flexibility is desired, the wall can be positioned along the neutral axis of bending.

If greater stiffness is needed, then the wall can be positioned like an "I Beam" at 90 degrees to the neutral axis to greatly improve the bending stiffness.

Molding the tubular parts using multiple tubes allows greater design options. Separating the internal tubes at selected axial locations along the lacrosse head in order to mold large oval shaped openings between the tubes, allows the characteristics of the lacrosse head to be varied as desired.

Molding in of apertures, or ports, at selected locations results in a double opposing arch construction. What is contributing to the structure, is the "double arch effect" of the ports, which are oval in shape creating two opposing arches which allow the tubular part to deflect, while retaining the cross sectional shape of the tube because of the three dimensional wall structure provided by the port. For example, a ported double tube structure has a combination of exterior walls, which are continuous and form the majority of the structure, and ported walls, which are oriented at an angle to the exterior walls, which provide strut like reinforcement to the tubular structure. The cylindrical walls of the ports prevent the cross section of the tube from collapsing, which significantly improves the strength of the structure. This provides an opportunity to reduce the wall thickness of the lacrosse head, add flexibility where needed for ball control, or add stiffness where needed for more throwing velocity. The stiffness and resiliency of the ported double tube structure can be adjusted to be greater or less than a standard single hollow tube. This is because of the option of orienting the internal wall between the tubes as well as the size, shape, angle and location of the ports. The ports can be stiff if desired, or resilient allowing more deflection and recovery, or can be designed using different materials or a lay-up of different fiber angles in order to produce the desired performance characteristics of the structure.

The structure can be further refined by using more than two tubes. For example, using three tubes allows for apertures to occur in 120 degree offsets, providing specific stiffness tailoring along those directions. Using four tubes provides the possibility of having apertures at ninety degree angles to each other and alternately located along the length of the tubular part to achieve unique performance and aesthetic levels. Another option is to locate the multiple ports in the same location to achieve more of an open truss design.

Another option is to combine a single composite tube with a multiple tube composite design. In this example, the single composite tube portion could be the throat portion of the lacrosse head, and co-molded with the multiple prepreg tubes which form the scoop or tip portion of the lacrosse head to produce a lower cost alternative to a 100 % multiple tube construction. Another option is to combine the composite head portion with a metal handle portion. In this example, the metal handle of the lacrosse stick is fused or co-molded with the multiple prepreg tubes in the head portion to produce a lower cost alternative to a 100 % carbon composite stick construction. This can produce a less expensive structure that can still achieve the performance and aesthetic requirements of the product.

Referring to Figs. 10-11, in order to make this construction, the forward ends 114 of a pair of prepreg tubes 116a, 116b, each having an inflatable bladder 118, are inserted into one end 120 of a metal tube 122. The shape of the tube may be any, e.g. cylindrical or octagonal. The unit is placed inside a mold having the same shape of the metal tube 122, at least at the juncture

124 of the prepreg tubes 116a, 116b and the metal tube 122. A pin or mold member (not shown) is placed between the prepreg tubes 116a, 116b where a port 38 is to be formed. The mold is then closed and heated, as the bladders 118 are inflated, so that the prepreg tubes assume the shape of the mold, the mold member keeping the facing walls 126a, 126b apart so as to form the port 38. As shown, the tubes 116a, 116b will form a common wall at seam 128.

After the prepreg tubes have cured, the frame member 130 is removed from the mold, and the mold member or pin is removed, leaving the port 38. In this embodiment, the seam 124 between the graphite portions 116a, 116b of the frame member 130 and the metal tube portion

122 should be flush.

Another option is to attach the composite ported lacrosse head to the metal handle by mechanical fastening means as is done with conventional lacrosse sticks. In this manner the handle can be removed and replaced by another if needed.

Another advantage of the invention is using the molded ports to attach elastomeric plugs.

These plugs can be fitted to the interior walls of the ports and can improved ball control by offering a softer surface to absorb ball movement. These plugs can come in a variety of shapes and hardnesses to customize to the player needs. The plugs can be connected to each other to form a continuous soft surface that is connected to the lacrosse head using the ports.

The ports provide a means to quickly attach the netting to the lacrosse frame head. The ports have continuous walls to support a variety of mechanical devices to secure the netting to the lacrosse frame. The continuous walls of the ports prevent any moisture or debris from getting inside the hollow tubular frame structure.

The aerodynamic benefit provided by the ports is determined by the size of the ports relative to the size of the lacrosse head frame. In comparing the frontal area of a shaft section which is subjected to an aerodynamic force, it is possible to achieve a reduced frontal area of up to

25%. This is a significant achievement for a lacrosse head, especially considering that stiffness and strength are not compromised, but in fact improved.

Finally, there is a very distinguished appearance to a lacrosse head made according to the invention. The ports are very visible, and give the tubular part a very light weight and aerodynamic look, which is important in lacrosse head marketing. The ports can also be painted a different color, to further enhance the signature look of the technology.

There are many combinations of options when considering a double opposing arch structure.

The ports can vary by shape, size, location, orientation and quantity. The ports can be used to enhance stiffness, resilience, strength, ball control, aerodynamics, and aesthetics. For example in a low stress region, the size of the port can be very large in order to maximize aerodynamics and appearance. If more deflection or resilience is desired, the shape of the aperture can be very long and narrow to allow more flexibility. The ports may also use designer shapes to give the product a stronger appeal.

If more vibration damping is desired, the ports can be oriented and shaped at a particular angle, and constructed using fibers such as aramid or liquid crystal polymer. As the port deforms as a result of head deflection, its return to shape can be controlled with these viscoelastic materials which will increase vibration damping. Another way to increase vibration damping is to insert an elastomeric material inside the port.

Another advantage of the invention could be to facilitate the attachment to the handle. Having a port where the handle attaches to the head provides a mechanical means of attachment of the head to the handle.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. A lacrosse head having a tip end, a throat end and side portions connecting said tip and throat ends, wherein at least a portion of said lacrosse head is formed of at least two tubes having facing surfaces, said tubes being formed of composite material, wherein said facing surfaces are bonded to one another at least along much of their lengths, thereby to form at least one internal reinforcing wall.

2. A lacrosse head as defined in claim 1, wherein said portion is formed of a double tube construction.

3. A lacrosse head as described in claim 1, wherein said facing surfaces are separated from one another at least at one selected axial location to form at least one port extending through said lacrosse head perpendicular to said axis.

4. A lacrosse head as defined in claim 3, wherein said at least one port is formed in said connecting portion.

5. A lacrosse head as defined in claim 1, wherein said facing surfaces are separated from one another at selected locations to form ports having a double opposing arch structure.

6. A lacrosse head as defined in claim 5, wherein each said port has an axis there through, and wherein at least two of said ports have different axial orientations.

7. A lacrosse head as defined in claim 5, wherein said ports vary in size.

8. A lacrosse head as defined in claim 5, comprising at least three ports adjacent ports, and wherein one of said adjacent ports is axially spaced from adjacent ports by at least two different distances.

9. A lacrosse head as defined in claim 1, wherein one or more tubes are added to a single tube structure in a local area.

10. A lacrosse head as defined in claim 1, with a port located at the throat end used as an attachment means.

11. A lacrosse head as defined in claim 1 , wherein said lacrosse head is formed of a first tube, a second tube, a third tube, and a fourth tube, each tube having two walls facing and bonded to, along at least most of their length, walls of two adjacent tubes, and forming internal walls which are oriented at approximately 90 degrees relative to one another.

12. A lacrosse head as defined in claim 11, wherein walls of said first tube and said second tube are separated from the facing walls of said third tube and said fourth tube at least at one selected axial location to form a first port.

13. A lacrosse head as defined in claim 12, wherein, at a second axial location, walls of said first tube and said third tube are separated from the facing walls of said second tube and said fourth tube to form a second port which is oriented at least generally perpendicular to said first port.

14. A lacrosse head as defined in claim 3, wherein said at least one port is formed, wherein said port is used to attach the netting portion to the lacrosse head.

15. A lacrosse head as defined in claim 14 wherein the attachment means is a rod inserted through loop ends in the netting.

16. A lacrosse head as defined in claim 14 wherein the attachment means is a string inserted through loop ends in the netting.

17. A lacrosse head as defined in claim 14 wherein the attachment means is a wedge shape to support the loop ends in the netting.

18. A lacrosse head as defined in claim 14 wherein the attachment means is a grommet positioned through loop ends in the netting and inserted into the ports of the lacrosse head.

19. A lacrosse head as defined in claim 14 wherein the attachment means is a cable tie inserted through loop ends in the netting.

20. A lacrosse head as defined in claim 3 with a portion formed by over molding a polymer structure over the composite ported structure.

21. A lacrosse stick having a unitary structure including the head and handle, the head comprised of a tip end, a throat end and side portions connecting said tip and throat ends, wherein at least a portion of said lacrosse head is formed of at least two tubes having facing surfaces, said tubes being formed of composite material, wherein said facing surfaces are bonded to one another at least along much of their lengths, thereby to form at least one internal reinforcing wall.

22. A lacrosse stick as defined in claim 21, wherein said portion is formed of a double tube construction.

23. A lacrosse stick as described in claim 21, wherein said facing surfaces are separated from one another at least at one selected axial location to form at least one port extending through said lacrosse head perpendicular to said axis.

24. A lacrosse stick as defined in claim 23, wherein said at least one port is formed in said connecting portion.

25. A lacrosse stick as defined in claim 21, wherein said facing surfaces are separated from one another at selected locations to form ports having a double opposing arch structure.

26. A lacrosse stick as defined in claim 25, wherein each said port has an axis there through, and wherein at least two of said ports have different axial orientations.

27. A lacrosse stick as defined in claim 25, wherein said ports vary in size.

28. A lacrosse stick as defined in claim 25, comprising at least three ports adjacent ports, and wherein one of said adjacent ports is axially spaced from adjacent ports by at least two different distances.

29. A lacrosse stick as defined in claim 21, wherein one or more tubes are added to a single tube structure in a local area.

30. A lacrosse stick as defined in claim 21, wherein said lacrosse head is formed of a first tube, a second tube, a third tube, and a fourth tube, each tube having two walls facing and bonded to, along at least most of their length, walls of two adjacent tubes, and forming internal walls which are oriented at approximately 90 degrees relative to one another.

31. A lacrosse stick as defined in claim 30, wherein walls of said first tube and said second tube are separated from the facing walls of said third tube and said fourth tube at least at one selected axial location to form a first port.

32. A lacrosse stick as defined in claim 31, wherein, at a second axial location, walls of said first tube and said third tube are separated from the facing walls of said second tube and said fourth tube to form a second port which is oriented at least generally perpendicular to said first port.

33. A lacrosse stick as defined in claim 21, wherein the handle comprises a metal tube for a portion of its length.

34. A lacrosse stick as defined in claim 21, wherein at least a portion comprises a single metal tube joined to a multi-tube member.

35. A lacrosse stick as defined in claim 34, wherein said multi-tube member includes a port.

36. A lacrosse stick according to claim 33 wherein said handle comprises a multiple tube construction in which the tubes have facing surfaces which are bonded to one another along at least much of their lengths.