Hockey stick construction

Claim 2

A hockey stick, comprising: (a) front and back metal outer skins of continuous one piece including an elongate handle portion and an integral blade portion, (b) metal honeycomb sandwiched between the metal outer skins along the handle and blade portions, the metal honeycomb including: (1) a first honeycomb portion between the outer metal skins along the handle portion, the first honeycomb portion tapering in thickness at the neck of the handle portion and extending to the blade portion, and (2) a second honeycomb portion, thinner than the first honeycomb portion, between the outer metal skins along the blade portion and extending to the handle portion, the tapered first honeycomb portion and the thin second honeycomb portion having substantially the same thin thickness at a juncture for flexibility of the blade portion and neck of the handle portion.

Claim 3

A hockey stick as defined in claim 1, in which: (e) an expandable foam adhesive is disposed in the thin second honeycomb portion between the metal outer skins along the blade portion, and is disposed in the tapered first honeycomb portion between the metal outer skins along the neck of the handle portion adjacent the blade portion, and (f) the edge filler is a urethane plastic extending between and adhering to the inner surfaces of the metal outer skins and adhering to the metal honeycomb.

Claim 4

A hockey stick, comprising: (a) front and back metal outer skins of continuous one piece including an elongate handle portion and an integral blade portion, (b) a metal honeycomb sandwiched between the metal outer skins along the handle and blade portions with the longitudinal axis of the honeycomb extending in a direction transversely between the metal outer skins, the metal honeycomb including: (1) a first honeycomb portion along the handle portion, the first honeycomb portion tapering in thickness at the neck of the handle portion, (2) a second honeycomb portion, thinner than the first honeycomb portion, along the blade portion and extending to the handle portion, the tapered first honeycomb portion and the thin second honeycomb portion having substantially the same thin thickness at an abutting juncture for flexibility of the blade portion and neck of the handle portion, (c) an adhesive of epoxy sheet material securing the metal honeycomb to the inner surfaces of the metal outer skins, (d) an expandable foam adhesive in the thin second honeycomb portion along the blade portion and in the tapered first honeycomb portion at the neck of the handle portion across the abutting juncture of the first and second honeycomb portions, and (e) a urethane plastic filler enclosing the side edges of the stick, the filler extending between and adhering to the inner surfaces of the metal outer skins and adhering to and filling the sides of the metal honeycomb.

Claim 5

A hockey stick, comprising: (a) front and back metal outer skins of continuous one piece including an elongate handle portion and an integral blade portion, (b) a metal honeycomb sandwiched between the metal outer skins along the handle and blade portions with the longitudinal axis of the honeycomb extending in a direction transversely between the metal outer skins, the metal honeycomb including: (1) a first honeycomb portion along the handle portion, the first honeycomb portion tapering in thickness at the neck of the handle portion, (2) a second honeycomb portion, thinner than the first honeycomb portion, along the blade portion and extending to the handle portion, the tapered first honeycomb portion and the thin second honeycomb portion having substantially the same thin thickness at an abutting juncture for flexibility of the blade portion and neck of the handle portion, (c) an adhesive of epoxy sheet material securing the metal honeycomb to the inner surfaces of the metal outer skins, (d) an expandable foam adhesive in the thin second honeycomb portion along the blade portion and in the tapered first honeycomb portion at the neck of the handle portion across the abutting juncture of the first and second honeycomb portions, and (e) a urethane plastic filler enclosing the side edges of the stick, the filler extending between and adhering to the inner surfaces of the metal outer skins and adhering to and filling the sides of the metal honeycomb.