Abstract: Methods for fabricating a 3D woven material and exemplary 3D woven material for sporting implements are disclosed. The exemplary weaves can be incorporated into any sporting implements, such as, baseball bats, lacrosse sticks, hockey sticks, rackets, helmets, and other protective equipment. The example sporting implement can be constructed, partially or entirely, with a woven or braided three dimensional structure. The 3D woven material can be a multi-directional layup having tows oriented in three directions (X, Y and Z) and also at any angle created by the combination of two or three directions. A single woven preform can be formed that can have a near net shape of the formed product, with the fibers oriented in a way that will be optimal for the particular application.

Abstract: A skate boot comprising an outer shell including medial and lateral side portions for facing the medial and lateral sides of the foot. Each of the medial and lateral side portions has an upper edge. The skate boot also comprises a lace member mounted to either of the upper edges of the medial and lateral side portions. The lace member has at least one opening for receiving an insert. The lace member has a first flexion mode when no insert is received in the at least one opening and a second flexion mode when the insert is received in the at least one opening. The second flexion mode is different from the first flexion mode.

Abstract: A skate boot having an outer shell and a toe cap. The outer shell has medial and lateral side portions having front medial and lateral end portions. The toe cap has rear medial and lateral extensions defining medial and lateral hollow spaces. The front medial and lateral side end portions of the outer shell are at least partially received in the medial and lateral hollow spaces of the toe cap for affixing the toe cap to the outer shell.

Abstract: A hockey skate includes a composite boot form having a rigid lower portion and a less rigid upper portion. The upper portion may be made of a thermoformable material that conforms to the shape of a wearer's foot and ankle. The construction of the boot form—particularly the lower portion of the boot form—may be varied across different size ranges by, for example, varying the fiber angles in the composite material. Varying the stiffness of the lower portion of the boot form in this manner allows the flexibility of different sized boots to be substantially equalized. A skate quarter and other skate-boot features may readily be attached to the upper portion of the boot form via stitching, rivets, or other connectors. The boot form also may include an integral toe cap having a flange or other element to which the skate tongue and other elements may be connected.

Abstract: A helmet for receiving the head of a hockey or lacrosse player, the helmet having an outer shell and an inner lining covering at least partially the inner surface of the outer shell. In one embodiment, the helmet comprises a skeleton at least partially covered by the inner lining, a movable occipital pad and movable temple pads. The inner lining can be made of an absorptive material such as foam, expanded polypropylene or expanded polyethylene and can be overmolded onto the skeleton. The occipital pad and the temple pads may be arranged with an inward bias so as to help the helmet self-adjust to provide an advantageous fit on the player's head. In some embodiments, the outer shell and skeleton, or the outer shell and the inner lining, cooperate to define a ventilation system.

Abstract: A skate boot comprising an outer shell with a heel portion for receiving the heel of the foot; an ankle portion for receiving the ankle, the ankle portion comprising a rear portion for facing at least partially the lower part of the Achilles tendon; and medial and lateral side portions for facing the medial and lateral sides of the foot respectively. The skate boot also comprises a tendon guard extending upwardly from the ankle portion of the outer shell for facing at least partially the upper part of the Achilles tendon, the tendon guard comprising a recess for receiving an insert. The tendon guard has a first flexion mode when no insert is received in the recess and a second flexion mode when the insert is received in the recess. The second flexion mode is different from the first flexion mode.

Abstract: A sport helmet having an outer shell, an inner padding for covering at least partially the wearer's head, an occipital inner pad for facing the occipital region of the wearer's head, a rear support having an upper part hingedly mounted to the helmet and a lower part mounted to the occipital inner pad, and a biasing member having a portion abutting the rear inner surface of the outer shell such that the rear support and occipital inner pad are movable between a first position wherein the rear support is biased to extend inwardly from the rear inner surface, and a second position when the wearer puts on the sport helmet to cause the rear support and occipital inner pad to be deflected towards the rear inner surface while the rear support and occipital inner pad maintain pressure on the occipital region of the wearer's head.

Abstract: A skate boot having an outer shell and an inner liner made of a first material. An outer surface of the inner liner is mounted to an inner surface of the outer shell, an inner surface of the inner liner being adapted to contact the player's foot or a sock covering the player's foot. An ankle portion of the inner liner has a medial upper inner region and a lateral upper inner region, and an overlay at least partially covers one of the medial and lateral upper inner regions of the ankle portion of the inner liner. The overlay is made of a second material having more abrasion resistance than the first material of the inner liner.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: An adjustable helmet having first and second shells and a single actuator comprising at least one tooth, the single actuator being moveable between: a first locked position, wherein the at least one tooth retains the first and second shells and the first and second shells define a first hollow space; a released position, wherein the at least one tooth no longer retains the first and second shells such that one of the first and second shells is moveable relative to the other of the first and second shells; and a second locked position, wherein the at least one tooth retains the first and second shells and the first and second shells define a second hollow space, the second hollow space being different than the first hollow space.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A dual-core blade and method for manufacturing a dual-core blade are disclosed. The blade is formed with a first core portion and a second core portion comprising an epoxy having a plurality of expanded microspheres. The method of forming the two foams generally comprises sizing a foam core to form a first core portion and providing and preparing an epoxy mixture to form a second core portion. The first core portion and the second core portion of the epoxy mixture are placed into a preform, and the preform is heated slightly so as to cause the epoxy mixture to flow into the shape of the preform and around the first core portion. The first core portion and the second core portion are then bonded in a molding operation. The formed structure can form part of a hockey stick blade.

Abstract: The invention relates to a leg pad for a hockey player. The leg pad extends along a longitudinal axis and comprises an upper portion, a lower portion and a band. The upper portion has a knee cap for covering a knee joint of the player. The lower portion has an upper shell for covering a substantial part of a shin of the hockey player and a lower shell for at least partially covering the shin and ankle of the hockey player. The band extends along part of a periphery of the upper shell and part of a periphery of the lower shell. The band interconnects the upper shell and the lower shell to one another wherein the lower shell is movable relative to the upper shell between a first position and a second position in response to flexion of the ankle.

Abstract: A protective athletic garment comprising a protective cap for protecting a body part of the user. The protective cap comprises a shell for overlying the user's body part. The shell comprises a first shell member and a second shell member. The protective cap comprises a liner mounted under the shell for being disposed between the shell and the user's body part. The protective cap also comprises a link interconnecting the first shell member and the second shell member to hold the first shell member and the second shell member together. The link extends along at least part of a periphery of the first shell member and at least part of a periphery of the second shell member such that the first shell member and the second shell member are movable relative to one another in response to movement of the user's body part.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A hockey or lacrosse helmet with a rear shell having a central elongated slot extending along a longitudinal axis of the helmet; a rear inner pad for facing the back and left and right side regions of the head, the rear inner pad being mounted to the rear shell; an occipital inner pad located below the rear inner pad for facing the occipital region of the head; and a single wedging member located between the rear shell and the occipital inner pad, the single wedging member being movable along the longitudinal axis of the helmet from a first position to a second position.

Abstract: A dual-core blade and method for manufacturing a dual-core blade are disclosed. The blade is formed with a first core portion and a second core portion comprising an epoxy having a plurality of expanded microspheres. The method of forming the two foams generally comprises sizing a foam core to form a first core portion and providing and preparing an epoxy mixture to form a second core portion. The first core portion and the second core portion of the epoxy mixture are placed into a preform, and the preform is heated slightly so as to cause the epoxy mixture to flow into the shape of the preform and around the first core portion. The first core portion and the second core portion are then bonded in a molding operation. The formed structure can form part of a hockey stick blade.